NEWIRPWM

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
INDIAN RAILWAYS
PERMANENT WAY
MANUAL
June, 2020
Published by :
Indian Railways Institute of Civil Engineering, Pune
For Government of India
Ministry of Railways (Railway Board),
New Delhi
Page 1 of 417
FOREWORD TO REDRAFTED IRPWM (2020)
“Indian Railways Permanent Way Manual” was published in the year 1986, as per
the recommendations of the 49th Track Standards Committee. Thereafter, it was
reprinted on different occasions incorporating Advance Correction Slips issued from
time to time.
There was need to issue updated Manual in view of various technological

advancements which have taken place over the years. Description of obsolete materials
like 90R Rails, Wooden Sleepers, Steel sleepers, etc. which are no longer in use have been
removed. Meter Gauge and Narrow Gauge have been omitted in this IRPWM. For these,
provisions of old IRPWM shall continue to hold. Reference to all relevant drawings &
specifications have also been provided in this manual, making it simple and more
useful.
The contents are reorganised, grouping similar topics in one chapter. In the beginning
abbreviation and terminology has been added for ready reference. There is a total reduction
of about 20% in volume.
The IRPWM and LWR manuals have been merged. Now in place of two manuals
related to track, only one manual needs to be referred by field officials. All relevant
provisions have been placed in logical sequence.
The redrafted manual has passed through several rounds of scrutiny by IRICEN faculty,
two member committees for each chapter, deliberation in 88thTSC, sub-committee of six
SAG officers, RDSO and Railway Board before its final approval.
It is hoped that this updated manual will help the Permanent Way men, in easy
understanding the provisions and implementing them in the field in their day to day
working.
(Vishwesh Chaube)
New Delhi Member Engineering
June, 2020 Railway Board
Page 2 of 417
PREFACE TO THE REDRAFTED IRPWM (2020)
The “Indian Railways Permanent Way Manual (IRPWM)” was first published in the
year 1986 after recommendation of 49th TSC. It has been reprinted later in the years 1999
and 2004 to incorporate Advance Correction Slips issued from time to time. The third and
the last reprint of this Manual in July 2019 was inclusive of the Correction Slips up to No.
149.
Railway Board vide letter No. 2013/CE-II/TK/IRPWM dated 24/09/2019 asked
IRICEN to redraft IRPWM with a view to remove obsolete topics and material components
which are not in use now and make it for only Broad Gauge by adding recent developments
in P. Way for the guidance of field officials. Accordingly, Shri Ajay Goyal, the then Director,
IRICEN along with a team of faculty members finalised the first draft of IRPWM keeping in
view the mandate given by Railway Board. Thereafter Rly Bd vide letter No.
2013/CEII/TK/IRPWM dated 02/12/2019 nominated two members committee as under:
S. Faculty from IRICEN 2nd Member Chapter(s)

No Shri. Shri. assigned.
1 C.S Sharma, SPT-1 S. C. Srivastava, PED/TM/RDSO 5
2 R K Bajpai, SPT-2 B P Awasthi, ED/TM/Rly Bd and 3 (welding),
Manoj Arora, CTE/WR 4 and 6
3 Anil Choudhary, SPTM P K Garg, CTE/CR and 7&8
Submoy Mitra, CTE/SER
4 S K Agarwal, PB-1 J. Parida, CTE/ECoR and 11 & 12
P S Gupta, ED/CE/G/Rly Bd
5 G S Yadav, PB-2 A K Jha, CTE/SCR 9, 10
6 P. Upadhyaya, PT-2 P K Garg, CTE/CR 1
7 N K Mishra, PT-1 P S Gupta, EDCE/G/Rly Bd 14
8 A. Siva Kumar, PW A M Rizvi, ED/TR-2/RDSO and 2,13 & Part 3
D. K Pandey, CE/TMS LWR portion
Each committee then finalised the nominated chapters which were compiled by IRICEN
and presented to TSC meeting held in Jan, 2020 at PURI. On recommendation of TSC, Rly
Bd nominated a sub Committee comprising of Shri R. K. Bajpai, Sr Professor Track-
1/IRICEN (Member and Convenor), Shri P K Garg, CTE/CR, Shri A K Jha, CTE/SCR, Shri
Ashish Bansal, CTE/NR, Shri S. Mitra, CTE/SER, and Shri A M Rizvi, ED Track-2/RDSO
as members to examine and submit the final draft. The final draft after initial vetting by
RDSO was sent to Railway Board. Rly Bd suggested certain changes which were examined
and incorporated by IRICEN. After final vetting by RDSO the redrafted IRPWM is approved
by Railway Board (Member Engineering). The provisions of the LWR manual have also
been amalgamated herein to make this Manual, a one stop source for all P. Way related
matters. The Chapters have been logically re-arranged so as to cater for the day-to-day
needs of the field officials. For Metre Gauge and Narrow Gauge track one can refer old
IRPWM which was reprinted on July 2019.
While revising the Manual, the provisions in the Indian Railway General Rules 1976,
Indian Railways Code for the Engineering Department and Indian Railway schedule of
Dimensions have been taken in to account. This redrafted edition incorporates all Advance
Correction Slips up to No. 155 of the earlier Manual. The hitherto obsolete designations
have been done away with and current designations of officials have been incorporated,
viz. Gangman as Track Maintainer, Permanent Way Supervisor / Permanent Mistry
(PWS/PWM) as JE(P.Way), PWI/PWI (In-charge) as JE/SSE(P.Way) Sectional or
SSE(P.Way) In-charge. In a volume of this type, it is not possible to provide for every
contingency that may arise during the course of the working, though every effort has been
made to make the instructions comprehensive. The Principal Chief Engineers of Zonal
Page 3 of 417
Railways may therefore supplement, where necessary, the practices and procedures
contained herein with such further instructions/orders, as would suit local circumstances on
their Railway. Such instructions must not of course contravene any of the provision in this
manual, the codes of the various departments of the Railways, General Rules, or any of the
statutory regulations in force.
It is expected that this updated Manual will be of immense use to the Permanent Way
Personnel in easily accessing latest instructions related to track and thereby helping them
in maintaining and upkeep of the track more effectively and efficiently. IRICEN will be glad
to consider any comments and suggestion from Railway Administrations. Any errors or
omissions found in this Edition may be brought to the notice of IRICEN.
(Santosh Kumar Agrawal)

Pune Director General
June, 2020 IRICEN
Page 4 of 417
CHAPTERS
ABBREVIATIONS AND TERMINOLOGY
CHAPTER 1 - DUTIES OF PERMANENT WAY OFFICIALS
CHAPTER 2 - TRACK STRUCTURE AND COMPONENTS

CHAPTER 3 - INSTALLATION AND MAINTENANCE OF WELDED
RAILS
CHAPTER 4 - CURVES & TURNOUTS
CHAPTER 5 - TRACK MONITORING& TOLERANCES
CHAPTER 6 - MAINTENANCE OF PERMANENT WAY
CHAPTER 7 - PERMANENT WAY RENEWALS

CHAPTER 8 - ENGINEERING RESTRICTIONS & INDICATORS,
WORKING OF TROLLIES, LORRIES & MATERIAL
TRAINS ETC.
CHAPTER 9 - LEVEL CROSSINGS AND GATEMAN
CHAPTER 10 - PATROLLING OF THE RAILWAY LINE
CHAPTER 11 - ACTION DURING ACCIDENTS INCLUDING

BREACHES AND PRE-MONSOON
PRECAUTIONARY MEASURES
CHAPTER 12 - CRS SANCTION
CHAPTER 13 - TRACK MANAGEMENT SYSTEM
CHAPTER 14 - TRAINING, COMPETENCY & REFERENCES
Page 5 of 417
CONTENTS
ABBREVIATIONS AND TERMINOLOGY

CHAPTER 1
DUTIES OF PERMANENT WAY OFFICIALS
PART ‘A’
DUTIES OF ASSISTANT DIVISIONAL ENGINEER (ADEN)
101 General. 102 Knowledge of Rules and Regulations. 103 Duties of ADEN.
PART ‘B’
DUTIES OF SENIOR SECTION ENGINEER/P.WAY IN OVERALL CHARGE
104 General. 105 Knowledge of Rules and Regulations. 106 Duties of SSE/P.Way
(In-charge).
PART ‘C’
DUTIES OF JUNIOR ENGINEER /SENIOR SECTION ENGINEER /P.WAY
(SECTIONAL)
107 General Responsibilities. 108 Knowledge of Rules and Regulations. 109 Duties
of JE/ SSE/ P.Way (sectional).
PART ‘D’
DUTIES OF JE/SSE/ P.WAY (OTHER THAN SECTIONAL OR IN-CHARGE)

110 General responsibilities. 111 Knowledge of Rules and regulations.
PART ‘E’
DUTIES OF GANG MATES, KEYMEN, PATROLMEN, GATEMAN AND TRACK
MAINTAINER
112 General. 113 Knowledge of Rules and Signals. 114 Important Duties of Gang
Mate. 115 Responsibilities of a Keyman. 116 Important Duties of Keyman. 117
Duties of Patrolmen / Stationary Watchmen. 118 Duties of Gateman. 119 Duties of
Track Maintainer.
CHAPTER – 2
TRACK STRUCTURE AND COMPONENTS
201 Classification of Lines. 202. Track Structure.
PART – A
RAIL AND RAIL FASTENINGS
203 Standard Sections of Rails. 204 Identification of Different Qualities of Rails in
the Field. 205 Recommended Rail Section. 206. Rail Fastenings
Page 6 of 417
PART – B
SLEEPERS & FASTENINGS
207 General. 208 Concrete Sleepers. 209 Sleeper Density. 210 Fastenings on PSC
sleepers.
PART – C
BALLAST.
211 Ballast Specifications. 212 Ballast Profile/Section/Depth of Cushion. 213
Assessment of Ballast Requirements 214 Collection and Training out of Ballast. 215
Handing over Charge by Assistant Divisional Engineer. 216 Unloading Ballast along
the Line. 217 Surplus Ballast along the Line.
PART – D
FORMATION
218 Classification of Formation Requiring Treatment. 219 Nature of Formation
Problems. 220 Site Investigation. 221 Soil Investigation and Testing. 222 Remedial
Measures Suggested.
PART – E
INSULATED JOINTS & SWITCH EXPANSION JOINTS
223 Insulated Joints. 224 Glued insulated Joints. 225 Switch Expansion Joint.
PART – F
TRACK STRUCTURE ON BRIDGES
226 Rail and Rail joints on Bridges. 227 Steel Sleepers on bridges 228 Provision of
Guard Rails on Bridges. 229 Provision of side pathways and walkways.
CHAPTER – 3
INSTALLATION AND MAINTENANCE OF WELDED RAILS
PART - A
ALUMINO-THERMIT WELDING OF RAILS
301 General. 302 Alumino Thermit Welding of Rails. 303 Selection of rails to be
welded. 304 Portion for welding. 305 Storage and transportation of Portions. 306
Equipment, staff and Traffic block for welding. 307 Execution of Welding and other
precautions. 308 Tolerances on finished welds. 309 Record of joint geometry. 310
Painting of Thermit welds. 311 Acceptance tests.
Page 7 of 417
PART - B
FLASH-BUTT WELDING OF RAILS
312 General 313 Rail Welding by Stationary Flash Butt Welding plant. 314 Rail
Welding by Mobile flash butt welding plant. 315 Suitability of rails for welding. 316
Acceptance Tests.
PART - C
SHORT WELDED RAILS
317 General. 318 Condition of Laying. 319 Laying of Short Welded Rails. 320 Gap
Survey and Adjustment of Gap. 321 Counteraction and Adjustment of creep. 322
Buckling of Track (other than LWR). 323 Conversion of SWR into LWR. 324
Maintenance of Short Welded Rails.
PART - D
LONG WELDED RAILS
325 Long welded Rail. 326 Permitted Locations for LWR/CWR. 327 Provision of
Glued Joints. 328 Location of SEJ. 329 Bridges with ballasted deck (without
bearing). 330 Bridges with ballasted deck (with bearing). 331 Bridges with un-
ballasted deck. 332 Measurement of Rail Temperature. 333 Temperature
Measurements. 334 Temperature Records. 335 Thermal Forces in LWR/CWR. 336
Laying of LWR / CWR. 337 Welding of Rails to form LWR. 338 Gaps at SEJ. 339
De-stressing operation of LWR. 340 De-stressing without Rail Tensors. 341 De-
stressing with Rail Tensors. 342 Joining of LWRs. 343 Reference Marks. 344
Maintenance of LWR/CWR. 345 Regular Track Maintenance. 346 Special Track
Maintenance. 347 Destressing during Maintenance 348 Unusual Occurrences. 349
Rectification of Rail Fractures. 350 Damage to Switch Expansion Joint. 351 Buckling
of Track. 352 Breaches, Temporary Girders and Diversions. 353 Hot and Cold
Weather Patrolling. 354 Inspections and Records.
CHAPTER – 4
CURVES & TURNOUTS
PART – A - CURVES
SECTION – I: GENERAL
401 Determination of Radius. 402 The Reference Rail for level. 403 Safe Speed on
Curves. 404 Super-elevation, Cant Deficiency and Cant Excess. 405 Length of
Transition Curve and Setting-out Transitions. 406 Running out Super-elevation. 407
Indicators/Boards Provided in Curves. 408 Speed over Turnout on Curves. 409
Permissible Speed over Curved Main Line at Turnouts. 410 No Change of Super-
Page 8 of 417
elevation over Turnouts. 411 Curves of Contrary Flexure. 412 Curves of Similar
Flexure. 413 Curves with Cross Overs. 414 Curves with Diamond Crossing. 415
Extra Clearance on Curves. 416 Compensation for Curvature on Gradient. 417
Vertical Curve.
SECTION – II: RE-ALIGNMENT OF CURVES
418 Running on Curves. 419 String lining Operations. 420 Realigning Curves on
Double or Multiple Lines. 421 Cuttings of Rails on Curves. 422 Joints on Curves.
423 Check Rails on Curves. 424 Wear on Outer Rail of Curves. 425 Measurement
of Rail Wear on Sharp Curves.
PART – B
POINTS & CROSSINGS
426 (1) Turnout. (2) Turn in Curve 427 Assembly drawings. 428 LWR through Points
and Crossings 429 Inspection and Maintenance of Points and Crossings. 430
Reconditioning of Switches and Crossing. 431 Periodical Inspection of
reconditioned Points and crossing. 432 Robotic Reconditioning.
CHAPTER – 5
TRACK MONITORING & TOLERANCES
PART – A
TRACK MONITORING
501 General. 502 Track Recording Cars. 503 Quick Calibration, Recording and
Speed. 504 Arrangements for Running Track Recording Car. 505 Officials to
accompany the TRC run. 506 Frequency of Track recording. 507 Track Geometry
Parameters recorded by TRC 508 Chords for measurements/report. 509 Reporting
of TRC results. 510 Action to be taken after Track Recording by TRC 511 Parameter
Indices. 512 Track Quality Index (TQI). 513 Oscillation monitoring system. 514
Frequency of OMS Recording. 515 Recording of defects. 516 Classification of Track
Quality. 517 Oscillograph Car. 518 Use of Oscillograph Car Recordings.
PART – B
TRACK TOLERANCES
519 General. 520 New Track Tolerances. 521 Planning of Maintenance. 522
Maintenance limits for Different Speed Bands. 523 Action to be taken based on TRC
results 524 Realignment criteria for Curves. 525 Track Parameters in floating
conditions. 526 Track Parameters for low speeds. 527 Stability of trains against
derailments.
Page 9 of 417
CHAPTER – 6
MAINTENANCE OF PERMANENT WAY
PART – A
REGULAR TRACK MAINTENANCE
601 Track Maintenance. 602 Annual Programme of Track Maintenance. 603
Maintenance Planning. 604 Mechanised Track Maintenance System. 605
Systematic tamping of plain track and Points & Crossings. 606 Picking Up Slacks.
607 Through Packing by Conventional Manual Method 608 Observance of Sleepers
under Passage of Traffic. 609 Systematic Overhauling.
PART – B
HANDLING AND MAINTENANCE OF RAILS, SLEEPERS, FASTENINGS &
OTHER MISC. ITEMS
610 Handling and Stacking of Rails. 611 Inspection of Rails in Service. 612 Causes
of Rail Deterioration. 613 Rail Maintenance to reduce Rail Deterioration. 614 Rail
Closures on other than LWR track. 615 Attention to Defective Rails and welds
detected by USFD. 616 Casual Renewal of Rails. 617 Rail Failures. 618 Action to
be taken in the case of Rail fractures/Weld failures. 619 Lubrication of Rail Joints.
620 Maintenance of Rail Joints. 621 Fish-plate failures. 622 Inspection and
Maintenance of Insulated rail joints/Glued Joints. 623 Laying of PSC Plain track
Sleepers. 624 Laying of Fan Shaped Turnout Sleeper. 625 Casual Renewal of
Concrete Sleepers. 626 Corrosion of Steel in Concrete Sleepers. 627 Maintenance
of Concrete Sleeper Fastenings. 628 Renewal of fastenings. 629 Steel sleepers for
Bridges. 630 Inspection and maintenance of Track on Approaches of Bridges. 631
Inspection and Maintenance of Track on Bridge proper. 632 Maintenance of yard
lines. 633 Sand hump/dead end. 634 Sample of Standard Section of Track. 635
Checking work of Gangs by JE/SSE/P.Way
PART – C
WORKS INCIDENTAL TO REGULAR TRACK MAINTENANCE
636 Deep Screening of Ballast. 637 Procedure for systematic Deep screening. 638
Lifting of Track. 639 Lowering of Track. 640 Side and Catch Water Drains and
Waterways. 641 Drainage in Station Yards. 642 Section Limit Boards. 643 Kilometre
and Gradient Posts. 644 OHE Mast /Hectometre Post Numbers. 645 Verification of
Land Boundaries. 646 Trolley Refuges. 647 Standard Dimensions. 648 Felling of
Trees Obstructing View. 649 Distance Pieces to Platform Lines. 650 Fouling Marks.
651 Maintenance of P.Way Store. 652 Action in case of Derailments.
Page 10 of 417
PART – D
RECORD KEEPING
653 Record of Gang Work. 654 Record of Work of Artisans and Other Workmen
Employed. 655 Half-yearly report on the condition of Permanent Way. 656 SSE's
(P.Way) in-charge Section Register. 657 Permanent Way Plans and Diagrams. 658
Musters. 659 Strength and jurisdiction of Gangs. 660 Custody of Gang Tools. 661
Records of Material under Trial.
PART – E
MAINTENANCE OF TRACK IN TRACK CIRCUITED AREAS
662 Provision and Maintenance of Signaling Fixtures in Track.
PART – F
MAINTENANCE OF TRACK IN ELECTRIFIED AREAS
663 General Instructions to Staff 664 Special Instructions to Staff Working in
Traction Area. 665 Maintaining Continuity of Track. 666 Additional precautions in
A.C. Traction Area. 667 Fire in Electrified Areas. 668 Catch Sidings. 669 Permanent
Way Tools. 670 Treatment of Persons Suffering from Electric Shock. 671 Accident
to Power Lines of outside Bodies.
CHAPTER - 7
PERMANENT WAY RENEWALS
701 Classification of Renewals. 702 Factors Governing Permanent Way Renewal.
703 Planning of Renewals. 704 Track Renewal Programme. 705 Track Standards
for Renewals. 706 Planning for Posting of Staff and Other Facilities. 707 Traffic
Facilities for Renewals. 708 Speed Restrictions. 709 Project Report for Track
Renewal Works. 710 Preliminary Works. 711 Unloading of Rails, Sleepers and
Fastenings. 712 Methods of Carrying Out Renewal. 713 Relaying with Mechanical
Equipment. 714 Manual Method of Relaying. 715 Essential Points to be observed
during Linking. 716 Track Laying standards. 717 Renewal of Points and Crossing.
718 Renewal of Track Fittings and other track components. 719 Sleepers in Yards
and Running Lines. 720 Rails in Station Yards. 721 Classification and Use of
Released Material. 722 Marking of Permanent Way Material. 723 Works to be
attended after completion of relaying.
Page 11 of 417
CHAPTER – 8
ENGINEERING RESTRICTIONS & INDICATORS, WORKING OF TROLLIES,
LORRIES & MATERIAL TRAINS ETC.
PART – A
ENGINEERING RESTRICTIONS & INDICATORS
801 Work Involving Danger to Train or Traffic. 802 Carrying Out of Works, in case
of Emergency. 803 Responsibility of the Railway Servant In-charge of the Work. 804
Works, which Obstruct the Line. 805 Categories of Engineering Works. 806 Works
of Short Duration. 807 Works of Long Duration. 808 Temporary Engineering Fixed
Signals – Location and Details. 809 Procedure for Passing Trains at Stop Dead
Restrictions. 810 Procedure for Blocking Line for Engineering Purposes. 811 Works
at Times of Poor Visibility. 812 Temporary Signals in Emergency. 813 Periodical
Notice of Engineering Restrictions. 814 Permanent Speed Restriction Indicators 815
Indicators (General) 816 Detonating Signals. 817 Warning Signal-Descriptions. 818
Use of Warning Signals. 819 Safe Working of Contractors.
PART – B
THE WORKING OF TROLLIES, MOTOR TROLLIES AND LORRIES
820 Rules for working trollies, motor trollies and lorries. 821 Distinction between
Trolley, Motor Trolley and Lorry. 822 Certificate of Competency. 823 Officials
Permitted to use Trollies, Motor Trollies and Lorries. 824 Responsibility for Safe
Working. 825 Efficient Brakes. 826 Attachment to Trains Prohibited. 827 Working
on Track Circuited Sections and Sections Provided with Axle Counters 828
Numbering of Trollies/Motor Trollies/ Lorries 829 Conveyance of Trollies/Motor
Trollies/ Lorries by Trains. 830 Trollies, Motor Trollies and Lorries not in use. 831
Conveyance of Non-Railway Officials. 832 Trolley-Permits for Private Sidings. 833
Military Officers Using Trollies in Ordnance Depots. 834 Trolley refuges and
observation posts 835 Equipment for Trolley/Motor Trolley/ Lorry. 836 Signals for
Trolley/Motor Trolley/Lorry. 837 Working of Trollies. 838 Working of Motor Trollies.
839 Working of Lorries. 840 Working of Cycle Trollies and Moped Trollies. 841 Rail
Dolleys.
PART – C
WORKING OF MATERIAL TRAINS AND TRACK MACHINES
842 Rules for working of material trains. 843 Material Train. 844 Economical
Working. 845 Restrictions in Running. 846 Brake-vans and Shelter Wagons. 847
Ordering of Material Trains. 848 Issue of “Fit-to-Run” Certificate. 849 Official – in –
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charge of Material Train. 850 Equipment 851 Testing of Brake Power. 852 Working
in Block Section. 853 Pushing of Material Trains. 854 Procedure to be followed while
Pushing Back. 855 Running on Ghat Section and Descending Grade. 856 Passage
over Points. 857 Speed of Material Train. 858 Stabling of a Material Train. 859
Reporting Deficiencies and Damages. 860 Warning to Workers on Material Trains.
861 Engine Crew’s Hours of Duty.
PART – D
LOADING AND UNLOADING FROM HOPPER BALLAST WAGONS
862 Staff responsible. 863 Working Trip. 864 Operation of Hoppers. 865 Training
Out Material and Daily Reports of Working. 866 Charges for Material Train Working.
867 Register of Engineering Vehicles. 868 Working of Track Maintenance
Machines.
CHAPTER - 9
LEVEL CROSSINGS AND GATEMAN
901 General Location. 902 Classification of Level Crossings. 903 Categories of
Roads. 904 Standards for Different Classes of Level Crossings. 905 Gates and
Locking Arrangements. 906 Skew Level Crossings. 907 Normal Position of Gates.
908 Signals for road users. 909 Traffic and Engineering Gates. 910 Equipment at
Level Crossings. 911 Location of Gate-Lodge 912 Appointment of Gatemen,
Rosters and Medical Fitness Certificates. 913 Maintenance of Level Crossing,
Examination of Gate Equipment and Gateman in Rules. 914 Level Crossing
Registers 915 Level Crossing indicators. 916 Provision of Speed Breakers on the
Approaches of Level Crossing. 917 Census of Traffic at Level Crossings. 918 Track
Structure at Level Crossings. 919 Level Crossings on National Highways / State
Highways and Other Important roads. 920 Elimination Level Crossings 921 Criteria
for Replacement of Existing Level Crossings
CHAPTER – 10
PATROLLING OF THE RAILWAY LINE
1001 Types of Patrolling. 1002 Key man’s Daily Patrol. 1003 Gang Patrol during
Abnormal Rainfall or Storm. 1004 Monsoon Patrolling. 1005 Hot and Cold weather
Patrolling for LWR/CWR. 1006 Watchmen at vulnerable locations. 1007 Security
Patrolling during Civil Disturbance and on Special occasions.
Page 13 of 417
CHAPTER 11
ACTION DURING ACCIDENTS INCLUDING BREACHES AND PRE-MONSOON
PRECAUTIONARY MEASURES
PART A
ACTION DURING ACCIDENTS INCLUDING BREACHES
1101 Observance of Rules. 1102 Report of Accident to the Station Master. 1103
Accidents Impairing Through Traffic. 1104 Action at Site. 1105 Report to the
Principal Chief Engineer. 1106 Attendance of Police at Site. 1107 Examination of
Site and Preparation of Sketches. 1108 Recording Particulars at Site of Accident.
1109 Use of Recorded Data.
PART B
RESTORATION OF THROUGH RUNNING
1110 Repairs to Damaged Track. 1111 Procurement and Arrangement of Labour.
1112 Diversion. 1113 Transhipment. 1114 Funds Required During Emergencies.
1115 Obstructions Found on Track. 1116 Flooded Causeways / Dips. 1117 Special
Precautions when Track is submerged. 1118 Driver’s Report on Defects in Track.
1119 Abnormal Occurrences Attributable to Locomotives and other Rolling Stock.
1120 Accident not affecting Through Traffic. 1121 Conducting Accident Enquiry.
1122 Records of Accidents. 1123 Accident Statements to the Railway Board.
PART C
PRE-MONSOON PRECAUTIONARY MEASURES
1124 General Precautions to be taken before Monsoon. 1125 Materials for
Emergencies. 1126 Service Spans and Rail Clusters. 1127 Railway Affecting Works
(Including Railway Affecting Tanks). 1128 Vigilance over Railway Affecting Tanks
during Heavy Rains. 1129 Weather Warnings and Action to be taken.
CHAPTER 12
CRS SANCTION FOR WORKS AFFECTING PASSENGER RUNNING LINES
1201 References to Act/Rules. 1202 Works Requiring Sanction of Commissioner of
Railway Safety and Notice thereof. 1203 Application for Sanction of Works. 1204
Documents to Accompany Applications. 1205 Submission of Safety Certificate.
1206 Deviations from Plans Approved by Commissioner of Railway Safety. 1207
Applications for Running of New Types / Increasing Speed of Existing locomotives
and/or Rolling Stock 1208 Notification to Railway Officials When Opening Works.
1209 Works Arising Out of Accidents Including Breaches. 1210 Opening of New
Lines.
Page 14 of 417
CHAPTER 13
TRACK MANAGEMENT SYSTEM
1301 General 1302 Modular Structure 1303 Integration with TRC and OMS 1304
Security features of TMS 1305 Single source of information management. 1306
Utilization of TMS. 1307 Withdrawal of Registers. 1308 Administrators in TMS.
CHAPTER 14
TRAINING, COMPETENCY & REFERENCES
1401 Types of Training Courses. 1402 Initial /Induction Courses. 1403 Promotional
Courses. 1404 Refresher Courses. 1405 Special Courses. 1406 Certificate of
Competency. 1407 Training and Certification of welders. 1408 Category of Medical
Examination. 1409 Books of Reference.
Page 15 of 417
ABBREVIATIONS
*********************
ADEN – Assistant Divisional Engineer
ART – Accident Relief Train
AT – Alumino Thermit
ATS – Actual Toe of Switch
BCM – Ballast Cleaning Machine
BFR – Bogie Flat for Rail
CAO(C) – Chief Administrative Officer (Construction)
CMS – Cast Manganese Steel
CMT – Chemical & Metallurgical Testing
CRS – Commissioner of Railway Safety
CTE – Chief Track Engineer
CWR – Continuous Welded Rail
DEN – Divisional Engineer
DRM – Divisional Railway Manager
DTS – Dynamic Track Stabilizer
ERC – Elastic Rail Clip
ETKM – Equated Track Kilometre
FBW – Flash Butt Weld / Flash Butt Welding
G&SR – General and Subsidiary Rules;
GFN – Glass Filled Nylon
GK – Gate Keeper
GMT – Gross Million Tonne
GRSP – Grooved Rubber Sole Plate;
HH – Head Hardened;
IMR – Immediate Removal;
IRBM – Indian Railways Bridge Manual;
IRCA – Indian Railway Conference Association;
IRPSM – Indian Railways Proposals & Sanction Management
IRPWM – Indian Railways Permanent Way Manual;
IRS – Indian Railway Standards;
IRSEM – Indian railways Signal Engineering Manual;
IRSOD – Indian Railways Schedule of Dimensions;
IRTMM – Indian Railway Track Machine Manual;
JE – Junior Engineer;
Page 16 of 417
JOH – Junction of Heads
LL _ Liquid Limit
LVDT – Linear Variable Differential Transducer
M&C – Metallurgical and Chemical (Directorate of RDSO)
MCI – Malleable Cast Iron
MCNTM – Manpower and Cost Norms for Track Maintenance
MM – Medium Manganese
MMG – Mobile Maintenance Gang
NBML – Need Based Maintenance Limit
OHE – Over Head Equipment
OMS – Oscillations Monitoring System
P&C – Points & Crossings
P.Way – Permanent Way
PCE – Principal Chief Engineer
PL _ Plastic Limit
PRC – Pre-stressed Reinforced Concrete
PSC – Pre-stressed Concrete Sleeper
RAW – Railway Affecting Works
RBMV – Rail Borne Maintenance Vehicle
RDSO – Research Design & Standards Organization
ROB – Road Over Bridge
RUB – Road Under Bridge
RVNL – Rail Vikas Nigam Limited
S&T – Signal & Telecommunication
SD – Standard Deviation (Statistics)
SKV – Short Preheat Welding
SL _ Shrinkage Limit
SM – Station Master
Sr. DEN (Co) – Senior Divisional Engineer (Co-ordination)
Sr. DSTE – Senior Divisional Signal & Telecommunication Engineer
SSE – Senior Section Engineer
SWR/SWP – Short Welded Rail/ Short Welded Panel
TMS – Track Management System;
TQI – Track Quality Index
Track Manual – Indian Railways Standard Track Manual (Volume I and II);
TRC – Track Recording Car
TRD – Traction Distribution Department
Page 17 of 417
TTM – Tie Tamping Machine
TVU – Train Vehicle Unit
TWS – Thick Web Switch
UIC – International Union of Railways
UML – Urgent Maintenance Limit
USFD _ Ultrasonic Flaw Detection
UTS – Ultimate Tensile Strength
WCMS – Weldable Cast Manganese Steel
WILD – Wheel Impact Load Detector
Page 18 of 417
TERMINOLOGY
*********************
(1) Alignment (AL) (of rails):
It refers to deviation of rails in horizontal plane, from its original/intended position,
measured individually for each of the rail with reference to a chord of specified length.
(2) Anchor Length (la):
The length of track required to resist the pull exerted on rails by the rail tensor at
temperature (tp). For practical purposes, it is taken as equal to 2.5 metre per degree
Celsius of (to - tp). If t0 is not known, td can be assumed as t0.
(3) Blanket:
The layer of granular material provided between ballast and sub grade/ Formation on
full width of Formation.
(4) Breathing Length:
The length at each end of LWR/CWR, which is subjected to expansion/contraction on
account of temperature variations.
(5) Buckling of Track:
Sudden or Gradual shifting of Track in lateral or vertical direction due to unbalanced
thermal stress in rail / track is called Buckling.
(6) Cant deficiency:
Cant deficiency occurs when a train travels around a curve at a speed higher than the
equilibrium speed. It is the difference between the theoretical Cant required for such
higher speed and actual Cant provided.
(7) Cant excess:
Cant excess occurs when a train travels around a curve at a speed lower than the
equilibrium speed. It is the difference between the actual Cant and the theoretical
Cant required for such a lower speed.
(8) Cant gradient and Cant deficiency gradient:
It indicates the amount by which Cant or deficiency of Cant is increased or reduced
in a given length of transition e.g., 1 in 1000 means that Cant or deficiency of Cant of
1 mm is gained or lost in every 1000 mm of transition length.
(9) Catch Sidings:
Catch Siding is a safety siding, taking off from the main line and of a suitable length,
provided with devices such as rising variable grades and sand drags to fully absorb
the Velocity Head attained by an inefficiently controlled train or part of train being
pulled up therein, without being wrecked. It is essentially a gravity catch siding
provided on long steep grades between stations, where curves are designed for a
lower speed than may conceivably be attained by a train or part of a train, which for
one cause or another, may have got out of control and when it is necessary to protect
a station from uncontrolled trains or parts of trains liable to enter it.
At any station situated in the immediate neighborhood of an incline steeper than 1 in
80 falling towards the station, a Catch Siding should be provided, if necessary. The
takeoff points to a catch siding should normally be set and locked for the siding, except
where required to the trailed through.
Page 19 of 417
(10) Centrifugal force:
The outward force acting on a vehicle while moving on a curved track. Its magnitude
depends upon the velocity of vehicle, mass and radius of curvature.
(11) Cold Weather Patrol
The patrolling of track carried out during the period (in winter) when rail temperature
is significantly lower than stress-free/de-stressing temperature.
(12) Consolidation of Track:
The process of building up ballast resistance to the tendency of movement of sleeper
either initially before laying LWR/CWR or making up subsequent loss of resistance.
(13) Cross level:
It is the level difference between two rails, on a sleeper, of a track. For the
measurement of cross level, one of the rails is taken as reference to define the level
of other rail.
(14) Crossing angle:
It is the angle contained between the gauge lines of the crossing. Usually defined by
the number of crossing, which is cotangent of angle of crossing.
(15) Cross Over:
A device to connect two lines by using two turnouts and straight or curved track in
between.
(16) Degree of curvature:
The angle subtended at the centre, of the circular curve, by a chord of 30.5 metres.
(17) De-stressing:
An operation undertaken with or without rail tensor to secure stress free conditions in
the LWR/CWR at the desired/specified rail temperature.
(18) Equilibrium speed:
The speed at which the centrifugal force developed during the movement of the
vehicle on a curved track is exactly balanced by the Cant provided.
(19) Gauge:
It is the shortest distance between the gauge faces of rails of a track between two
rails. It is usually measured at a level between 13 to 15 mm below the rail top.
(20) GMT:
The total traffic carried on a line, expressed as the Gross Million Tonnes of Traffic
(GMT), recorded and advised by the Statistical branch of each Zonal Railway as on
31st March of every year is called the GMT of the line.
(21) Hot Weather Patrol:
The patrolling of track carried out during the period (in summer) when rail temperature
is significantly higher than stress-free/de-stressing temperature.
(22) Lead curve or the turn out curve:
The curve beginning (usually from the toe of curved switch) and extending up to toe
of crossing.
(23) Machined Joint:
These joints are fish plated joints, which are provided where zero gap is required
between rail ends.
Page 20 of 417
(24) Maximum permissible speed of the curve:
The highest speed which may be permitted on a curve taking into consideration the
radius of the curvature, actual cant, Cant deficiency, Cant excess and the length of
transition.
(25) Rail Failure:
A rail is said to have failed if it has fractured in track or it is considered necessary to
remove it from track on account of defects other than those due to accidental
damages due to buckling, kinking, derailments, abnormal wheel burns etc.
(26) Rail Temperature:
Temperature of the rail as recorded by an approved type of rail thermometer at site.
It differs from the ambient temperature, which is the temperature of air in shade at
that place, as reported by the Meteorological Department.
Indian Railways have been divided into four rail temperature zones. Fig. 3.6 of
Chapter 3 is a map showing the four temperature zones and the annual mean rail
temperatures at all important places are shown in the map.
(a) Destressing Temperature (td):
The average rail temperature during the period of fastening the rails to the sleepers
after de-stressing LWR/CWR without the use of rail tensor. If rail tensor is used, td for
all practical purposes is equal to t0. The Range of td or t0 shall be within the limits of
rail temperature shown below:
Temperature Zone Rail Section Range
I, II, III All Sections tm to tm+ 5° C
IV 52 kg/m & heavier tm+5° C to tm+10° C
(b) Installation temperature (ti):
The average rail temperature, during the process of fastening the rails to the sleepers,
at the time of installation of SWR/LWR/CWR.
(c) Mean annual rail temperature (tm):
The average of the maximum and minimum rail temperature recorded during the year.
tm is fixed locally wherever rail temperature records are available for a reasonable
period of five years.
Where rail temperature records are not available, tm can be read from the rail
temperature map (Fig. 3.6 of chapter 3)
(d) Prevailing Rail Temperature (tp):
The rail temperature prevailing at the time when any operation connected with LWR
such as de-stressing etc., is carried out.
(e) Stress-free Temperature (t0):
The temperature of Rail in LWR/CWR at which the rail is free of thermal stresses.
(27) Rail Tensor:
A hydraulic or mechanical device used for stretching the rail physically.
(28) Rate of change of Cant or rate of change of Cant deficiency:
It is the rate at which Cant or Cant deficiency is increased or reduced per second, at
the maximum permissible speed of the vehicle passing over the transition curve, e.g.,
35 mm. per second means that a vehicle when traveling at a maximum speed
permitted will experience a change in Cant or deficiency of Cant of 35 mm in each
second of travel over the transition.
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(29) Sand Hump:
A sanded track, which works as an isolation, provided after loop lines to avert collision
with main line vehicles.
(30) Shift:
An introduction of transition curve, laid out as a cubic Parabola, causes main circular
arc to move inwards by an amount called the “Shift”.
(31) Slip siding:
These are shorter length sidings located on the lower side of a station on steep grade,
where there is a risk, whether owing to gradients or due to high wind velocity, of
uncontrolled vehicles running out of stations from stand still or during shunting, fouling
the main line. These sidings take off from the main line, outside all points, to prevent
wagons breaking away from the station, entering into the block section.
At any station situated in the immediate neighbourhood of an incline steeper than 1
in 100 falling away from the station, a Slip siding should be provided, if necessary, in
a suitable position. The takeoff points to a slip siding should normally be set and
locked for the siding, except where required to the trailed through.
Whenever, for any cause. it is found necessary to lay a slip siding off the main line or
off the through loop line, so that there is risk of whole trains getting trapped, the design
of such a slip siding must be identical with that of catch sidings as already defined.
(32) Stock rail joint (SRJ):
The joint of stock rail with the running rail at the approach.
(33) Super-elevation (SE):
Super-elevation is the amount by which one of the rail is raised with reference to the
other rail of a track.
(34) Switch Expansion Joint (SEJ):
An expansion joint installed at each end of LWR/CWR to permit expansion/contraction
of the adjoining breathing lengths due to temperature variations.
(35) Symmetrical Split:
These are the turnouts where centre line of track coincides with bisector of crossing
angle. The radius of lead curve of Symmetrical split turnout is twice the radius of
ordinary turnout.
(36) Transition curve:
An easement curve which has curvature change throughout its length
(37) Turn-in curve:
The connecting curve starting after the heel of the crossing leading up to the adjacent
track.
(38) Turnout:
It is a device to allow movement of train from one track to another track. The turnout
consists of sub-assemblies of Switch, Crossing and Lead. Depending on the side to
which the train gets diverted, a turnout may be called left or right hand.
(39) Twist:
Twist is Parameter, calculated by using cross level values at two locations separated
by a specific distance (base). It is also defined as the rate of change of cross levels
(in mm/m) over a given base.
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(40) Unevenness (UN) (of rails):
It refers to deviation of rails in vertical plane, from its original/intended position,
measured individually for each of the rail with reference to a chord of specified length.
(41) Versine:
Versine is the perpendicular distance measured at the midpoint of a chord from the
arc of curved track.
(42) Vertical curve:
A circular curve in vertical plane.
(43) Welded Rails:
(a) Continuous Welded Rail (CWR):
A LWR, which continues through station yards including points and crossings.
(b) Long Welded Rail (LWR):
A welded rail, the central part of which does not undergo any longitudinal movement
due to temperature variations.
(c) Short Welded Rail (SWR):
A welded rail that contracts and expands, throughout its length, due to temperature
variations.
Page 23 of 417
CHAPTER 1
DUTIES OF PERMANENT WAY OFFICIALS
*********************
PART ‘A’
DUTIES OF ASSISTANT DIVISIONAL ENGINEER (ADEN)
101 General –
The Assistant Divisional Engineer (ADEN), in-charge of a sub-division, is generally
responsible for the inspection, maintenance and safety of all way & works including bridges
in the sub-division; for the accuracy, quality and progress of new works and control over all
expenditure in relation to budget allotment.
102 Knowledge of Rules and Regulations – (Back to Para 105)
ADEN should have knowledge of Rules and Regulations as laid down in:
(1) The Indian Railways Act;
(2) Indian Railways (Open Lines) General Rules and Subsidiary Rules;
(3) Indian Railways Schedule of Dimensions 1676 mm Gauge (BG);
(4) Indian Railways Permanent Way Manual;
(5) Indian Railways Standard Track Manual (Volume I and II);
(6) Manual for Flash Butt Welding of Rails;
(7) Manual for Fusion Welding of Rails by the Alumino Thermic Process;
(8) Manual for Glued Insulated Rail Joints;
(9) Manual for Reconditioning of Medium Manganese (MM) Steel Points & Crossings,
Switch Expansion Joints (SEJs) and Cast Manganese Steel (CMS) Crossings;
(10) Manual for Ultrasonic Testing of Rails and Welds;
(11) Indian Railway Track Machine Manual;
(12) Indian Railways Small Track Machine Manual;
(13) Indian Railways Bridge Manual;
(14) Indian Railways Works Manual;
(15) Indian Railways Code for the Engineering Department;
(16) Other departmental codes & Manuals;
(17) Latest correction slips, Instruction, and circulars issued from time to time, relating
to aforesaid;
ADEN shall have up-to-date copies of these codes and manuals with all correction
slips etc. He should be well versed with the various modules of the Track
Management System (TMS). He shall ensure that all the staff under him are
acquainted with the relevant rules and working methods connected with their duties.
103 Duties of ADEN –
(1) Inspection and maintenance of Track in a satisfactory and safe condition. He shall
conduct inspection as per the Schedules laid down (Table-1A) by the Administration
from time to time. He shall enter the inspection details in Track Management System
(TMS), and shall ensure compliance of the instructions within a reasonable period.
Page 24 of 417
ADEN shall:
(a) Bring to the notice of the DEN/Sr.DEN, any work pertaining to track, which is
considered beyond the capacity of ADEN to deal with and any other item
considered necessary for safe functioning of track.
(b) Ensure that the staff are fully conversant with their respective responsibilities with
regard to laying and maintenance of track.
(c) Ensure that all remedial action for LWR/CWR showing unsatisfactory behaviour
are taken in time.
(d) Issue certificate once in a year before summer, i.e., in the month of February, that
all the LWR/CWR in his jurisdiction are behaving satisfactorily and send it to
DEN/Sr.DEN.
(2) Track Machines- Monitoring and ensuring quality and output of all the track machines
working in the sub-division. ADEN shall-
(a) Ensure all prerequisites, pre-block, during block and post-block activities for quality
output;
(b) Ensure sufficient lighting during night working and arrange Fuel/oil well in advance;
(c) In the eventuality of breakdown of a machine, ADEN shall take all possible actions
to clear the block section expeditiously, if the machine cannot be repaired during
the line-block;
(d) inspect the track machines as per the prescribed schedule and check the items /
checklist laid down in Indian Railways Track Machine Manual;
(3) Preparation of plans and estimates for works and submission of detailed proposals
with justifications to Division for sanction of works. ADEN shall also prepare special
conditions, if any, specific to site for execution of work(s)/part of the work(s).
(4) Execution and monitoring of works as per the tender conditions and approved plan &
schedule of the work. Every work should be efficiently organized and programmed to
progress speedily and completed within the specified period. ADEN shall ensure
timely measurements and preparation of bills with prescribed test checks for ensuring
quality and quantity;
(5) Measurement of Ballast – ADEN may either measure and record the measurements
of ballast or carry out 100 % check on quality and quantity, if measurements are
recorded by the SSE/P.Way (In-charge) or SSE/Works (In-charge) as per the practice
prevailing in Railway
(6) Co-ordination with Officials of other Departments as warranted;
(7) Monitoring of inspections, works and other records of subordinate officials. The ADEN
shall also scrutinize the inspection entries made by SSE/P.Way (In-charge) and
JE/SSE/P.Way (Sectional) in Track Management System (TMS), and shall ensure
compliance of the items, which need attention within a reasonable period.
(8) Inspection and test check of USFD-Checking of work of JE/SSE/P.Way (USFD) at
least once during each month or as specified by higher authority;
(9) Inspection of Office and Stores of all SSE/P.Way (In-charge) at least once a year.
When checking stores, particular attention should be paid to the availability and proper
distribution of Imprest materials, upkeep and working of small track machines,
Engineering indicators, protection equipment and other important items in stores and
records in offices;
(10) Accompanying Inspection by Higher Officials – ADEN shall accompany higher
officials on their inspections and shall carry following records: (Back to Para 106 (12))
(a) All relevant manuals (soft / hard copy) duly updated,
Page 25 of 417
(b) List of Permanent and Temporary speed restrictions,
(c) TMS Information Dump of Assets and Inspections (section details, track diagram,
TRC / OMS records, fracture details and analysis, inspection details of various
assets, etc.) in tab / laptop;
(d) Important registers and other relevant records;
(e) List of sanctioned works and their status;
(f) Inspection notes of higher officers with compliance reports;
(g) Working time table; and
(h) Other specific papers and plans that are likely to be discussed should also be
carried for reference.
(11) Accompanying Track Recording/OMS/Oscillograph Car runs and take down notes
regarding the spots needing attention and ensure rectification of the defects.
(12) Control over Expenditure – ADEN shall exercise due care in passing requisitions for
materials and tools and in the execution of new and maintenance works, ensuring in
all cases that the expenditure is within the allotment or provision available in the
sanctioned estimate.
(13) Training of Probationers – ADEN shall take interest and impart training of all
probationers deputed for training according to the specified programme. ADEN should
also periodically examine the training notes prepared by probationers.
(14) Material under Trial – ADEN shall be responsible for monitoring performance of
‘material under trial’ in his section and ensure that the required details for the same
are collected as per the trial scheme and submitted to divisional office through TMS.
(15) Dealing with staff matter – ADEN shall ensure that:
(a) Strict discipline is maintained within the framework of the rules;
(b) Service and leave records are maintained correctly and up-to-date;
(c) Appeals and representations are dealt with promptly;
(d) Selection for the various posts like Mates and Keymen are made in time and the
posts promptly filled up;
(e) All Senior Section Engineer and other staff working under him receive proper
training in maintenance practices, safety and protection rules at appropriate
stages.
(f) Timely supply of uniform, winter jackets, safety shoes, torches etc. to the staff as
per the stipulated criteria.
(16) Action in case of Emergencies – In case of an accident, including a breach, affecting
the running of trains, he should proceed to the site by the quickest available means.
On the way, he should ascertain the requirements of materials and men at site and
arrange for the same. He should also order for the Accident Relief Equipment as
necessary. He should take all possible measures to restore the traffic quickly.
(17) Ensuring preparedness for action during extreme weather condition:
(a) ADEN shall ensure that preparatory works have been completed and due
precautions have been taken well before the onset of monsoon, summer and
winter;
(b) ADEN shall keep the List of Railway affecting Works with brief history and List of
vulnerable locations, where stationary watchmen are to be posted;
(c) ADEN shall ensure availability of required equipment and proper training /
counselling of patrolmen and stationary watchmen according to the extreme
weather and remedial action requirement;
Page 26 of 417
(d) ADEN shall ensure patrolling of track as per the instruction and patrol chart issued
from division.
(18) Inspection of on-going works, of construction and other organizations (like RVNL,
RITES, DFCCIL etc.) or authorized agencies, in the section as much as possible
during Foot plate/Trolley inspections to check quality of work and ensuring safety of
the running trains.
(19) Inspection of Railway Affecting Works (RAW) / Railway Affecting Tanks (RAT) just
before monsoon jointly with concerned state authority.
(20) Relinquishment/Transfer of charge – ADEN shall follow the Instructions on “Transfer-
of-charge” contained in Para 143 to 147 of the Indian Railways Code for the
Engineering Department.
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Table-1A (Para 103)
Inspection Schedule of Assistant Divisional Engineer
Sl.
Type of Inspection Schedule of Inspection
No.
1 Foot Inspection i. Routes having speed above 110 Kmph and
Note: Items to be checked: Multiple Line Routes: Entire section including
1. Condition of track including track loops lines and yards once in 6 months.
drainage, cuttings and formation. ii. Other Routes: One block section per
Specific items such as SSE/P.Way ( In-charge) each quarter
completeness and condition of Note: In case of multiple lines running closely
fittings, greasing of ERC, toe load Parallel, inspection of all the lines would be
of ERC, soundness and covered in one on- foot inspection; else separate
squareness of PSC sleepers, on- foot inspection will be required for each group
creep in LWR track etc. of such lines.
2. Attendance of Gang, gang work,
equipment, gang chart/ diary, and
books with reference to prescribed
schedule of track maintenance.
3. Work done by minimum one gang
in each SSE/P.Way (In-charge)
jurisdiction every quarter and
record the result of inspection.
2 Trolley Inspection i. Routes having speed above 110 Kmph and
Note: Multiple Line Routes: Entire section once in
Items, which are required to be 6 months by Push Trolley/ Motor Trolley
checked in on foot inspection, would Note: All form of trolley inspection should be
also be checked in trolley inspection. done under block protection.
ii. Other Routes: Entire section including loops
and yard once in 3 months
Note: In case of multiple lines running closely
Parallel, inspection of all the lines would be
covered in one trolley inspection; else, separate
trolley inspection will be required for each group
of such lines.
3 Fast Train Inspection Once in a month - Entire sub-division to be
covered by either Engine or Rear Window of fast
train
4 Level Crossing Once in six months - all level crossings.
5 Curves Inspect the curves based on results of
TRC/OMS/FP and inspection details of JE/
SSE/P.Way
6 Points & Crossings Once a year - All P & C on passenger running
lines; and 10 % of P & C on other lines
7 LWR / SEJ Once in six months- All LWR / SEJs
(Preferably in hottest and coldest months, )
8 Track on Bridges The track on Girder Bridges should be inspected
as a part of the annual Bridge inspection, besides
normal track inspections.
Channel sleepers Once in a year along with
bridge inspection
9 AT welding site At least one welding team under each
SSE/P.Way (In-charge) in a month
10 USFD Test check Monthly- Minimum two hours during regular
trolley inspection
11 Monsoon Patrolling When introduced; should check the work of
Patrolmen at night once in a month either by
Train/Push trolley/Motor Trolley
12 Hot Weather Patrolling When introduced; should check the work of
Patrolmen during day time (preferably between
12:00 to 16:00 hrs.) once in a month either by
Page 28 of 417
13 Night foot plate inspection Once in a month - to check alertness of Gateman
/ Station staff, Patrolmen, Stationary watchmen,
observance of speed limits by Loco Pilots,
visibility of signals/engineering fixed signals /
hectometre posts, riding quality etc.
(Inspection should preferably be done between
00.00 hrs. to 04.00 hrs.)
14 Bridge Inspection Once in a year (after monsoon) – All bridges
including ROB/RUB (Bridges whose condition
warrant special attention to be inspected more
frequently) as per the procedure and instructions
given in Indian Railways Bridge Manual.
15 Tunnels Once in a Year - All tunnels before monsoon
(Tunnels, condition of which, warrants special
attention to be inspected more frequently) as per
the procedure and instructions given in Indian
Railways Bridge Manual.
16 RAW / RAT Every year before monsoon jointly with state
authority as per the procedure and instructions
given in Indian Railways Works Manual.
17 Cuttings Once in a Year before onset of Monsoon as per
the procedure and instructions given in Indian
Railways Bridge Manual.
18 Private Siding Once in a Year.
19 Land Verification Once in a Year as per the procedure and
instructions given in Indian Railways Works
Manual.
20 Side drains, catch water drains, Once in a Year before onset of Monsoon
bridge waterways
21 Office and store of SSE/P.Way Once in a Year.
22 Small Track Machine Once in Six Months
23 Track Machines Fortnightly :
TEXP, CSM, DTS, WST, UNIMAT, BCM,SBCM,
PCCM, TLE, RGM and TRT
Once during deployment: MPT, BRM. UTV and
all others not included above.
(Note: Inspection shall be done as per the Items
and inspection checklist given in IRTMM)
24 Work of Other Organization like As much as possible during Foot plate/Trolley
RVNL, RITES, DFCCIL, Construction inspections.
etc. Inspection to check quality of on-going work and
safety of the running trains on adjacent lines.
Note:
1. Availability of a reasonable level of road access in the section is required for enabling
substitution of trolley inspection by On-foot inspection. On some of the routes, which would
mainly be situated in Ghat sections, this condition may not get fulfilled. Trolley inspection
and On-foot inspection as per frequency for “Other Routes” would be followed on all such
routes even in the category of “Routes having speed above 110 Kmph and Multiple Line
Routes”. These sections would be identified and approved by PCE. While identifying these
sections, the lowest unit would be a complete section of an SSE/ P.Way (In-charge).
2. It would be desirable that in the absence of trolley, UTV/Rail Borne Maintenance Vehicle
(RBMV) supplement the movement by road utility vehicle. This would be particularly useful
for some of the work sites, such as AT welding work, and for repairs in emergency.
Availability of UTV/RBMV would enable efficient utilization of the available manpower. Steps
would be taken for early induction of UTV/RBMV on these routes.
3. Implementation of inspection as per schedule 1 (i) and 2 (i) would be decided by PCE taking
into consideration availability of infrastructure for required mobility. Till the time inspection as
per schedule 1 (i) and 2 (i) is implemented, inspection would be done as per schedule under
1 (ii) and 2 (ii) for all the routes.
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4. For personal safety during on-foot inspection, inspecting officials, along with their assistants,
should be accompanied by additional Trackman/Trackmen specially to alert officials from
approaching train and have Personal Protective Equipment, which needs to be prescribed.
They should also carry Approaching train warning system. Zonal Railways should prioritize
its availability for higher speed routes and Ghat section.
Page 30 of 417
PART - ‘B’
DUTIES OF SENIOR SECTION ENGINEER / P.WAY IN OVERALL
CHARGE
104 General – The Senior Section Engineer/P.Way in overall charge, abbreviated as
SSE/P.Way (In-charge), is generally responsible for:
(1) Maintenance and inspection of track in a satisfactory and safe condition for traffic.
(2) Efficient execution of all works incidental to track maintenance, including track
relaying works.
(3) Accountal and periodical verification of stores and tools.
(4) Maintenance of land boundaries between stations and at unimportant stations as may
be specified by the administration.
(5) Compliance of Inspection notes of higher officers in reasonable time.
105 Knowledge of Rules and Regulations – (Back to Para 108, 111)
1) Every SSE/P.Way (In-charge) shall have in his possession up-to-date copies of the
codes and manuals etc. with all correction slips up-to-date as per Para 102.
2) SSE/P.Way (In-charge) shall be well acquainted with the rules, regulations and
procedures concerning the work and duties as enjoined in these codes, manuals
etc. He shall keep himself in touch with the instructions and circulars issued by
higher authorities from time to time and efficiently act upon them.
3) SSE/P.Way (In-charge) shall ensure that all the staff are well acquainted with the
relevant rules and working methods and efficiently perform assigned duties.
4) SSE/P.Way (In-charge) shall be well conversant with the various modules of the
Track Management System.
106 Duties of SSE/ P.Way (In-charge) are detailed as below:
(1) Inspection and maintenance of track in a satisfactory and safe condition.
SSE/P.Way (In-charge) shall conduct inspection in his jurisdiction as per the
Schedules laid down (Table-1B) by the Administration from time to time, enter the
inspections details in TMS, and ensure compliance within a reasonable time as per
the guidelines.
SSE/P.Way (In-charge) being directly responsible for the safety of the track, shall
(a) Devote sustained attention to Permanent way as regards safety, smooth running,
economy and neatness.
(b) Be vigilant to locate all faults/irregularities in the Permanent Way and ensure
prompt remedy.
(c) Observe the behaviour of track under passing trains to detect inadequate packing
during routine inspections.
(d) Travel on the footplate of Engine / Rear brake-van/last Vehicle of fast trains, take
down notes of bad running locations, and get them rectified.
(e) Immediately bring the defects, which are beyond powers to remedy, to the notice
of Assistant Divisional Engineer and obtain advice.
(f) Ensure timely removal / cutting of trees in proximity to and liable to foul the track
during a storm.
(g) During routine inspections, independent of detailed periodical inspections, watch
for any signs of weakness in bridges and structures affecting track and promptly
report any matter demanding the attention of Assistant Divisional Engineer.
Page 31 of 417
(2) SSE/P.Way (In-charge) of section should have a thorough knowledge of important
pre-requisites for proper functioning of LWR/CWR and the limitations and precautions
laid down for work on LWR/CWR and ensure that the maintenance instructions are
strictly followed by all the staff dealing with maintenance of LWR/CWR. (Back to Para
110(5))
(a) SSE/P.Way (In-charge) of section shall- (Back to Para 109(2))
(i) Supervise all track maintenance work for which they are responsible and
authorised.
(ii) Make arrangements for patrolling of track in hot and cold weather and post
mobile watchmen as and when required and ensure that patrolmen and mobile
watchmen are issued proper equipment for carrying out patrolling.
(iii) Responsible for repairs and restoration of traffic in case of accident, derailment,
buckling, wash-away, rail fracture etc.
(iv) Responsible for greasing of ERCs, effectiveness of all fittings, soundness and
squareness of sleepers, track drainage etc.
(v) Responsible for carrying out de-stressing, welding and other maintenance
operation correctly and complete them within the block period for which block
has been taken.
(vi) Record rail temperatures, de-stressing temperature, minimum and maximum
rail temperatures and also periodically check the rail thermometers used for
recording rail temperature with reference to standard thermometer.
(vii) Ensure imposition of necessary speed restriction, in case the temperature
exceeds td + 20°C after the maintenance work has been completed on LWR/
CWR for the period of consolidation.
(viii) Ensure proper ballast section of the track and shall arrange to recoup the
ballast, as per standard ballast profile, before the onset of summer.
(b) SSE/P.Way (In-charge) of section shall be responsible for:
(i) The procurement of the permanent way materials and the equipment required
for the maintenance of LWR/ CWR for all the staff working under him.
(ii) Maintenance of a permanent record of each LWR/CWR as per the proforma
and shall be responsible for keeping the records up-to-date.
(3) Inspection and maintenance of Bridges: SSE/P.Way (In-charge) shall; (Back to Para
109(3))
(a) Inspect the track and approaches of all the bridges including footpath (and runoff
frame if any) once a year during the prescribed months prior to monsoon (Para-
1101 of IRBM).
(b) Inspect the track and approaches at every tunnel and cutting before monsoon or
as specified, and take the remedial action if required for safety of track. SSE/P.Way
(In-charge) shall be responsible for clearing the drains before monsoons in tunnels
and cuttings.
(c) Follow instructions given in relevant manuals and the local instructions of higher
authority while maintaining the track in Ghat section, in cuttings, on high banks or
any other vulnerable section.
(4) Track Machines- SSE/P.Way (In-charge) shall monitor and ensure progress and
quality output of various track machines working in the section, and shall
(a) Ensure all prerequisites, pre-block, during block and post-block activities according
to track machine and for quality output.
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(b) Be responsible for temporary storage and timely arrangement and transportation
of HSD oil from the depots to various machines working in his jurisdiction.
(c) Be responsible for making lighting arrangement during night working.
(d) Ensure transportation of tamping tools to be reconditioned and bringing back
reconditioned tamping tools to the machine.
(e) Be responsible for protection of the site of work and adjoining track wherever
necessary.
(f) Be responsible for arranging adequate precautionary measures for the protection
of the site of work and adjoining track wherever necessary along with the safety of
staff working with machine in the block section against danger of trains on the
adjoining line(s).
(g) Arrange for track protection and provide look out men for safety at site.
(h) Be responsible to ensure that the machine(s) are stabled in suitable sidings and at
such stations as to minimize idle run of the machines as well as wastage of block
hours in entering and clearing of the block section.
(i) Arrange for protecting and watching of stabled machines and also ensure that no
sick vehicles etc. are pushed into the same siding affecting the taking out of the
machines to avail blocks.
(j) Co-ordinate with other departments like Traffic, OHE and S&T in the field to
facilitate smooth working.
(k) Take all possible actions to clear the block section expeditiously, in the eventuality
of breakdown of machine, once it is known that it cannot be repaired during block.
(l) Inspect the track machines as per the prescribed schedule (Table-1B) and items /
check lists as per IRTMM;
(5) Preparation of plans and estimates of various track works and submission of
proposals to ADEN for further action.
(6) Execution and monitoring track works as per the tender conditions and approved plan
&schedule of the work. SSE/P.Way (In-charge) shall ensure timely measurement and
bill preparation with proper test check and ensuring quality. (Back to Para 109 (5))
(a) Special works: Before commencing any work, SSE/P.Way (In-charge) shall ensure
that all necessary materials and tools are in possession.
(b) SSE/P.Way (In-charge) should programme the works by organizing the labour in
an efficient manner; and maintain detailed accounts of materials received and
issued to the work.
(c) SSE/P.Way (In-charge) shall ensure that Engineering Signals are exhibited at the
specified distances according to rules and Flagmen are posted with necessary
equipment; and should exercise as much as possible checks but minimum once in
a month on quality and quantum of work and submit progress reports on works
periodically as may be prescribed.
(d) Quality of welding and avoidable fractures – The direct responsibility for quality of
AT welding being done in the section shall rest on the SSE/P.Way (In-charge) of
the section. He will ensure that the equipment available with the welding team are
complete and are in good condition.
(e) The responsibility for avoidable fractures taking place in the section shall also rest
with the SSE/P.Way (In-charge) of the section, except in cases where the USFD
testing was done and found good up to three months before the fractures.
(f) SSE/P.Way (In-charge) shall ensure to arrange for the repairs and maintenance of
small track machines available with him.
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(g) Other P-Way maintenance works: SSE/P.Way (In-charge) shall ensure that all the
P.Way maintenance works like casual sleeper / rail /fittings renewal, de-stressing,
bad spot attention, overhauling at level crossings, oiling and greasing of joints and
ERCs, fracture attention, glued joint / SEJs/ Switches / Crossings replacement,
rails / sleepers transportation through rail dolly, handling of material trans like
ballast / rails/ sleepers unloading in block etc. are being done as per the stipulated
provisions of IRPWM / G&SR and with proper safety of running trains and working
staff.
(7) Material Under Trial: SSE/P.Way (In-charge) shall be responsible for monitoring
performance of ‘material under trial’ in his section and ensure that the required details
for the same are collected as per the trial scheme and submitted to ADEN through
TMS.
(8) Measurement of Ballast: SSE/P.Way (In-charge) will measure the ballast, if so
directed by the ADEN, and record measurements. SSE/P.Way (In-charge) will also
keep proper records of training out and spreading of ballast in the track.
(9) Co-ordination with Works, Bridge and Staff of other Departments – SSE/P.Way (In-
charge) should keep close co-ordination with the Works, Bridge, Operating, Signalling
and Electrical Staff, when they are required to work jointly.
(10) Inspection and test check of USFD- SSE/P.Way (In-charge) shall check the work of
SSE/P.Way/USFD at least once in each round of testing or as specified by higher
authority. SSE/P.Way (In-charge) shall also ensure the USFD testing of AT welds
within the earliest possible time and as per the specified period/frequency.
(11) Dealing with store: SSE/P.Way (In-charge) is the in-charge of store depot and shall
be accountable of each item of P.Way in the jurisdiction. SSE/P.Way (In-charge) shall
(a) See to the security of rails, sleepers, fastenings and other materials and ensure
that unused materials are stacked properly clear off the line, so as not to interfere
with the safe running of trains.
(b) Be responsible for submitting the requisition/indent for the procurement of various
materials as per the need well in advance to avoid critical situation especially of
safety items like fittings, gang tools and other safety equipment etc.
(c) Be responsible for ensuring availability of various materials like Imprest rails, CMS
crossings, switches, SEJs, Glued joints, etc. at nominated locations in the section
in order to avoid the delay in attention of emergency repairs/replacement.
(d) Be responsible for offering the scrap and unused materials for their timely disposal.
(e) Keep the records of every transaction of each material from and to the store.
(f) Keep his store in neat and tidy condition and will cooperate in verification of stores
with stock verifier.
(12) Accompanying Inspection by Higher Officials: In addition to the compliance to Para-
103 (10), SSE/P.Way (In-charge) shall arrange to carry the following measuring
devices/equipment for these inspections –
(a) Gauge-cum-level.
(b) Flange way gauge.
(c) Fishing cord.
(d) Tape.
(e) Metric steel scale (30 cm).
(f) Tapered gauge& Feeler gauge.
(g) Magnifying glass and mirror.
(h) Versine measuring equipment.
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(i) Inspection hammer etc.
(j) Rail Thermometer.
(13) SSE/P.Way (In-charge) shall accompany Track Recording / OMS / Oscillograph Car
runs in the jurisdiction and take down notes regarding the spots needing attention,
and take appropriate actions to rectify the defects/irregularities.
(14) Training of P.Way officials – SSE/P.Way (In-charge) should take interest in all P.Way
officials sent to him for training and see that the training is given according to the
specified programme.
SSE/P.Way(In-charge) should also ensure that all the P.Way supervisors and staff
are undergoing refresher courses / mandatory and other trainings as per the
schedules laid down; and instructions of higher authorities.
SSE/P.Way (In-charge) shall also be responsible for counselling of Trackmen,
Gateman, Keyman, Patrolman and Stationary Watchman for their specific duties,
safety and protection rules at the appropriate stage, better maintenance practices,
and also examine/check at frequent interval during routine trolley and other
inspections.
(15) Dealing with staff matter: SSE/P.Way (In-charge) shall ensure that:
(a) Strict discipline is maintained within the frame work of the rules;
(b) Service and leave records of staff are maintained correctly and up-to-date;
(c) All staff are sent for medical examination and are fit for the medical standards, as
per the relevant instructions in force, before appointment or promotion.
(d) Ensure that the staff under him are sent for periodical medical examination as laid
down in the relevant rules.
(e) Supply of uniform, winter jackets, safety shoes, torches etc. to the staff are made
timely as per the stipulated criteria.
(f) The relevant provisions of the Payment of Wages Act, Workmen’s Compensation
Act, Hours of Employment Regulations etc., as amended from time to time are
followed and complied with.
(g) Issue of passes, preparation of pay bills etc., as may be allotted by the
administration is being done promptly.
(h) Selection of proper Gatemen and Patrolmen are carried out from the existing Track
Maintainers and train them in their duties.
(i) Prompt processing for filling up of the vacancies of Keyman, Gang Mate and
artisans etc.
(j) Appeals and representations are dealt with promptly;
(16) Action in case of Emergencies – In the case of an accident, including a breach,
affecting the running of trains, SSE/P.Way (In-charge) should proceed to the site by
the quickest available means. (Back to Para 109 (9))
On the way, SSE/P.Way (In-charge) should ascertain the requirements of materials
and men at site and arrange for the same.
SSE/P.Way (In-charge) should also order for the Accident Relief Equipment as
necessary and take all possible measures to restore the traffic quickly.
(17) Ensuring preparedness for action during extreme weather condition: SSE/P.Way (In-
charge) shall- (Back to Para 109(10))
(a) Keep the List of Railway Affecting Works with brief history and List of vulnerable
locations, where stationary watchmen are to be posted.
(b) Ensure that preparatory works have been completed and due precautions have
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been taken well before the onset of monsoon, summer and winter.
(c) Ensure proper watch at vulnerable locations as per the requirements;
(d) Arrange for patrolling (hot weather, cold weather and monsoon) of track as per the
instruction and patrol chart issued from division.
SSE/P.Way (In-charge) shall ensure availability of patrol book and required
equipment with them. Before deploying trackmen for patrolling, proper training /
counselling of patrolmen should be done. Stationary watchmen at vulnerable
locations according to the extreme weather should be deployed with necessary
equipment to ensure safety of track.
(18) Inspection of on-going works of construction and other organization like RVNL,
DFCCIL etc – SSE/P.Way (In-charge) should inspect the ongoing works in the section
as much as possible during Foot plate/Trolley inspection to check quality and safety
of the running trains.
(19) Upkeep of Station Yards – SSE/P.Way (In-charge) shall ensure cleanliness of station
yards. Under- growth should be cleared every year, usually in the month, before the
seeds has ripened. At stations where it is proposed to stack engineering or
contractor’s materials, the stacking area should be carefully selected and clearly
demarcated. The materials should be stacked methodically in a tidy manner.
(20) SSE/P.Way (In-charge) shall be responsible for maintaining the land boundaries
intact and free from encroachment by outsiders in his jurisdiction. SSE/P.Way (In-
charge) should keep watch and take immediate necessary action for removal of any
type of encroachment, if noticed.
(21) Maintenance and up keep of Correspondence and records- SSE/P.Way(In-charge)
shall keep all correspondences up-to-date and see that the TMS records, office
records, registers and stores ledgers are maintained systematically and posted
regularly and as required.
SSE/P.Way (In-charge) shall update the data in TMS timely in appropriate fields
relating to all types’ inspections, all kinds maintenance works and all
casual/scattered/planned renewal activities etc. for all the assets.
(22) Relinquishment of charge – SSE/P.Way (In-charge) shall follow the Instructions on
“Transfer-of-charge” contained in Para 143 to 147 of the Indian Railway Code for the
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PART ‘C’
DUTIES OF JUNIOR ENGINEER /SENIOR SECTION
ENGINEER/P.WAY/(SECTIONAL)
107 General Responsibilities – The Junior Engineer/Senior Section Engineer /P.Way,
working as sectional and abbreviated as JE/SSE/P.Way (Sectional) is generally responsible
for:
(1) Inspection and maintenance of track in the sub-section in a safe and satisfactory
condition for traffic, lorrying out of material, including execution of all works incidental
to track maintenance.
(2) Efficient execution of Special Works, such as Renewals, Spot attention, Curve
realignment and deep Screening, as per approved plans and specifications.
(3) Making a date wise schedule and record in the Keyman’s book indicating the Kms/TPs
that the Keyman has to attend on each day of the month to complete the task required
to be done as per his duties.JE/SSE/P.Way (Sectional) during their inspections should
check to ensure that such locations have really been thoroughly attended to and initial
against the entries.
108 Knowledge of Rules and Regulations – As per provisions contained in Para
105.
109 Duties of JE/SSE/P.Way (Sectional) are detailed as below:
(1) Inspection and maintenance of track in a satisfactory and safe condition.
JE/SSE/P.Way (Sectional) shall conduct inspection as per the Schedules laid down
by the Administration (Table-1B); enter the inspections data in TMS, and attend to
the deficiencies noticed at the earliest possible.
JE/SSE/P.Way (Sectional) being directly responsible for the safety of the track; shall
(a) Devote sustained attention to Permanent way as regards safety, smooth running,
economy and neatness.
(b) Be vigilant to locate faults/irregularities in the Permanent Way and ensure prompt
remedy.
(c) Observe the behaviour of track under passing trains to detect inadequate packing
during routine inspections.
(d) Travel on the footplate of Engine /Rear brake-van/last Vehicle of fast trains, take
down notes of bad running locations, and get them rectified.
(e) Immediately bring the defects, which are beyond powers of remedy, to the notice
of SSE/P.Way (In-charge) and obtain advice.
(f) Ensure timely removal / cutting of trees in proximity to and liable to foul the track
during a storm.
(g) During his routine inspections, independent of detailed periodical inspections,
should watch for any signs of weakness in bridges and structures affecting track
and promptly report any matter demanding the attention of higher authority.
(2) JE/SSE/P.Way (Sectional) should have a thorough knowledge of important pre-
requisites for proper functioning of LWR/CWR and the limitations and precautions laid
down for work on LWR/CWR and ensure that the maintenance instructions are strictly
followed by all the staff dealing with maintenance of LWR/CWR.JE/SSE/P.Way
(Sectional) shall be responsible for the duties as mentioned in Para 106(2) (a).
(3) Inspection and maintenance of track at Bridges/Tunnels/cuttings: As per provisions
contained in Para-106 (3). (Relating to track only)
(4) Track Machines- while deputed on machine JE/SSE/P.Way (Sectional) shall be the
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in-charge of the supervision of the work of track machine and responsible for following
duties:
(a) Ensuring safe movement of machine from siding to block section and back as per
the provisions given in IRTMM and G&SR.
(b) Undertaking & ensuring all prerequisites, pre-block, during block and post-block
activities according to track machine and for quality output.
(c) Arranging adequate precautionary measures for the protection of the site of work
and adjoining track wherever necessary along with the safety of staff working with
machine in the block section against danger of trains on the adjoining line(s).
(d) Ensuring various important Parameters of track machines like tamping depth,
squeezing pressure, wear and tear of tamping tools, squeezing time, condition of
cutter bars etc. as per the type of machine and provisions of IRTMM in order to
ensure quality and output of machine during block.
(e) Checking of the track Parameters and condition of track, during working of track
machines, and ensuring that the track Parameters are well within the tolerances.
(f) Ensuring that track is free of obstructions and infringements for safe passage of
traffic before clearing the traffic block. As required or stipulated JE/SSE/P.Way
(Sectional) shall allow traffic at suitable speed restriction based on the condition of
track after machine working.
(g) To investigate and take suitable remedial measures in coordination with JE/SSE
(Track Machine), in case the quality of work done by the machine is not
satisfactory.
(h) To issue of all necessary caution orders for machine working.
(i) For ensuring that the machine(s) are stabled in suitable sidings and at such
stations as to minimize idle run of the machines as well as wastage of block hours
in entering and clearing of the block section.
(j) Co-ordinate with other departments like Traffic, OHE and S&T in the field to
facilitate working
(k) Take all possible actions to clear the block section expeditiously, in the eventuality
of breakdown of machine, once it is known that it cannot be repaired during the
block.
(5) Execution and monitoring track works – As per provisions contained in Para -106(6)
JE/SSE/P.Way (Sectional) shall carry out maintenance works as assigned to him by
SSE/ P.Way (In-charge).
(6) Co-ordination with Works, Bridge and Staff of other Departments – JE/SSE/P.Way
(Sectional) should keep close co-ordination with the Works, Bridge, Operating,
Signalling and Electrical Staff, whenever they are required to work jointly.
(7) JE/SSE/P.Way (Sectional) should work in the SSE/P.Way (In-charge) office and
assist the SSE/P.Way (In-charge) as required.
(8) Training of P.Way officials – JE/SSE/P.Way (Sectional) shall be responsible for
counselling of Trackmen, Gateman, Keyman, Patrolman and Stationary Watchman
for their specific duties, safety and protection rules at the appropriate stage, better
maintenance practices, and also examine/check at frequent interval during routine
trolley and other inspections.
(9) Action in case of Emergencies – As per the provisions contained in Para -106(16).
(10) Action during extreme weather condition: As per the provisions contained in Para -
106(17).
(11) Inspection of on-going works of construction and other organization (like RVNL,
RITES, DFCCIL etc.) or authorized agencies in the section as much as possible
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during Foot plate/Trolley inspection to check quality of work and ensuring safety of
the running trains.
(12) Upkeep of Station Yards – JE/SSE/P.Way (Sectional) shall be responsible for
cleanliness of station yards. The materials should be stacked methodically in a tidy
manner.
(13) JE/SSE/P.Way (Sectional) shall observe the track movement in yards especially at
turnouts, SEJs, glued joints and other fish plated joints during passing of trains and
shall take corrective measures to rectify the defects observed.
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Table-1B (Para 106, 106(4(l)), 109)
Inspection Schedule of SSE/P.Way (In-charge) and JE/SSE/P.Way (Sectional)
Sl.
Type of Inspection Schedule of Inspection
No.
1 Foot Inspection i) Routes having speed above 110 Kmph
Note: Items to be checked: and Multiple Line Routes
1. Condition of track including track SSE/P.Way (In-charge):Entire section including
drainage, cuttings and formation. loops lines and yards once in 3 months
Specific items such as JE/SSE/P.Way (Sectional) :Entire section
completeness and condition of including loops lines and yards once in a fort
fittings, greasing of ERC, toe load night
of ERC, soundness and ii) Other Routes
squareness of PSC sleepers, SSE/P.Way (In-charge): Entire section including
creep in LWR track etc. loops lines and yards once in a year
2. Attendance of Gang, gang work, JE/SSE/P.Way (Sectional) : Entire section
equipment, gang chart/ diary, including loops lines and yards once in 6 months
books with reference to prescribed Note: In case of multiple lines running closely
schedule of track maintenance, Parallel, inspection of all the lines would be
counselling for safety and method covered in one on foot inspection; else separate
of maintenance. on foot inspection will be required for each group
3. Check to ensure that every man in of such lines.
the gang is aware of safety rules
by examining them periodically at
least once in two months.
4. Routine check and review of
inspection done by his
subordinates.
2 Trolley Inspection i) Routes having speed above 110 Kmph
Items, which are required to be and Multiple Line Routes)
checked in on foot inspection, would SSE/P.Way (In-charge):Independent Push/
also be checked in trolley inspection. Motor Trolley or Accompanying ADEN/ DEN to
cover once in 3 months
JE/SSE/P.Way (Sectional) :- Not defined
Note: All form of trolley inspection should be
done under block protection.
ii) Other Routes
SSE/P.Way (In-charge):Entire section including
loops lines and yards once in 2 months
JE/SSE/P.Way (Sectional): Entire section
including loops lines and yards once in a fort
night
Note: In case of multiple lines running closely
Parallel, inspection of all the lines would be
covered in one trolley inspection; else, separate
trolley inspection will be required for each group
of such lines.
3 Loco/ Break van / Rear window SSE/P.Way (In-charge):Once in a fortnight
JE/SSE/P.Way (Sectional) :Once in a month
4 Level Crossing SSE/P.Way (In-charge) and JE/SSE/P.Way
(Sectional) will inspect all level crossings once in
a month by rotation. They should examine the
Gateman’s knowledge of rules, check the
equipment, track, road approaches and all other
safety aspects.
5 Curves a) For curves > 2 degree: JE/SSE/P.Way
(Sectional) shall inspect once in 6 months
on rotation with SSE/P.Way (In-charge).
b) For curves ≤ 2 degree: JE/SSE/P.Way
(Sectional) shall inspect once in a year. SSE
in-charge shall inspect the curves based on
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results of TRC/OMS/FP and inspection
details of JE/SSE/P.Way (Sectional)
6 Points & Crossings Passenger and running lines- Once in three
months on rotation by SSE/P.Way(In-charge)
and JE/SSE/P.Way (Sectional)
Other lines and yard lines- Once in six months
on rotation by SSE/P.Way(In-charge) and
JE/SSE/P.Way (Sectional)
7 LWR / SEJ Once in fortnight during two hottest and two
coldest months on rotation by SSE/P.Way(In-
charge) and JE/SSE/P.Way (Sectional)
(The hottest and coldest months are specified by
the DEN/Sr.DEN)
Otherwise once in two months on rotation by
SSE/P.Way(In-charge) and JE/SSE/P.Way
(Sectional)
8 Track on Bridges The track on Bridges and approaches once in a
year in a prescribed month before monsoon by
SSE/P.Way (In-charge).
Channel sleepers -
SSE/P.Way(In-charge): Once in 6 months by
rotation with JE/SSE/P.Way (Sectional)
JE/SSE/P.Way (Sectional) : Once in 6 months
by rotation with SSE/P.Way(In-charge)
9 AT welding site SSE/P.Way(In-charge): At least once each
welding team in a month
JE/SSE/P.Way (Sectional): Not defined
10 USFD Test check Monthly- Minimum two hours during regular
trolley inspection by SSE/P.Way (In-charge)
11 Night Inspection Once in a month by SSE/P.Way (In-charge).
12 Monsoon Patrolling SSE/P.Way (In-charge) - once in a month
JE/SSE/P.Way (Sectional) - once in fortnight by
train and inspection by trolley- as per the
schedule laid down by administration.
13 Hot Weather Patrolling SSE/P.Way (In-charge):
When introduced; should check the work of
Patrolmen during day time (preferably between
12:00 to 16:00 hrs.) once in a month either by
14 Night foot plate inspection Once in a month by SSE/P.Way(In-charge)and
JE/SSE/P.Way (Sectional)- to check alertness
of Gateman / Station staff, Patrolmen, Stationary
watchmen, observance of speed limits by Loco
Pilots, visibility of signals/engineering fixed
signals / hectometre posts, riding quality etc.
Inspection should preferably be done between
00.00 hrs. to 04.00 hrs.
15 Bridge Inspection All Bridges once in a year in a prescribed month
before monsoon by SSE/P.Way (In-charge) as
per the procedure and instructions given in
Indian Railways Bridge Manual.
16 Tunnels Once in a Year- All tunnels after monsoon by
SSE/P.Way (In-charge) as per the procedure
and instructions given in Indian Railways Bridge
Manual.
Tunnels condition which warrants special
attention to be inspected more frequently
17 Cutting Once in a Year immediately after monsoon by
SSE/P.Way (In-charge) and before monsoon by
JE/SSE/P.Way (Sectional) as per the procedure
and instructions given in Indian Railways Bridge
Manual.
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18 Private Siding Once in three months by JE/SSE/P.Way
(Sectional)
Once in Six month by SSE/P.Way (In-charge)
19 Inspection of Land Boundary and By SSE/P.Way (In-charge)
encroachment Land Boundary: - Once in a Year.
Encroachment: Once in three months.
(As per the procedure and instructions given in
Indian Railways Works Manual.)
20 Side drains, catch water drains, bridge SSE/P.Way (In-charge)- Once in a Year before
waterways onset of monsoon
JE/SSE/P.Way (Sectional) - once in a year in the
month of April prior to monsoon.
21 Accompanying TRC/OMS Run SSE/P.Way(In-charge) : Accompanying each
run
22 Small track machines SSE/P.Way (In-charge): Once in three months.
23 Work of Other Organization like As much as possible during Foot plate/Trolley
RVNL, DFCCIL, Construction etc. Inspection to check quality of on-going work and
safety of the running trains on adjacent lines by
SSE/P.Way (In-charge) and JE/SSE/P.Way
(Sectional) both.
24 Inspection of washable apron Once in three months on rotation basis by
(Sectional)
25 Inspection of Yard lines All yard lines once in six months by SSE/P.Way
(In-charge) and JE/SSE/P.Way (Sectional) by
rotation.
26 Sand humps and dead end All sand humps and dead end to be inspected by
(Sectional) once in a month, by rotation
27 Joint Inspection with S& T Department
(1) Points & Crossings (1) Once in three months on rotation basis by
SSE/P.Way(In-charge)and JE/SSE/P.Way
(Sectional)
(2) Inspection of insulated Steel (2) Once every six months on rotation basis by
Sleepers on bridges SSE/P.Way(In-charge) and JE/SSE/P.Way
(Sectional) for insulated Steel Sleepers on
bridges
28 Inspection of Track Machine (When SSE/P.Way (In-charge) & JE/SSE/P.Way
working in section) (Sectional): During supervision of pre-block,
during block and post-block works but not less
than once a week.
Note: Inspection shall be done as per the Items
and inspection checklist given in IRTMM
Note: Note below Table -1A regarding road access, availability of vehicle such as UTV/RBMV,
decision of implementation of system of inspection and personal safety during on – foot inspection
would also be applicable for Table-1B .
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PART ‘D’
DUTIES OF JE/SSE/ P.WAY
(OTHER THAN SECTIONAL OR IN-CHARGE)
110 General Responsibilities – The JE/SSE/P.Way not in overall charge or sectional;
but working as in-charge of assigned Gang(s); or of special Works, is responsible for:
(1) Regular inspection of all assets as per laid down frequency as per Table 1-C and
maintenance of track in the assigned jurisdiction (section of gang/Yard) in a safe and
satisfactory condition for traffic, lorrying out of material, including execution of all
works incidental to track maintenance. He shall remain with the gang for at least two
days in a week and supervise gang work unless otherwise directed by SSE/P.Way
(In-charge).He should record all the details of his inspection in his diary and rectify
the noted deficiencies as early as possible.
(2) Efficient execution of Special Works, such as Renewals, spot attention, or as
instructed from higher authority.
(3) Working in the SSE/P.Way (In-charge) office and assist the SSE/P.Way (In-charge)
as directed.
(4) He will be responsible for the output and quality of works entrusted to him and ensure
that the all such works are carried out with safety following the stipulated rules.
(5) JE/SSE/P.Way (Special/Relaying) posted for carrying out special works etc. in
LWR/CWR territory shall be responsible for all the items indicated in Para 106(2) apart
from any other responsibilities assigned.
(6) Keep watch on vulnerable locations and ensure safety.
(7) Observe the track movement in yards especially at turnouts, SEJs, trespasses, glued
joints and other fish plated joints during passing of trains and shall take corrective
measures to rectify the defects observed.
(8) Ensure quality of work executed under his supervision.
(9) Whenever JE/SSE/P.Way is in-charge of gang(s) / units, they He will carry out all the
duties/ responsibilities assigned to the Gang Mate as laid down in Part 'E' of this
chapter in addition to the duties mentioned in above Para.
(10) Any other duties assigned by SSE/P.Way (In-charge) or any other higher officials
111 Knowledge of Rules and Regulations – As per provision contained in Para 105.
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Table-1-C (Para 110)
Inspection Schedule of JE/SSE/P.Way (Other than In-charge or Sectional)
S.N. Type of Inspection Schedule of Inspection
1 Foot Inspection i. Complete section once in a month in a systematic manner of
Note: all individual passenger running lines including through lines
This inspection may of yard portion.
be done with ii. Other than passenger running lines – Once in three months.
concerned Keyman Note: During inspection, he will note down all the irregularities
in his jurisdiction like details of missing/ineffective fittings in plain track,
and submit the greasing of ERC, turnouts, SEJs, Glued Joints and on
report to bridges, cracked/damaged sleepers, unsquared
SSE/P.Way(In- sleepers, ballast deficient locations, Trespass locations,
charge) through bridge approaches requiring immediate attention.
JE/SSE/P.Way He will observe the packing condition under the running
(sectional) train especially at turnout/ SEJ/Tress pass locations
/glued joints etc. and will note down in his diary, the bad
patches requiring attention.
All such locations needing attention, shall be attended by
him using the gang under his jurisdiction.
2 Inspection of Gang i. Once in a week-
Note: Include checking attendance of gang, gang work, equipment,
gang chart/ diary, counselling for safety and method of
maintenance.
Checking of gang working of previous day. He shall also
make entry of gang work in TMS on daily basis as directed.
3. Level Crossing Will inspect all Level Crossing once in a month for missing / loose
fittings and make good the deficiencies as noted.
4 Curves All curves once in six months for condition of Rails, sleeper,
fittings, ballast, packing, gauge and cross level etc.
5 Points & Crossings i. On passenger running lines once in a month.
ii. Other lines - Once in three months.
Note: -All points and crossing shall be inspected for condition of
fittings, rail, sleeper stock and tongue rail, crossing, check rails
etc. including packing condition and other track Parameters. All
such locations needing attention, shall be attended by him using
the gang under his jurisdiction.
6 Night Inspection As prescribed by higher authority.
7 Hot Weather Should check the work of Patrolmen during day time (preferably
Patrolling between 12:00 to 16:00 hrs.) once in fortnight with on foot
inspection covering his entire jurisdiction.
8 Work of Other During on Foot inspection - Inspection to check safety of the
Organization like running trains on adjacent lines.
RVNL, DFCCIL,
Construction etc.
9 Inspection of SEJ Once in fifteen days for condition of packing, fittings etc. with
oiling and greasing. All such locations with deficiencies as noted
shall be attended by him using the gang under his jurisdiction.
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PART ‘E’
DUTIES OF GANG MATE, KEYMAN, PATROLMAN, GATEMAN
AND TRACK MAINTAINER
112 General: Every Gang Mate, Keyman and Track Maintainer shall be responsible for
maintenance and safety of track in every situation. They shall follow the instructions of their
concerned higher authorities.
113 Knowledge of Rules and Signals – Every Gang Mate, Keyman and Track
Maintainer shall have the correct knowledge of hand and detonating signals and shall be
conversant with the following rules:
(1) “Safety first” rules.
(2) Method of fixing and safety range of detonators.
(3) Protecting the line in an emergency and during work(s) affecting the track/safety.
(4) Action to be taken when a train is noticed to have parted, having hot axle or any other
unusual(s).
(5) Action to be taken where sabotage is suspected and patrolling in emergencies.
114 Important Duties of Gang Mate:
(1) Safety of the Line – Every Gang Mate shall see that the line is kept safe for the
passage of trains. All locations needing urgent attention shall be attended to without
waiting for orders from the JE/SSE/P.Way.
(2) Knowledge of Track Maintainer - Gang Mate shall ensure that every track
maintainer is having knowledge of safety rules before deploying them on track.
Gang Mate shall ensure that the safety equipment and signals supplied to the Gangs
are kept in good order and ready for use and that every person in the Gang has correct
knowledge of all these safety equipment and signals.
(3) Equipment at Site of Work – Gang Mate shall ensure that all the requisite tools and
equipment as prescribed with gang are with the trackmen at the site of work.
(4) Musters and Gang Charts/Diary Books –
(a) The muster and Gang chart /diary shall be in the possession of each Gang Mate.
The Gang chart should be carefully kept in a container provided for the purpose.
(b) The muster should normally be marked by the Gang Mate. However, literate Track
Maintainer may be allowed to sign muster, which should be checked by Gang
Mate.
(c) The Gang Mate shall see that the prescribed system of track maintenance is
adhered to and the tasks allotted, according to verbal instructions or entries made
in his Gang chart / diary, and explained to him, are efficiently carried out including
lubrication of rail joints, attention to bad spots and isolated renewed of sleepers, if
capable of entering details of work done in Gang diary, the Gang Mate should do
so.
(5) Observance of Sleeper Packing During Passage of Train – During the passage of
the first and last trains in working hours, the Gang Mate and the Trackmen should
stand on the cess, each about one rail length apart, and observe the effect on the
sleepers. Loose sleepers should then be marked and adequately packed. On double
line, the Gangs shall invariably stand on the cess side and not in between the tracks.
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(6) Precautions when View is Obstructed –
When working at a place from where an approaching train cannot be seen at least
600 metres away a Track Maintainer with hand signals should be sent out by the Gang
Mate:
(a) On double line in the direction of approaching trains,
(b) On a single line in the direction the view is obstructed (in both directions if view is
obstructed on both sides).
It will be the duty of such Flagman to warn the Gang Mate by means of signals
when a train is approaching.
The Gang Mate will be responsible for warning the Gang in good time to enable
them to get clear off the track. It may be deemed expedient, as an additional
precaution, to issue portable whistle boards of the type indicated to the Gang
Mates, who should fix them at least 600 metres from the work-site, in the direction
the view obstructed to less than this distance.
(7) Tidiness of Section – Gang Mate shall see that the entire Gang length is kept neat
and tidy and that all loose materials are collected and brought to stations, gang’s
quarters or gate lodges.
(8) Safe Custody of Tools – Gang Mate shall be responsible for the safe custody of
tools used by himself, the Keymen and all Track Maintainers. Gang Mate should see
that Track Maintainers on work remove their tools clear of the track on the approach
of a train. After the day’s work the Gang Mate should secure the tools in the toolbox.
In no case should Track Maintainers be permitted to take tools home. Before Track
Maintainers break for mid-day meals the Gang Mate should see that the tools are kept
away from track.
(9) Action when Line is Unsafe or in the Event of Accident –
(a) If a Gang Mate or his Keyman considers that the line is likely to be rendered unsafe,
or that any train is likely to be endangered in consequence of any defect in the
permanent way or works, or due to abnormal rain or flood or any other occurrence,
Gang Mate shall take immediate steps to secure the safety of trains by using the
prescribed signals to “Proceed with Caution” or to “Stop” as necessity may require,
vide Para 806/812, and shall, as soon as possible, report the circumstances to the
nearest Station Master and the JE/SSE/P.Way.
(b) In the event of an accident, the Gang Mate, Keymen and Track Maintainers should
lookout for broken fittings of wagons and track components and see that these are
not disturbed until these have been seen and recorded by a responsible official.
(10) Patrolling during Abnormal Rainfall – During abnormal rainfall, the Gang Mate
should organise patrolling on the gang-length, whether or not Patrolmen are on duty.
In the event of damage being detected, action should be taken to safeguard traffic by
protecting the line in accordance with Para 812.
(11) Commencing Work Affecting Safety of Trains – No work, which may involve
danger to trains, should be under taken by the Gang Mate except under the personal
supervision of the JE/SSE/P.Way, a competent Railway servant authorised by special
instructions, unless it is an emergency where the requirements of safety warrant the
commencement of the work. In such cases the Gang Mate shall ensure that
Engineering Signals are exhibited at the specified distances according to rules and
Flagmen are posted with necessary equipment to man them before commencing the
work.
(12) Weekly Inspection of Gang Length by Gang Mate – Gang Mate shall inspect the
entire Gang length once a week. On that day Gang Mate will carry out the Keyman’s
duties; and the Keyman will remain in-charge of the Gang.
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(13) Preventing Trespass and Theft of P.Way Fittings – Every Gang Mate and the
trackmen shall endeavour to prevent trespass in Railway limits by persons or cattle
on the gang length, of line, and report any attempts at encroachment or unauthorised
structures when noticed. Gang Mate along with Gang, should also attempt to prevent
theft of P.Way fittings and report any attempt to steal, to JE/SSE/P.Way.
(14) Relief arrangement in Emergencies – Gang Mate shall arrange immediate relief for
Keymen, Gatemen, Patrolmen and Watchmen when, due to sickness, they are unable
to perform their duties.
(15) Assistance in protection of Trains – Gang Mate and the trackmen should render
assistance to Guards and Drivers of the trains for the protection of the trains in the
event of an accident between stations, when called upon to do so.
(16) Assistance in Placing Fog Signals – On requisition from the Station Master, the
Gang Mate of a yard gang may depute, if available, two Track Maintainers for placing
of detonators, during time of poor visibility, in the rear of approach signals of the
station.
(17) Responsibilities of the Gang Mate in LWR Track – The specific duties and
responsibilities of the Gang Mate in LWR sections are as under:
(a) To carry out maintenance work under personal supervision, only if in possession
of valid competency certificate issued by Zonal/Divisional Training Centre to work
on LWR/CWR section.
(b) To undertake only those works of track maintenance for which Gang Mate is
authorised.
(c) To maintain additional/special equipment issued in good condition and bring to the
notice of JE/SSE/P.Way, if any defective equipment need repairs.
(d) To introduce hot/cold weather patrolling when instructed by the Supervisors and
ensure that hot/cold weather patrolmen turn out on duty during the specified patrol
period and carry out the patrolling duties correctly.
(e) To be vigilant during hot weather and order patrol if the temperature is likely to
reach td+20°C and report to the supervisors any unusual occurrences that take
place on the LWR/CWR in his beat.
(f) To take prompt action to protect the track in case of rail/weld fractures and carry
out emergency repairs to permit the restoration of traffic promptly and report to
nearest Station Master /SSE/JE/P.Way.
(g) To take immediate steps to secure the safety of the trains as per Para 806/812, if
they consider that track is likely to be rendered unsafe.
(h) To report any ballast deficiency or disturbance of track to the JE/SSE/P.Way.
(i) To inspect SEJ and LWR/CWR under his jurisdiction frequently, especially during
the hottest part of the afternoons in summer and report any unusual occurrence on
LWR/CWR to JE/SSE/P.Way to obtain further order.
(j) The Gang Mate shall note down the details of missing fittings and fastenings on
plain track, turn-outs, SEJs, Glued Joints, bridges etc. and recoup them as soon
as possible. He will also note down the details of cracked/ broken/ notched
sleepers in the track and advise the same to JE/SSE/P.Way.
(k) On receipt of advice of a danger of buckle,
i. The Gang Mate should proceed to the site quickly with all available
men/resources and ensure protection of affected portion at site.
ii. Thereafter the Gang Mate should inspect the condition of track 100 m on either
side of this suspected zone and commence heaping of surplus ballast, if
available, on the shoulders and up to the rail head and keep on compacting the
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ballast with available tool.
iii. No attempt should be made to slew or align the track or disturb the existing ballast
section. The Gang Mate should continue to remain at site till the arrival of
JE/SSE/P Way.
iv. The rail temperature will also be noted by one of these officials at the place of
apprehended/actual buckle. The rail facing the sun will be covered up to the level
of rail-head on the outside by ballast or leaves etc. to bring down the temperature
of the rail.
115 Responsibilities of a Keyman:
(1) General: The Keyman shall inspect the entire beat once a day on foot, both the tracks
and bridges, and return along the opposite rail to that taken on outward journey in
case of single line. On double line, Keyman will carry out one round of inspection in
morning hours by going along up line and then returning along down line or vice-
versa. On the days of Gang holidays and rest, the Keyman shall perform the usual
duties and get a day’s rest in the week as per the roster duties in force. On rest days
or during absence or leave or sickness, a competent Track Maintainer should be
deputed in place of the regular Keyman.
(2) Roster duty hours of Keyman – The roster duty hours of Keyman for winter months
should be so adjusted as to ensure one round of track inspection in early morning to
enable detection of any rail or weld fractures that might have occurred during the night
or early morning. DEN/Sr.DEN of the section shall decide and notify the exact timings
and the period of each section.
(3) Equipment of Keyman – Keyman shall carry two red flags, and one green flag, ten
detonators, a keying hammer, Alloy Spanner D/E, Spanner Tubular, Tapered Gauge,
Tapered Pin, Keyman Diary, spare fittings and a rail closure of 30 mm size.
116 Important Duties of Keyman –
(1) While walking the Keyman should look for defects, such as loose fish bolts, loose
bolts on joggled fish plates, SEJ, fittings in switches and crossings, fittings on girder
bridges and open top culverts, broken or notched sleepers, broken plates or tie bars
and attend to them as necessary.
If the Keyman finds that fittings are consistently working loose even after repeated
attention, he should report the matter to the Gang Mate, JE/SSE/P.Way. If the defects
are serious, it should be informed at once to the Gang Mate, duly protecting the line
in the meantime, if necessary, according to rules.
(2) The Keyman shall keep a special watch on the rails and welds marked for observation
by the USFD team.
(3) If the Keyman notices any condition of danger, such as broken rail, broken weld or
wash away of ballast, theft of fittings in large numbers etc., the line shall be protected
at once as per rules, and the Keyman shall take such action as is possible and report
the matter to the Gang Mate, the nearest Station Master and JE/SSE/P.Way.
(4) Keyman, in addition to the normal round of the entire beat inspection and tightening
of loose fittings, should attend one OHE mast /hectometre post on one line thoroughly
on every day and carryout other works assigned by Gang Mate. This thorough
attention should consist of checking of each bolt and fittings including fittings of
fishplates, joggled fishplates, & PRC sleepers in these OHE mast /hectometre post of
the beat during that particular day and tightening them, wherever required. Missing
ERCs, liners, keys and other missing fittings will be recouped by Keyman, who would
also ensure correct driving of fittings in this stretch.
(5) Keyman with the assistance of Track Maintainer(s) will also carry out rail end
examination, lubrication of fish plated joints as per direction of JE/SSE/P.Way.
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(6) For imposing of caution after stopping the train or otherwise, wherever required for
safety, the Keyman will be provided pre-printed paper slips by JE/SSE/P.Way. The
Keyman, after filling location and speed, will hand over the paper slip to Driver or ASM
and obtain acknowledgement.
(7) The following are the additional duties and responsibilities of the Keyman in
LWR/CWR territories:-
(a) Periodical (fortnightly) oiling and greasing of SEJ, checking and retightening of
fastenings at SEJ and other sleepers, if necessary.
(b) Tighten loose fittings and replacement of missing fastenings not requiring lifting or
slewing of track in accordance with Para 345(5) (a).
(c) To watch for sun kinks, loose or missing fastening which may result in buckling or
any damage to LWR/CWR and SEJ. On noticing any buckling or damage to track,
the Keyman shall take necessary action to protect the track and report the same
immediately to JE/SSE/P.Way (sectional), SSE/P.Way (In-charge), and Station
Master. However, the Keyman will continue to perform duties of daily inspection.
(d) To keep a sharp vigil in cold mornings, especially during winters to detect any
fractures which may occur, in case of rail/weld fracture, the Keyman shall take
prompt action to protect the track and carry out emergency repairs to permit the
restoration of traffic promptly and report to SSE/P.Way (In-charge), JE/SSE/P.Way
(Sectional) and nearest Station Master.
(8) The Keyman shall promptly report to Gang Mate/SSE/JE/P.Way any encroachment
or unauthorised structures as and when they take place in the Railway land.
(9) After completing inspection of the beat, the Keyman should assist the Gang Mate in
the day’s work being done.
(10) When Materials, such as dynamo-belts, engine parts and personal articles of
passengers, are found on line, the Keyman should collect them and arrange for
handing them over to the nearest Station Master.
(11) The Keyman will remain in-charge of the gang in absence of the Gang Mate once a
week. On that day, the Gang Mate is required to carry out the work and duties of
Keyman.
(12) Whenever directed the Keyman will supervise rail dolly working. However, the
Keyman must have competency certificate for the same.
(13) The Keyman shall watch height gauges for any damage. In case of any such damage,
the Keyman shall also look for any damage/shifting of girder, infringement to track or
damage to overhead electrical installations and shall report the matter to the Gang
Mate, the nearest Station Master and JE/SSE/P.Way and also protect the line as the
situation warrants.
(14) The Keyman shall maintain the Keyman’s book supplied to them up to date wherein-
(a) All special work done, missing fittings and their recoupment with location and date
are to be entered.
(b) Special locations to be watched by the Keyman should be entered.
(c) The special fittings like joggled fishplates and other Material provided in the
section, which are vital for safety and for restoration of traffic should also be
mentioned in the book.
117 Duties of Patrolman / Stationary Watchman
It is of paramount importance that patrolmen and watchmen thoroughly understand what
they have to do in the event of emergency. Every effort should be made to instruct and
drill the persons for their duties. In the event of an emergency the patrolmen should
devote their whole time and energy to the protection of the line and summoning of
assistance. Having protected the line and summoned assistance, they should resume
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their patrolling.
(1) Monsoon Patrolman:
The duties of a Patrolman undertaking monsoon patrolling are as follows –
(a) Walk to and fro over the beat in accordance with the chart pertaining to the “patrol-
section” looking out for subsidence, slips, signs of erosion, trees blown across the
track during storms or any other causes likely to endanger the safety of line. The
bridges and their approaches should especially be watched.
(b) Apprehend damage to line when-
(i) the flood exceeds danger level at any of the bridges, or
(ii) when there is damage to the protection work on bridges or on their approaches
even before danger level is reached, or
(iii) the water on one side of the embankment is at a much higher level than on the
other side, or
(iv) When any obstruction such as a fallen tree is blocking the waterway of a bridge.
(c) If the track shows signs of a settlement; take immediate steps in accordance with
Para 1004 (8) to stop trains when any portion of the line is likely to be rendered
unsafe due to abnormal rain or flood or any other cause.
(d) When no danger is apprehended, stand on the cess on the left hand side facing
the train and exhibit his number plate, turning the light of his lamp on to it, so that
the number can be seen from the passing train. The Patrolman should also blow
the whistle, when the engine and the brake-van of the train passes.
(e) Obtain the signature of the Station Master/Block Hut-in-charge on duty at the
Station/Block Hut concerned for arrival and departure and exchange patrol books
with adjacent patrolmen.
(f) Exchange the reports as to the conditions on their beats with adjacent patrolmen
and stationary watchmen on the way.
(g) Heed instructions from drivers, who may report a condition of danger at any
location, and proceed to the place indicated, and take necessary measures.
(2) Hot Weather Patrolman:
The duties of a Patrolman undertaking hot weather patrolling are as follows –
(a) Patrol the track during the hottest part of the day, to look for prominent kinks,
incipient buckles or tendency towards buckling.
(b) Protect the track at the site of the prominent kinks, incipient or actual buckles and
report the same to nearest Station Master and JE/SSE/P.Way immediately.
(c) Walk over his beat slowly over one rail in one direction and on the other rail in the
return direction. On double lines, repeat this procedure alternately on UP and DN
tracks.
(d) Be vigilant and look out for kinks in the rail especially during the hottest part of the
days. When a kink is observed, immediately examine at least 100 sleepers ahead
and in the rear of the kink for any floating/misaligned condition of track.
(e) Should the track reveal a floating/misaligned condition, under which a buckle may
be anticipated or the patrolman has detected actual buckling of track, the
patrolman will take immediate steps to protect the affected portion by display of
hand signals as per rules in force. After protecting the track, the patrolman will
arrange to advise the Gang Mate, JE/SSE/P.Way of his apprehension of a
buckle/actual buckle.
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(3) Cold Weather Patrolman:
The duties of a Patrolman undertaking cold weather patrolling are as follows –
(a) Patrol the track during the coldest part of the night and lookout for weld/rail
fractures and excessive gaps at SEJ.
(b) Protect the track at the site of weld/rail fractures, or excessive gaps at SEJ, or
shearing/snapping of bolts; and report to nearest Station Master, JE/SSE/P.Way.
(c) On single line; walk over the beat slowly along one rail in one direction and on the
other rail in the return direction. On double line; repeat this procedure alternately
on UP and DN tracks.
(d) Be vigilant and look out for rail/weld failure, or excessive gaps at SEJ, or
shearing/snapping of bolts etc.
(e) In case it is noticed that a rail/weld failure has occurred or gap at SEJ becomes
more than the designed maximum gap, the patrolman will take immediate action
to suspend the traffic and protect the line. After protecting the track, the patrolman
will arrange to report to Keyman/Gang Mate, JE/SSE/P.Way, and Station Master
of adjacent station.
(4) Mobile Watchman:
The duties of a Mobile Watchman are as follows –
(a) A Mobile Watchman is posted, till period of consolidation is over, on stretches
where after maintenance operation, rail temperature has exceeded t d+ 20°C during
the period of consolidation as given in Para 337 (5)
(b) Number of Mobile watchmen required to be posted would depend upon the length
of track attended by manual methods or by tampers.
(c) The mobile watchman would patrol such section/beat to look for prominent kinks,
incipient buckles or tendency towards buckling, rail/ weld fracture, excessive gaps
at SEJs and shearing/snapping of bolts.
(d) Mobile watchman will be provided with all equipment as per Para 1005 as the case
may be, shall protect the track at site if any of the situations as given in Para
1004(8) occurs and report the same to nearest Station Master/ JE/SSE/P.Way.
(e) Mobile watchman posted on these sites would patrol the section and perform the
duties of Hot/Cold Weather patrolman as the case may be.
118 Duties of Gateman
(1) Knowledge of Gate working rules- Gateman should have knowledge of gate working
rules for opening and closing of gates. Gateman should also know the safety rules to
protect the track in case of any unsafe situation for train movement.
(2) Alertness – Gateman should be on the alert and be prepared to take immediate action,
should danger be apprehended. The keys of the gates shall be on his person.
(3) Position during passage of trains – Gatemen should stand facing the track on the
gate-lodge side of the approaching train. Gateman should observe all passing trains
and be prepared to take such action as may be necessary to ensure safety of trains.
(4) Upkeep of safety equipment like tri-colour torch, banner flag, detonators, flags, hand
signals etc. is the responsibility of gateman.
(5) Action in emergency – In case of an obstruction at the level crossing, Gateman should
maintain the gate signals, if any, in the “ON” position and if unable to remove it, protect
the line as under –
(a) On double line, if both lines are obstructed during day, Gateman shall plant a red
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banner flag at a distance of 5 metres from the end of check rails on the line on
which a train is expected to arrive first, then plant another red banner flag on the
other line at the site of obstruction. The Gateman shall then pick up red hand signal
and showing it, proceed on that line towards the direction of an approaching train
to a point 600 metres from the level crossing and place one detonator on the line,
after which proceed further to not less than 1200 metres from the level crossing
and place 3 detonators on the line about 10 metres apart. Having thus protected
the line on which a train is expected to approach first, the Gateman should return
to the level crossing, picking up the intermediate detonators on his way back. He
shall then proceed on the other line showing red hand signal, place detonators in
the similar manner, as done in the other direction and return to the site of
obstruction to warn the Driver of an approaching train.
(b) On single line, if the line is obstructed during day, Gateman shall plant a red banner
flag at a distance of 5 metres from the end of check rails towards the direction from
which a train is expected to arrive first, then plant another banner flag towards the
opposite direction at the site of obstruction. The Gateman shall then pick up red
hand signal and as in Sub-Para (a) above, protect the line in the direction from
which a train is expected to approach first, return to the site of obstruction, and
proceed with all haste in the other direction to protect the line. Having protected
the line on both sides, the Gateman should station himself at the place of
obstruction to warn the Driver of an approaching train. (Annexure - 9/7).
(c) At night, Gateman should light the two hand signal lamps and take action to exhibit
red light and protect the lines as in Sub-Para (a) and (b) above.
(d) Gateman should take immediate action to inform the Gang Mate, JE/SSE/P.Way
and the nearest Station Master about the obstruction at the level crossing through
messenger or other means available.
(6) Parting of a Train – If a Gateman notices that a train has parted, he shall not show a
stop hand signal to the Driver, but shall endeavour to attract the attention of the Driver
and the Guard by shouting, gesticulating or other means.
(7) Hot axle detection, flat tyre detection, hanging parts in train: The Gateman shall take
immediate necessary action as per the instructions given in Gate Working Rules.
119 Duties of Track maintainer:
Track maintainers are responsible for maintenance of track and performing various
duties like relieving Gateman/Keyman, patrolling, Material leading / loading/ unloading
etc. as instructed by Gang Mate and controlling supervisor, in order to ensure safety
of track. The Track Maintainer shall follow the instructions of senior(s).
*********************
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CHAPTER – 2
TRACK STRUCTURE AND COMPONENTS
*********************
201 Classification of Lines – The BG lines have been classified into six groups ‘A’ to
‘E’ on the basis of the future maximum permissible speeds as under –
(1) Group ‘A’ – Speeds up to 160 Kmph
(2) Group ‘B’ – Speeds up to 130 Kmph
(3) Group ‘C’ – Suburban Sections of Mumbai, Delhi, Chennai and Kolkata.
(4) Group ‘D’ Special – Speeds up to 110 Kmph and the annual traffic density is 20
GMT or more.
(5) Group ‘D’ – Speeds up to 110 Kmph and the annual traffic density is less than
20 GMT.
Note – While classifying route, in case of double and multiple lines, annual traffic density on
each line shall be considered separately. The route shall be classified based on the
highest GMT on any one line.
(6) Group ’E’ – All other Sections and branch lines with speed up to 100 Kmph.
202. Track Structure: - The track structure for operation of Passenger train for
speeds beyond 110 Kmph and up to 160 Kmph on Indian Railway routes is given
as under: (Back to Para 212 (2) (a))
Track Structure for speeds beyond 110 Kmph of Passenger carrying train on BG IR
Speed above 110 Kmph and up to Speed above 130 Kmph and up to
Speed
130 Kmph 160 Kmph
Rails 60 kg 90 UTS 60 kg 90 UTS
Sleeper/
PSC at 1660 PSC at 1660*
Sleeper Density
Note - * Wider and Heavier PSC sleeper shall be used during renewals
Ballast Cushion
Total 300 clean 150 Total 350 clean 150
in mm
Turnouts
Switch Thick Web Switches on all turnouts Thick Web Switches on all turnouts
Crossing CMS Weldable CMS
SEJ Improved Type Improved Type
Bridge Sleepers H – Beam Sleepers/Composite sleepers
Level Crossings Interlocked No Level crossing
Fencing All along the track All along the track
All the curves shall be suitably realigned and proper transition lengths shall
be provided. Maximum permissible cant of 165 mm can be provided in the
section so that speed potential on curves is fully exploited, however, this
shall be subject to the consideration of maximum cant excess for the slowest
Curves moving train. This will require survey of each curve including the fixed
installation and thereafter realignment should be undertaken keeping all the
constraints in view. With a cant deficiency of 100 mm, the maximum
permissible speed on 1 degree curve and 2 degree curve works out to be
160 Kmph and 130 Kmph respectively for 165 mm cant.
Note – In case track structure does not fulfill the above requirement, relevant instructions of Railway
Board would be referred.
Page 53 of 417
PART – A
RAIL AND RAIL FASTENINGS
203 Standard Sections of Rails –
(1) General –
The rails are manufactured as per the Indian Railway Standards specification for flat
bottom rail (IRS-T-12). On Indian Railways, flat-footed rails of 60 Kg/m and 52 Kg/m
are being used predominantly. The typical cross-section and key dimensions of these
rail sections are reproduced below.
52 Kg/m Rail
Cross- Weight Dimensions in mm

Rail Section per
Section Area meter in A B C D E F G H J K L M N O P Q R S T U
(cm2) Kg
52 Kg 66.15 51.89 156 136 67 15.5 51 29 60 19 24 44 305 381 80 13 13 17.5 18 22.5 5 38.82
60 Kg/m Rail (UIC 60)
Cross- Weight Dimensions in mm

Rail Section per
Section Area meter A B C D E F G H J K L M N O P Q R S T
(cm2) in Kg
60 Kg
(UIC 76.86 60.34 172 150 74.3 16.5 51 31.5 60.25 32 11.5 19.5 37.5 72 21 33 300 80 14.3 35 120
60)
For 60 Kg/m rail, the UIC 60 profile has been changed to 60 E1 profile, which is accurately
dimensioned profile developed from the previous less accurately dimensioned profile of UIC
60. In this profile, there is a minor variation in the profile of rail head top as compared to the
UIC 60 profile. There is no difference in the dimensions of Rail flange and web including the
fishing planes.
Page 54 of 417
Cross-section and key dimensions are as below:
60 Kg/m rail (60 E1)
Cross-Sectional Area - 76.70 cm2, Mass per metre - 60.21 Kg/m

Indicative dimensions: A = 20.456mm, B = 52.053mm
Note: These are for guidance only. For details, please refer IRS specification - T-12
(2) Marking of Rails:
Brand marks are rolled in relief on one side of the web of each rail. These brand
mark usually include:
(a) Rail section
(b) Grade of steel. E.g. for grade 880 - "880"
(c) Identification mark of the manufacturer.
(d) Month (using Roman numbers) and last two digits of year of manufacture.
(e) Process of steel making: e.g. for Basic oxygen - "O", for Electric - "E" etc.
(f) Rolling direction
204 Identification of Different Qualities of Rails in the Field –
(1) ‘Prime Quality’ Rails –
These rails are to suitable for use in running track at all location and are classified
as Class ‘A’ and Class ‘B’ rails based on tolerance in End straightness as given
below.
End Tolerances
Straightness Class ‘A’ rail Class ‘B’ rail
Deviation of 0.5 mm Deviation of 0.7 mm
Measured as maximum ordinate Measured as maximum ordinate
Horizontal
from the chord of 2.0 M standard from the chord of 1.5 M standard
straight edge. straight edge.
Deviation of 0.4 mm measured as Deviation of 0.5 mm measured as
Vertical
maximum ordinate from the chord of maximum ordinate from the chord
(up Sweep)
2.0 M standard straight edge. of 1.5 M standard straight edge.
Vertical (Down
NIL NIL
Sweep)
(2) ‘Industrial Use’ Rails (IU rails) –
There is no deviation in chemical composition or mechanical properties in ‘Industrial Use’
rails from that of ‘Prime Quality’ rails. The deviations exist only in tolerances for
Parameters as mentioned in IRS-T-12.
Page 55 of 417
These rails can be used in industrial sidings with a speed restriction of 50 Kmph. IU rails
can be identified by blue paint on end face of flange and both sides of flange for a
distance of 500 mm from each end. The letter ‘IU’ (Industrial Use Grade) as the case
may be in 15 mm size shall be stamped on both end faces of rails in addition to colour
marking.
(3) Colour Code: The rails are painted with colour code as given in IRS-T-12 (Annexure
- 2/1)
(4) Permissible Variations in Dimensions of Rail:
S. Prime Quality rails IU rails
Item
No (mm) (mm)
1 Overall height of rail +0.8 to -0.4 +2.0 to -1.0
2 Width of head Measured 14 mm below the rail top ±0.5 +2.0
For sections less than 60 kg/m ±1.0
3 Width of flange +1.5 to -2.0
For sections 60 kg/m and above +1.2 to -1.0
4 Thickness of web Measured at the point of minimum +1.0 to -0.5 +2.0 to -1.0
thickness
Note: Rails loaded in one wagon should not be mixed with other rails for dispatch.
(5) Longer rails:
As per IRS-T-12, the standard length of rails is 13 m or 26 m. However, the
manufacturer may also supply longer rails of 65 m, 130 m and 260 m length as
required by purchaser.
Page 56 of 417
Annexure - 2/1 (Para 204)
COLOUR CODE FOR RAILS
Common lengthwise colour code

1. No paint on gauge/non-gauge face indicates class ‘B’ rails.
2. Yellow paint on each end face on web region indicates 13 m, 26 m, 130 m, and
260 m length.
3. Blue paint on each end face on web region indicates 12 m, 25 m, 129 m, and 259
m length.
4. White paint on each end face on web region indicates 11 m, 24 m length.
5. Green paint on each end face on web region indicates 10 m length.
Note: - This colour code is for new rails; for second hand rails Para 722 may be referred to.
Page 57 of 417
205 Recommended Rail Section – (Back to Para 705)
(1) Main line – Track Renewals, Doubling, New Lines and Gauge Conversions – 60kg/m
rails with minimum 90 UTS
Note – For Gauge Conversion works & new line works having projected traffic of less
than 5 GMT, 60kg/m (SH) rails, if available with Railways, can be used depending
upon future projected extension of lines etc.
(2) Loop Lines –
Renewal of loop lines is to be done with 60 kg/m (SH) or 52 kg/m (SH) rails. The new
rails can also be used for these rail renewals with prior approval of Railway Board.
(3) Private and other sidings –
Sidings taking off from DFC or feeder routes to
(i) 60 kg/m
DFC or 25t axle load routes.
Sidings other than (i) above; 52 kg/m (SH); or
(ii)
With permissible speed up to 50 Kmph. 52 kg/m (IU)
Sidings other than (i) above;
(iii) 60 kg/m
With permissible speed more than 50 Kmph.
206 Rail Fastenings:

(1) Fish plates: Fishplates are used to join the ends of rails using fishbolts and other
fittings such as washers, etc. These are manufactured to comply with RDSO
specification, IRS-T-1.
(2) Joggled fish Plates: Joggled fish plates with clamps or with far end bolts are used
at welded joints or at rail fracture locations. Joggled fishplates shall comply with RDSO
specification IRS-T-1.
(3) Combination Fish-Plates –
(a) A set of four combination fishplates is to be used at joints of two different rail
sections. The 4 fishplates are different from each other and are marked I.R. (Inside
Right), O.R. (Outside Right), I.L. (Inside Left) or O.L. (Outside Left) apart from their
drawing numbers. Combination fishplates shall comply with RDSO specification
IRS-T-1.
(b) The following points should be ensured:
i) On either side of combination fishplates, full length of rail should be used.
ii) Combination rails prepared by welding two rail sections as per standard
drawings should, preferably be used in place of combination fishplates.
Note: For the guidance of field officials, some of the commonly used fittings referred in this
section is listed in Annexure - 2/4 (A) and 2/4 (B). For detailed information, respective
RDSO drawings with their latest alterations and / or Track Manual may be referred.
Page 58 of 417
PART – B
SLEEPERS & FASTENINGS
207 General:
(1) Types of Sleepers: depending on type of Material, there are following types of
sleepers:-
(a) Wooden Sleepers
(b) Cast Iron Sleepers
(c) Steel Trough Sleepers
(d) Concrete Sleepers
(2) Wooden, Cast Iron and Steel Trough Sleepers have become obsolete and at present
concrete sleepers are being used widely. For certain specific locations e.g. girder
bridges, points and crossings etc. composite sleepers are being gradually introduced.
208 Concrete Sleepers:
(1) Amongst the mono-block and twin-block concrete sleeper types, Indian Railway uses
the Mono-block Pre-stressed concrete sleepers predominantly. These PSC sleepers
provide longitudinal & lateral stability required for LWR and due to the Flat bottom,
these sleepers are suitable for mechanised tamping.
(2) The PSC sleepers are manufactured to conform to RDSO specification No IRS: T-
39 (Plain Track) and IRS: T-45 (Turnout sleepers).
(3) Identification of Sleepers
(a) Concrete sleepers can be identified by the drawing no. and code of sleeper
manufacturer with year of manufacture engraved on the top end surface of
sleepers. Permanent Way staff should take care to see that they are not obliterated
during maintenance.
(b) All the PSC sleepers are tested for electrical resistance at the time of manufacture,
and sleepers are marked by paint with “FTC” to indicate Fit for Track Circuiting and
“NFTC” to indicate not fit for track Circuited location. This shall be noted while using
the sleepers at site.
(4) When concrete sleepers are used in yards with fish-plated track/SWR, the sleeper
spacing at fish-plated joint shall be kept uniform. In addition, 1 m long fishplates may
preferably, be provided at such joints.
209 Sleeper Density: (Back to Para 705, 719)
(1) Definition: The Sleeper density is expressed as the number of sleepers per km of
track and is fixed taking into consideration the maximum permissible speed and the
traffic density of the section.
(2) Minimum Sleeper Density:
(a) The minimum sleeper density for all track renewals (complete track renewal and
through sleeper renewal), doubling, gauge conversion, new line construction works
for main lines shall be 1660 nos. per km and for loop lines & sidings (permissible
speed up to 50 Kmph) it shall be 1540 nos. per km. For sidings with permissible
speed more than 50 Kmph minimum sleeper density shall be 1660 nos. per km.
Note: Higher sleeper density may be provided with the approval of the Principal
Chief Engineer.
(b) 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, 1 m long fishplates, be provided at fish plated joints.
Page 59 of 417
210 Fastenings on PSC sleepers: Only approved types of fittings and Elastic
fastenings shall be used with concrete sleepers. Some of the approved type of
fastenings on PSC sleepers are as under:
(1) Elastic Rail Clip (ERC): Manufactured from Silico-manganese Spring steel by
approved/ Developmental suppliers as per RDSO specification IRS-T: 31. They offer
a designed Toe load at design deflection.
(2) Grooved Rubber Sole Plate (GRSP): Manufactured from rubber compound
conforming to RDSO specification No IRS -T-47, the Grooved Rubber Sole Plate
absorbs high frequency vibrations, shocks and reduces noise.
(3) Composite GRSP:
(a)For improved performance Composite GRSP with two layers of different types of
rubber are developed, which has the top layer having higher modulus of elasticity
(harder) while bottom is of softer Material.
(b) These are manufactured to RDSO specifications for Composite GRSP
(provisional) number RDSO/M&C/RP-198/2006 for 6.2 mm and
RDSO/M&C/RP-200/2007 for 10 mm CGRSP.
(c) As per above referred specification, the harder layer should be kept in contact of
Rail, Thus, the surface of CGRSP where the manufacturer’s initials are embossed
should be placed on rail seat, facing up.
(4) Nylon Cord Reinforced GRSP: These GRSPs are specifically designed for use
below Crossings of Turnouts conforming to “RDSO specifications for 6 mm thick
Nylon Cord Reinforced GRSP for placing beneath rails at turnouts, Provisional
2007(RDSO/M&C/RP-201/2007)”.
(5) Liner:
(a) These are the fittings used in conjunction with the GRSP/ CGRSP and rail , on both
sides of the rail foot to achieve the correct track gauge to provide for the correct
deflection of the ERC for the designed Toe load. The combination liners also allow
flexibility to use lighter rail sections on the sleepers meant for heavier rail section.
(b) Liners are made of two Materials viz., Glass filled Nylon (GFN) liners (as per
“RDSO specifications IRS: T-44”) and Metal Liners (as per “RDSO
specifications for Metal liners – Provisional 2013”). The GFN liners are
generally used in track-circuited locations.
(c) Cut liners shall be used with ERC J clip at fish plated Joint/ Glued Joint
Note: For the guidance of field officials, some of the commonly used fittings referred in
this section are listed in Annexure - 2/4 (A) and 2/4 (B). For detailed information,
respective RDSO drawings with their latest alterations and / or Track Manual may
be referred.
Page 60 of 417
PART – C
BALLAST
211 Ballast Specifications: Crushed Stone ballast to be used on all lines including
points and crossings shall be conforming to RDSO specifications for Track Ballast
No. IRS -GE -1, June 2016 with latest amendments.
212 Ballast Profile/Section/Depth of Cushion: (Back to Para 354, 705)
(1) Ballast profile: -The following ballast profiles shall be provided for the various groups
of track for LWR/CWR and other than LWR/CWR as given in Annexure - 2/2A, 2/2B
& 2/2C of this section. The approximate quantity of ballast required per metre run of
track for standard ballast sections has also been indicated in the sketch.
Note:
(i) Minimum Formation width to be ensured for new works/alteration to existing
works in embankment and in cutting (excluding side drains), as also indicated in
the sketch of Annexure - 2/2A, 2/2B & 2/2C
• For single line straight track – 7850 mm
• For double line straight track – 13160 mm
(ii) On curves, additional formation width over (i) above, shall have to be ensured
as given below:
(a) Increase due to extra widening of ballast shoulder on outer side of curves in
both single/double line, as indicated in sketch of Annexure - 2/2A, 2/2B & 2/2C
(b) Increase due to requirement of extra clearances on curves as stipulated in the
Appendix to the IRSOD-(BG).
(iii) Increase in formation width on curves will be decided after taking into account the
increase mentioned in (a) & (b) above.
(iv) Minimum Cess width of 90 cm shall also have to be ensured for both straight
track & on curves, along with ensuring minimum Formation width as specified for
Single/Double line including additional formation width on curves as described
above.
(v) If even after provision of additional formation width, cess width on the outer side of
curves reduces below 90 cm on account of increased ballast width due to super
elevation, formation width shall be increased further, over and above additional
width as stipulated in Note (ii) above, to meet the requirement of minimum cess
width of 90 cm.
(2) Depths of Ballast Cushion –
(a) The minimum depth of the ballast cushion below the bottom of the sleepers at the
rail seat for BG should be as under –
Minimum depth of the ballast cushion for all
In case of
routes
Track Renewals (complete track renewals 300 mm
and through sleeper renewals) (Where possible 350 mm shall be provided)
All Doubling, Gauge Conversion & New Line
350 mm
construction works
Loop Lines 250 mm
For higher speed, Para 202 would also be referred
(b) Sidings –
Private and For permissible speed up to 50 Kmph. 300 mm
Other Sidings For permissible speed more than 50 Kmph 350 mm
Note – Minimum depth of clean ballast cushion at all times for mechanised maintenance under
the rail seat of the PSC sleepers shall not be less than 150 mm.
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(c) Increase in ballast cushion to make up the recommended depth will be carried out
during complete track renewal, through sleeper renewal or programmed deep
screening of track.
(3) Special attention should be given at locations such as bridge, level crossing and
tunnel approaches so as to ensure full ballast section for six rail lengths on either side.
213 Assessment of Ballast Requirements –
(1) The requirement of ballast shall be assessed separately for
(a) Making good the deficiencies as existing in track,
(b) Making good deficiencies arising out of overhauling, through packing/tamping and
deep screening,
(c) For providing adequate cushion in the case of mechanical tamping,
(d) For providing extra cushion/profile for converting into LWR or up-gradation of track
structure for higher axle load.
(2) The ballast required for maintenance purposes shall be estimated by assessing the
quantity approximately if necessary, by a survey, over a rail length in every 1 km. Care
should be taken that the cores under the sleepers are not disturbed.
(3) In case of deep screening, assessment of ballast required for recoupment and
providing standard section should be made by deep screening the ballast section to
the full depth in a rail length for two to three sleepers at every 0.5 to 1 km. In this case
screening is done under the sleepers as well.
(4) The quantities assessed vide Sub-Para above will be the net quantities of ballast
required to recoup the deficiencies to provide required profile / sections. The above
net quantities may be enhanced suitably (say 8%) to arrive at gross quantities of
ballast for the purpose of procurement action in case measurements are proposed to
be taken in stacks or in wagons at originating station.
214 Collection and Training out of Ballast – The collection of ballast can either be
done-
(1) By resorting to alongside collection, or
(2) By collecting at depots and training them out in ballast trains.
(3) The mode of collection will have to be decided taking into account proximity of quarry,
availability of good stone ballast, service roads alongside the line for carrying of
ballast, availability of ballast trains, the turn round of ballast trains and availability of
block for unloading.
215 Handing over Charge by Assistant Divisional Engineer – During transfer of
charge of a sub division, the Assistant Divisional Engineer taking over, should satisfy
himself by test checking some of the stacks at each depot and along the cess to the
effect that the quantities of Materials shown in the registers are correct. He should
certify that this has been done by initialing each entry so checked.
216 Unloading Ballast along the Line – When unloading ballast along the line care
shall be taken that the heaps at the sides and the centre are clear of prescribed
running dimensions. Care should be taken to ensure that Ballast shall be cleared from
the signal wires or point rods and no stone is left inadvertently between the stock rail
and tongue rail.
217 Surplus Ballast Along the Line – All surplus ballast left alongside the line should
be collected and stacked in regular heaps and not left scattered on the slopes to be
overgrown by grass and lost.
Page 62 of 417
Annexure - 2/2(A) (Para 212)
Quantity of Ballast
G Type of per meter in
A B C* D E* F H
Gauge Sleeper Straight Curved
Track (M3) Track (M3)
250 350 500 2693 2851 7850 646 2.030 2.120
1676
PRC 300 350 500 2772 2930 7850 698 2.304 2.401
mm
350 350 500 2851 3009 7850 751 2.585 2.690
Note :
1. Depth of ballast cushion should be provided as per Para 212(2) of IRPWM.
2. Cross-Slope of 1 in 30 shall be provided for New Works.
3. Minimum Formation width of 7850 mm shall be ensured for new works in both
embankment and in cuttings (excluding side drains).
4. Suitable dwarf walls shall be provided in case of cuttings, if necessary for retaining
ballast.
5. *On outer side of curves only.
6. Super elevation has not been considered in calculation of ballast quantity for
curved track.
7. The cess width on existing track is to be increased on programmed basis wherever
required so that minimum cess width as per side slope given above is ensured.
8. All dimensions are in mm.
Page 63 of 417
Annexure - 2/2(B) (Para 212)
Quantity of Ballast per Meter

S. Depth of
No. Ballast Cushion On Straight and Curves of Curves of Radius sharper
Radius flatter than 600 M than 600 M
1 250 mm 1.769 M3 1.820 M3
2 300 mm 2.022 M3 2.078 M3
3 350 mm 2.282 M3 2.344 M3
Note :
(1) In the case of ordinary fish plated track: * To be increased on the outside of curves to 400
mm in the case of curves sharper than 600 M radius.
(2) In short welded panel Track* To be increased to 400 mm on outside of all curves, flatter than
875 M radius and to 450 mm, in the case of curves sharper than 875 M radius.
(3) * To be increased to 550 mm on the outside of turn in curves of turnouts in passenger yards.
(4) Depth of Ballast cushion should be provided as per Para 212(2) of IRPWM.
(5) Minimum Formation width of 7850 mm shall be ensured for new works in both embankment
and in cuttings (excluding side drains).
(6) Super elevation has not been considered in calculation of ballast quantity for curved track.
(7) The cess width on existing track is to be increased on programmed basis wherever required
so that minimum cess width as per side slope given above is ensured.
Page 64 of 417
Annexure - 2/2(C) (Para 212)
G Type of
A B C* D E* F H J
Gauge Sleeper
250 350 500 2785 2943 13160 707 5300

1676
PRC 300 350 500 2864 3022 13160 760 5300
mm
350 350 500 2943 3101 13160 812 5300
Note:
1. Depth of ballast cushion should be provided as per Para 212(2) of IRPWM.
2. Cross-Slope of 1 in 30 shall be provided for New Works.
3. Minimum Formation width of 13160 mm shall be ensured for New works in
both embankment and in cuttings (excluding side drains).
4. In doubling work of existing lines, cross-slope of 1 in 40 in existing old
formation need not be disturbed.
However, the cross slope of 1 in 30 shall be provided in widened formation
width, newly constructed for doubling.
5. Suitable dwarf walls shall be provided in case of cuttings, if necessary, for
retaining ballast.
6. *On outer side of curves only.
7. Super elevation has not been considered in calculating various dimensions.
8. The cess width on existing track is to be increased on programmed basis
wherever required so that minimum cess width as per side slope given above
is ensured.
9. All dimensions are in mm.
Page 65 of 417
PART – D
FORMATION
218 Classification of Formation Requiring Treatment:
Following steps shall be adopted to classify the Formation requiring treatment:
(A) Identification of Weak Formation- Weak Formation shall be identified based on either
of the following condition-
(i) Stretches having speed restrictions due to weak formation.
(ii) Stretches where more than normal track attention is required.
(iii) Stretches where ballast penetration profile is of ‘W’ shape and maximum depth of
penetration is more than 30 cm.
In case any of the above conditions are met in field, then the 4-step action plan given
below is to be followed.
(B) Action to be taken for weak formation- Following 4-step action plan should be adopted
for stretches identified as weak formation:-
(i) Make the formation width, cess level and side drains strictly in accordance with
prescribed profile.
(ii) Carry out shallow screening of ballast section (or deep screening where required).
(iii) Ensure no loose or missing fitting.
(iv) Increase the depth of ballast section to 30 cm or even up to 35 cm.
If track maintenance problem persists even after adoption of above measures, then it is a
suspect formation and further detailed Geotechnical investigation is to be done for
assessing the problem. Based on investigation results, the formation is to be classified as
Bad Formation, if warranted. Remedial measures for rehabilitation/Strengthening of bad
formation should be taken accordingly.
219 Nature of Formation Problems:
In such stretches, the track levels get disturbed frequently causing problems in track
maintenance. These problems are attributable to –
(1) Excessive or uneven settlement of banks affecting track Parameters.
(2) Slope failure leading to slips, heaving beyond the toe, creep or bulging of slopes.
(3) Ballast penetration and mud pumping of poor Subgrade Material.
(4) Swelling and shrinkage of expansive soils in fills such as black cotton soil.
(5) Cracks on the cess, affecting track Parameters.
220 Site Investigation – The following data should be collected for determining the type
of treatment to the formation –
(1) History of the affected section –
• Period when constructed;
• Method of construction;
• Date of opening to traffic;
• Subsoil bank settlements;
• Slips if any; and
• Speed restrictions on formation account.
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(2) Site details –
• Bank heights;
• Formation width, cess level and side slope.
• Depth of cutting;
• Nature of existing slopes (Turfed or not, with or without berms);
• Drainage conditions;
• Stagnation of water;
• Condition and proximity of borrow pits;
• Signs of movement and bulging in the slopes;
• Ground water level and its position during rains.
• Cracks on the cess.
(3) Number of attentions to track – The particulars of the number of attentions to track
should be obtained from gang charts and/or TMS reports for the last five years, to get
an idea about track maintainability. Man-days utilised for maintenance per Km should
also be collected vis-à-vis men required for normal maintenance.
(4) Ballast penetration profile – These profiles should be obtained at regular intervals of
hectometers/O.H.E. masts, to indicate the extent of ballast penetration and condition
of ballast (loose, caked, mixed with sub-soil etc.)
(5) Exact nature of present trouble – The exact nature of the present trouble should be
identified whether it is due to –
• Bulging of ballast between cribs or at the cess;
• Mud pumping;
• Slope movement;
• Slope failure; etc.
• Cracks on the cess.
221 Soil Investigation and Testing –
(1) Soil investigation –
(a) Undisturbed soil samples should generally be collected at every hectometer/
O.H.E. mast. Undisturbed soil samples in 100 mm sampling tubes should be
collected from the following places as necessary
(i)
From the formation below the depth up to which the ballast has penetrated.
(ii)
From inside the bank along the probable circle through which the slip has
occurred, where the bank has been found to be structurally unstable.
(iii) From various depths below the ground level at the toe of the bank, where base
failures/settlements have occurred.
(iv) From two sections in the slipped portion and one section at the toe adjoining the
site where slip has not occurred in the past.
(b) Two cross sections of the bank in both the sections should also be taken by means
of precise levelling.
(c) In addition to this, disturbed soil samples should also be collected at regular
intervals of a hectometer/O.H.E. mast, to determine the index properties of the
formation soil.
(2) Soil Testing – Selected undisturbed/disturbed soil samples (as per Annexure - 2/3)
should be tested at the soil Mechanics Laboratory, to determine the following
properties –
(a) Index properties viz., grain size analysis and Atterberg limits (i.e., LL, PL & SL).
(b) Natural moisture content and natural dry density.
Page 67 of 417
(c) Optimum moisture content and Maximum dry density.
(d) Shear property.
(e) Differential free swell.
For banks, which are structurally weak/unstable, the shear property of the soil sample
is very important and sufficient number of samples must be tested so as to get an
accurate idea of the shear strength of the bank soil and soil strata below ground level.
For banks where settlement has occurred, consolidation test should also be carried
out.
222 Remedial Measures Suggested – Based on the site investigations and soil testing,
the relevant remedial measures should be formulated. Some of the remedial
measures suggested for the formation troubles generally encountered are listed
below for guidance:
Sr.
Nature of Problems Remedial measures*
No.
1. Inadequate drainage due to high cess, fouled Improve side drainage by lowering the
ballast cess and screening of ballast.
2. i) Weak soil at formation top on contact with
i. Improve the drainage,
rain water resulting into mud pumping under
ii. Provision of blanket of suitable
trains,
thickness
ii) Fouling of ballast with Subgrade fines,
iii. Laying of Non-woven Geotextile
iii) Impaired drainage
3. i) Strength failure below ballast causing i. Provision of blanket of suitable
heaving up of cess or in between sleepers, thickness,
ii) Ballast penetration exceeding 30 cm below ii. Laying of Non-woven Geotextile below
formation blanket
4. i. Blanket of suitable thickness,
Seasonal variation in moisture in formation top ii. Thickness of blanket may be reduced
in expansive soils causing alternate heaving, with provision of Geogrid layer,
shrinkage of formation. iii. Laying of Non-woven Geotextile below
blanket
5. i. Provision of Sub-bank
Gradual consolidation of earth below ii. Prefabricated vertical drain along with
embankment (Bank settlement & heaving of Sand layer at top/Geo-composite drain
soil beyond toe). (Horizontal) or ,
iii. Stone columns in sub soil
6. Flatting of side slopes with sandwiched
Creep of formation soil.
construction.
7. (i) Inadequate sides slopes, causing Flattening slopes or provision of berms as
embankment slips after prolonged rains, per slopes analysed with slope stability
(ii) Longitudinal cracks on cess/slopes analysis & with proper drainage system.
8. Hydro-static pressure built up under live loads Draining out of ballast pockets by sand or
in ballast pockets containing water causing boulder drains.
bank slips.
9. i. Repair of slope/cess,
Erosion of slope/cess of banks
ii. Provision of turfing, mats, etc.
10 Cut slope failure i. Adequacy of slope/slope protection
measure as required,
ii. Provision of adequate drainage
arrangement (Side drain/Pucca catch
water drain etc. and ensure its proper
functioning)
* The above measures suggested are only indicative in nature and final remedial
measures shall be decided based on the site investigation, soil testing, past failure
history (if any) etc. For details, relevant latest instructions issued through various
guidelines/specifications for Earthwork by RDSO, shall also be referred to. RDSO’s help,
wherever necessary, may be taken for formulating the remedial measures.
Page 68 of 417
Note:
1. Depending on the type of failure, Bores are to be made at the top of Embankment,
Mid Slope of Embankment and near Toe as shown above.
2. Soil Samples to be collected up to the depths as indicated above at intervals of 1.5
to 3 metres.
3. One set of bores are required from adjoining stable bank for comparison of soil
behaviour.
Page 69 of 417
PART – E
INSULATED JOINTS & SWITCH EXPANSION JOINTS
223 Insulated joints –
(1) Description – Track circuited sections are ‘insulated’ electrically from the track on
either side by insulated joints. The standard insulated joint in normal use, is made out
of ordinary fishplates duly planed on the fishing planes for accommodating channel
type insulation between rails and fishplates with ferrules/ bushes over the fish bolts
and end posts between the rail ends.
(2) Laying –
(a) Insulated joints provided shall be laid as square joints. Where staggering cannot
be avoided, the distance between staggered joints should not exceed the minimum
wheelbase of the vehicles.
(b) Rail ends of the insulated joints shall be square and true.
(c) All rough edges and burrs should be removed from bolt-holes.
(d) Battered ends must be put right and the gap between the rails should be equal to
the thickness of the end post.
(3) Inspection and Maintenance of Insulated rail joint should be done as per Para 622.
224 Glued insulated joints –
(1) Glued insulated joints have been developed using resin adhesives. These joints
consist of web-fitting fishplates glued to the rails with a high polymer adhesive and
bolted with high tensile steel bolts. The insulation is provided by special type of
insulating side channels, bushes and end posts made of fiberglass cloth roving.
(2) In all future works of Track circuiting, Glued insulated joints should be provided in
place of standard insulated joints, wherever feasible. There are two kinds of glued
joints viz. G3L (with six bolts) and G3S (with four bolts) for usage in LWR/CWR and
SWR/FR track respectively.
(3) The instructions for Fabrication, installation and Maintenance of Glued insulated rail
joints are given in the Manual for Glued Insulated Rail joints.
(4) Marking of Glued Joints: - The details of glued joint number, month, year of
manufacturing and the code of the manufacturer is embossed on the gauge and non-
gauge face sides of the head of the rail as per provision of the Manual for Glued
Insulated Rail Joints.
225 Switch Expansion Joint: (Back to Para 328)
(1) An expansion joint installed at each end of LWR/CWR to permit expansion/contraction
of the adjoining breathing lengths due to temperature variations.
(2) Normally, SEJ are provided for same rail sections. In case SEJ is required to be
provided between the junction of two different rail sections such as 52 Kg rail and 60
Kg rail, Combination SEJ as per standard RSO drawing shall be provided.
Note: For the guidance of field officials, some of the commonly used Glued Joints and SEJ
are as per Annexure - 2/4 (A) and 2/4 (B). For detailed information, respective RDSO
drawings with their latest alterations and / or Track Manual may be referred.
*********************
Page 70 of 417
PART – F
TRACK STRUCTURE ON BRIDGES
226 Rail and rail joints on Bridges – (Back to Para 318, 715)
(1) Longitudinal Profile of Rails – In standard plate girders no camber is provided. Open
web girders of span 30.5 m and above are provided with camber. Track on these
bridges are laid correctly following the camber of the girder.
(2) Rail joints over the Bridge – In the case of small bridge openings less than 6.1 m, rail
joints should be avoided. For other spans, the preferred position of the rail joint is at
1/3 the span from either end.
(3) SWR on Bridges –
(a) SWR maybe continued over girder bridges with un-ballasted decks up to 13.3 m
opening if the length of SWR is symmetrical to the centre line of bridge and up to
6.1 m opening if the length of SWR is unsymmetrical to the centre line of the bridge.
(b) No fish-plated joint should be located on the girder or within six metre from either
abutment. In all such cases rail free fastenings, such as rail free clips shall be used,
so that relative movement between rail and sleepers may take place.
(c) 26 m long rolled rail may be laid on bridges with 1.0 m long fishplate and 06 bolts.
Joint gaps to be provided and maintained as per Para 319 & 320.
(4) LWR/CWR on Bridges – In the case of laying LWR/CWR, provisions contained in
Para 329, 330 & 331 should be followed.
(5) Precautions for arresting Creep – Track on girder bridges with un-ballasted deck is
always laid with rail free fastenings in all cases. Track on girder bridges laid with
standard single rails and fish-plated joints should be isolated from the SWR, if existing,
on approaches on either side by providing at least two well-anchored Standard rail
lengths or one rail of 26 m. Similarly, the track on the girder bridges not laid with
LWR/CWR shall be isolated from LWR/CWR by a minimum length of 30 metre of well-
anchored SWR on either side.
227 Steel Sleepers on Bridges – (Back to Para 631)
(1) Steel Sleepers on bridges refer to both Steel Channel Sleepers and Steel H Beam
Sleepers. Steel sleepers to be used on girder bridges should be fabricated as per
approved drawings. For girder bridges on curved track, and track on skewed
alignments, steel sleepers should be designed to suit the specific locations.
(a) Steel channel sleepers, including its fittings, may be provided on girder bridges
as per applicable RDSO drawings.
(b) H-Beam steel sleeper, including its fittings, for Girder Bridges may be provided as
per applicable RDSO drawings.
(c) All standard drawings should be followed as per Latest alterations.
(2) Sleeper spacing – Maximum centre-to-centre sleeper spacing should be 600 mm at
all locations on the bridge except at the cross girder in open web girders, where the
spacing may be suitably increased depending upon the top flange width of the cross
girder. However, in case of width of top flange of cross girder exceeds 450 mm. then
special channel sleeper to be provided as per applicable RDSO drawing for such
situations. The clear distance between joint sleepers should not be more than 200
mm.
(3) Fabrication of Steel sleeper and other components –
(a) Fabrication of Steel Sleepers on bridges and its protective coating should be in
conformity with BS-45 issued by RDSO.
Page 71 of 417
(b) For girder, location of Steel Sleepers should be marked and numbered after
detailed survey of the girder. The fabrication of Steel Sleeper should be location
specific considering the girder centre, top flange cover plates, pitch of rivets etc.
(c) In case of bridges on curves, the location of Steel Sleepers should be marked after
taking into account the realigned curve. In case transition curve lies on bridge fully
or partially, the thickness of steel pad plate should take care of cant gradient.
(4) Laying of Steel sleepers on bridges –
(a) Minimum level of supervision while laying of channel sleepers shall be JE/P.Way.
(b) Before laying Steel Sleepers, creep if any, should be pulled back and rail joints
should be so located that after laying sleepers, joints should not become supported
joints.
(c) The top flange of girder should be cleaned of old paint and then re-painted as
specified.
(d) Wherever required the existing cross level and misalignment of girder/ track should
be corrected in advance of Steel Sleeper laying.
(e) Single pad plate below Steel sleeper is preferable. Packing plates can be used
along with pad plate to adjust Parameters, wherever required. The pad plates are
not required where neoprene pad is provided to cover the rivet head.
228 Provision of Guard Rails on Bridges – (Back to Para 630)
(1) Location – Guard rail should be provided on all girder bridges (including pre-stressed
Concrete girder bridges without deck slab) whether major or minor. Guardrails should
also be provided on all major and important ballasted bridges and also on such other
minor bridges where derailment may cause serious damages.
On all flat top, arch and pre-stressed concrete girder bridges with deck slab, where
guardrails are not provided the whole width of the bridge between the Parapet walls
shall be filled with ballast up to the top of sleeper level.
The provision of guardrails along the inner rail can be dispensed with, in case of
ballasted deck bridges located on sharp curves where the maximum permitted speed
is not more than 30 Kmph and track is laid with PSC sleepers having arrangement for
provision of checkrail due to which guardrail cannot be provided.
In case of ROB/FOBs, the guard rail shall be provided on the track adjacent to a
column/pier/abutment which is located within a distance of 8m from centre of track.
(2) Design of Guard rails – The typical arrangement of a guard rail, with the important
dimensions are shown in the sketch and table as shown below –
Sl. No PARTICULARS SKETCH REF Dimension (mm)

1 Clearance between guard rail and running rail “a” 250± 50
Length of guard rail outside ballast wall and
2 L1 1825
maintained to Clearances mentioned in Item-1
Length of guard rails to be bent so as to be
3 L2 4875
brought together at the middle of the track.
Page 72 of 417
The top table of the guardrail should not be lower than that of the running rail, by more
than 25 mm. In the case of bridges on curves with canted track, the difference should
be measured with reference to a straight line connecting the running tables of inner
and outer rails.
(3) Fixing of Guard Rails –
(a) Splaying of Guard rails – In the case of through girder bridges on double lines, the
Guard Rails should be splayed on both ends on both lines. In the case of bridges
other than through bridges on double lines, the splaying need be done only on the
facing direction of the particular line. The ends of Guard Rails should be bent
vertically and buried and a block of timber fixed at the end to prevent entanglement
of hanging loose couplings
However, the non-splayed end should be bent downwards after it is stopped at the
end of the abutment or a wooden block provided.
(b) The fixing of Guard Rail on concrete sleepers on ballasted deck bridges and
approaches shall be done as per approved RDSO drawings by proper tightening
of rail screws
229 Provision of Side Pathways and Walkways- Side Pathways shall be provided
on all new girder bridges as per applicable RDSO drawings to ensure safety of
maintenance staff. Possibility should be explored to provide Side Pathways on
existing girder bridges also. Properly secured walkways (or inspection gangways),
made of chequered plates with hole, should be provided inside the track to cover the
width available between the Guard Rails, and at other suitable locations to ensure
safety of maintenance staff and to facilitate inspections.
Note: For the guidance of field officials, some of the commonly used RDSO drawings
for commonly used steel Channel sleepers, H Beam sleepers and fixing of
Guard Rails is as per Annexure - 2/4 (A). For detailed information, respective
RDSO drawings with their latest alterations and / or Track Manual may be
referred
********************
Page 73 of 417
Annexure - 2/4(A) (Para 206, 210, 223, 224, 225)
LIST OF COMMONLY USED TRACK FITTINGS FOR THE GUIDANCE OF FIELD

ENGINEERS.
S
Component DRG. No DESCRIPTION
No
1 T-090(M) Fish Plate For 52 Kg/M Rail.
2 Fish Plate T-1898 Fish Plate For 60 Kg/M Rail.
3 T-5915 Fish Plate For 52 Kg/M Rail (1 Meter Long)
4 T-5916 Fish Plate For 60 Kg/M Rail (1 Meter Long)
5 Joggled T-5551 Joggled Fish Plates & Clamps for Rail-Fracture B.G. For 52 Kg.
6 Fish Plate EDO/T-2242 & Joggled Fish Plates For 75 mm Wide Gap A.T. Weld For 52 Kg
2243 with C.I. Block
7 EDO/T-2246 Joggled Fish Plates For 75 mm Wide Gap A.T. Weld For 60 Kg
&2247 (UIC) With C.I. Block
8 T-5849 Joggled Fish Plates for Use on Welded Joint for B.G. 60 Kg.
9 T-5848 Joggled Fish Plates for Use on Welded Joint for B.G.52 Kg.
10 Combination T-696 to 699 Fish Plate Combination For 60 Kg (UIC) And 52 Kg
11 Fishplate T-6594 TO-6597 Combination Joggled Fish Plates For 60 Kg. (UIC)/52 Kg Rails
with C.I. Block for B.G.
Prestressed Concrete Sleeper for 52 kg Rail designed for 22.9
12 T-2495
t Axle load
Ordinary
Prestressed Concrete Sleeper for 60kg / 52 kg Rail designed
13 PSC T-2496
for 22.9 t Axle load
sleepers
Prestressed Concrete Sleeper for 60kg /136 RE Rail designed
14 T-8527
for 25.0 t Axle load
15 RT-4183-4186 PSC Sleeper for Curve with Check Rail for 60Kg Rail
Slack
16 PSC Sleeper for Curve with Check Rail for 136RE / 60 Kg rail
Gauge RT-8621-8624
for 25T Axle load
Sleeper
17 RT-5738 – 5740 PSC Sleeper for Curve with Check Rail for 52Kg Rail
18 Sleeper for RT-4088-4097 PSC Sleeper for Guard Rail on Bridge and approach
19 Guard rail & PSC Sleeper for Guard Rail Bridge and approach for 25T axle
Bridge RT-8672-8680 load / wider sleeper
approaches
20 Sleeper for RT-4148/4148A PSC sleeper for LC for 60/52 kg running rail & 52 kg check rail
21 LC RT-8671 (25t) PSC sleeper for LC for 25T axle load
22 Sleeper for RT-4149 PSC sleeper for SEJ
23 SEJ PSC sleeper for SEJ (with 300 mm max: gap) 60kg (UIC) rail
RT-6253
on bridge approaches.
24 RT- 4865 Sleeper Set for 1 in 8 ½ Fan shaped layout
Sleeper for
25 RT- 4218 Sleeper Set for 1 in 12 Fan shaped layout
P&C
26 RT- 6068 Sleeper Set for Derailing switch
27 Shallow (RT-4852) PSC shallow sleeper (160 mm) deep
28 Depth RT-8326 PSC shallow sleeper with Guard Rail
Sleeper
29 Sleeper for RT-6420-6440 PSC Sleeper for Re-Railing Ramp On 52 Kg Running Rail
30 Re-Railing RT-8265-8291 PSC Sleeper for Re-Railing Ramp On 60 Kg Running Rail
Ramp
31 Nylon Cord RT-7014 to 6mm thick nylon cord reinforced GRSP for placing beneath
Reinforced 7021 crossing portion in 1 in 12 turnouts on PSC sleepers
GRSP
32 RDSO/T-2572 Glued Insulated Rail Joint for B.G. 60kg (UIC)-G3(L)
33 RDSO/T-2576 Glued Insulated Rail Joint for B.G. 60kg (UIC)-G3(S)
Glued Joints
34 RDSO/T-671 Glued Insulated Rail Joint for B.G. 52kg G3(L)
35 RDSO/T-1259 Glued Insulated Rail Joint for B.G. 52kg G3(S)
36 Steel B-1636/R2, B- Steel Channel Sleepers and its fittings
Channel 1636/1/R2 and
sleepers B-1636/2
Page 74 of 417
S
Component DRG. No DESCRIPTION
No
37 Fittings for RT-5155 to RT- Fittings for Steel Channel Sleepers on bridges with 60 Kg
Steel 5164 running rail and 52 kg guard rail
38 Channel RT-5197 to RT- Fittings for Steel Channel Sleepers on bridges with 52 Kg
Sleepers 5200 running rail and 52 kg guard rail
39 No. B-1636/8 H-Beam steel sleeper for 60KG Running rail
H-Beam
40 RT-8240 to RT-
steel sleeper fixing of running rail on H-Beam sleeper
8245
41 Fixing of PSC Guard Rail Sleeper for Use on Bridge Approach Sleepers
T-4088 to 4097
Guard rail on With 60/52 Kg Running Rail & 60/52 Kg/90 R Running Rail
42 ballasted
Deck T-8672 to 8680 PSC Guard Rail Sleeper for wider sleeper
bridges*
Note: * -1. Provision of guardrails on PSC sleeper for bridges on sharp curves for more than 5°
curves shall be as per PSC sleeper drawing No. RDSO/T-8695 or RDSO/T-8757 (wider
sleeper) having arrangement for provision of check rail along inner rail and guard along
outer rail.
2. For detailed information, respective RDSO Drawings / Track Manual to be referred.
Annexure - 2/4 (B) (Para 206, 210, 223, 224, 225)

(a) Some of the commonly used ERCs and their salient features
Sl. RDSO Toe load Toe def. Dia. Approximate
ERC type
No. drawing no. (kg) (mm) (mm) Weight (kg)
1 ERC-J RT-8258 650 8.5 20.64 1
2 Mk- III RT-3701 850-1100 13.5 20.64 0.91
3 Mk-V RT-5919 1200-1500 13.5 23/20.64 1.08
4 Anti-theft RT-6254 850-1100 13.5 20.64 0.937
(b) Some of the commonly used GRSPs
Sl.
RDSO Drawing No Usage
No
1 RT-3703 6 mm GRSP for 52 kg Rail and 52 kg Sleeper
2 RT-3711 6 mm GRSP for 52/60 kg Rail and 60 kg Sleeper
10 mm GRSP for 52/60 kg Rail and slack gauge PSC sleeper
3 RT-3709
RT-4183-4186
RT-4218, RT-4219, GRSP Set for Turnout 1 in 12 - 60 kg (as contained in the three
4
RT-4220 drawings of Layout Assembly, Switch and Crossing)
RT-4865, RT-4966, GRSP Set for Turnout 1 in 8.5 - 60 kg (as contained in the three
5
RT-6068 GRSP Set for 60 Kg for Derailing Switch (as contained in the
6
drawing of Derailing switch)
RT-5836 GRSP Set for 52 Kg for Derailing Switch (as contained in the
7
drawing of Derailing switch)
RT-4732, RT-4733 GRSP Set for Turnout 1 in 12 - 52 kg (as contained in the three
8
RT-4865, RT-4866 GRSP Set for Turnout 1 in 8.5 - 52 kg (as contained in the three
9
GRSP Set for Turnout 1 in 12 with Thick Web Switch (TWS) -
RT-6154, RT-6155
10 60 kg (as contained in the three drawings of Layout Assembly,
RT-4220
Switch and Crossing)
GRSP Set for Turnout 1 in 8.5 with Thick Web Switch (TWS) -
RT-6279, RT-6280
11 60 kg (as contained in the three drawings of Layout Assembly,
RT-4967
Switch and Crossing)
12 RT-4159 6 mm thick GRSP for SEJ
13 RT-5163 6 mm thick GRSP for 52 Kg guard rail on channel sleeper
14 RT-5156 10 mm thick GRSP for 60 kg running rail on channel sleeper
15 RT-5199 10 mm thick GRSP for 52 Kg running rail on channel sleeper
16 GRSP 8292 to 8295 6 mm thick GRSP with horns for Turnouts (1 in 12 & 1 in 8.5)
Page 75 of 417
(c) Some of the commonly used Composite GRSPs
RDSO Thickness of
S No Description/Usage
Drawing No CGRSP
1 For 52kg / 60 kg Rail on PSC sleeper RT-2496 RT-6618 6.2 mm
2 For 52 kg Rail on PSC sleeper RT-2495 RT-8327 6.2 mm
3 For 136RE/60 kg Rail on Wider PSC sleeper RT-8527 RT-8528 10 mm
(d) Some of the commonly used Liners

Sl. Rail Sleepers meant RDSO Type of Colour band
No. Section for rail section Drg. No. Liner
1 52 kg 52 kg RT-3738 Metal
2 60 kg 60 kg RT-3740 Metal
3 RT-3741(GS) Metal Yellow
52kg 60kg
RT-3742 (NGS) Metal Green
4 52 kg 52 kg RT-3702 GFN Pink
5 60 kg 60 kg RT-3706 GFN White
6 52kg 60kg RT-3707 (GS) GFN Yellow
RT-3708 (NGS) GFN Light Green
7 60kg 136RE RT-8616(GS) Metal Blue
RT-8617(NGS) Metal Brown
8 60kg 136RE RT-6938(GS) GFN Light Brown
RT-6939(NGS) GFN Grey
9 136RE 136RE RT-8618 Metal -
10 136RE 136RE RT-6937 GFN Sky Blue
For details of Cut liners, RDSO drawing no. RT-4322(for 52 kg rail) & RT- 4511(for 60 kg rail) may
be referred
(e) Commonly used SEJs

S. No RDSO Drawing No Rail section Maximum Design Gap
1 RT-4160 52 Kg/m 80 mm
2 RT-4165 60 Kg/m 80 mm
3 RT- 6902 60 Kg/m 80 mm (Single Gap)
4 RT- 6914 52kg/m 80 mm (Single Gap)
5 RT- 6922 60 Kg/m 65 mm (Double Gap)
6 RT- 6930 52kg/m 65 mm (Double Gap)
Note: - Combination SEJ to RDSO Drawing No. RT-6782 with 80 mm gap shall be provided
between the junction of 52 Kg rail and 60 Kg rail
Page 76 of 417
CHAPTER – 3
INSTALLATION AND MAINTENANCE OF WELDED RAILS
*********************
PART – ‘A’
ALUMINO-THERMIT WELDING OF RAILS
301 General – Thermit welding process is used for carrying out welding of rails at site.
302 Alumino Thermit Welding of Rails –
On Indian Railways Alumino-Thermic welding with short pre-heating process by using high
silica sand mould (carbon dioxide dried) is being followed at present for welding rails of
different chemistry and sections. Short pre-heating is done by air-petrol fuel mixture, Oxy-
LPG and compressed air petrol fuel mixture.
303 Selection of rails to be welded –
For both new as well as second hand rails, before welding it should be ensured that the end
bends of the rails are within +0.5 mm, -0 mm in vertical and + 0.5 mm in lateral direction
when checked with one metre straight edge as shown in Fig. 3.1(a), (b) and (c) in
Annexure - 3/1. Further, in case of welding of new rails as well as repair/maintenance
welding, fish boltholes are to be eliminated as far as possible to make the weld amenable
for USFD testing for lack of fusion.
(1) New rails: New rails to be welded shall conform to the tolerances stipulated in the
specification IRS-T-12 (Indian Railway Specification for Flat Bottom Rails).
(2) Second hand rails: For conversion of existing single rails/short welded panels into
SWP/LWR/CWR or during secondary rail renewal, old serviceable rails may be
welded subject to the following conditions:
(a) Obsolete rail sections and rails older than 50 years shall normally not be welded.
Specific approval of the CTE may, however, be obtained in special cases.
(b) The Chief Track Engineer shall satisfy himself that second hand rails have a
substantial rail life to make it a safe and economical proposal.
(c) Rails shall be free from corrosion or excessive wear. The height of rail and width
of railhead shall not be less than the values as indicated below.
Normal height Minimum Width of Minimum width of head of old
Rail
of new rail height of old head of new rail (as measured at the gauge
section
(mm) rail (mm) rail (mm) corner) (mm)
60 kg/m 172 163 72 66
52 kg/m 156 150 67 61
The limit of lateral wear in the rail head as mentioned in table above may be followed
subject to uniform gauge without any abrupt change.
(d) Rails shall be tested before welding with Ultrasonic Flaw Detector apart from visual
inspection, so that rails having cracks and internal flaws are not welded. In order
to achieve satisfactory running on welded rail panels, rails with excessive
scabbing, wheel burns, corrugations and wear of rail seats are not to be welded.
The rail flange bottom is to be visually inspected to ensure freedom from defects
like dent, notch, corrosion, etc.
(e) Even where cracks/flaws are not detected during visual/USFD examination before
welding, the ends of second hand rails should be suitably cropped so as to
eliminate fish bolt holes.
(f) The rail ends shall be cut by sawing or using abrasive disc cutter and not by flame
cutting.
Page 77 of 417
(g) Second hand rails shall be match-marked before releasing from track to enable
matching of the rail ends at the time of welding. Kinks, if any, in the rails shall be
removed before welding.
(h) The rolling marks on the web of rails shall be checked before welding to ensure
that generally rails of different Grades of rails are not welded together. However,
in unavoidable circumstances, where rails of Grade 710 (72 UTS) rail chemistry
and that of Grade 880 (90 UTS) chemistry are to be welded, the portion of Grade
880 (90 UTS) chemistry shall be utilised for welding.
(i) The rail ends to be welded shall be checked and aligned both in horizontal and
vertical planes to the dimensional limits given in Fig 3.2 Annexure - 3/1
304 Portion for welding-The portion used for welding shall conform to the technical
requirements as mentioned in “Indian Railway Standard Specification for Fusion
Welding of Rails by Alumino – Thermic Process”. The suitability of the ‘portion’ for the
welding process in respect of the type and section of rails to be welded shall be
ensured before commencing welding. Thermit welding portions and consumables to
be used for welding shall be from RDSO approved sources only. Separate portion
and moulds shall be used for execution of combination welds for 60 kg / 52 kg rails
from RDSO approved vendors only. Welding Parameters viz. preheating time,
preheating pressure, mould waiting time etc., as approved by the RDSO for the
particular source and particular welding technique shall be ensured, while executing
the AT weld at site.
(1) Shelf life of portion: No specific shelf life has been indicated for AT welding portions.
The life of portions would depend on the quality of packing and storage condition. AT
welding portion is sensitive to moisture. Once the portion absorbs moisture, the same
cannot be removed even by drying as chemical reaction takes place in the ingredients.
Such portion should not be used for welding. Portions should be used in rotation i.e.
first in-first out.
(2) Notwithstanding aforesaid, in (1) above, the following procedure may be adopted for
permitting use of portions beyond two years after the date of manufacturing:
(a) One sample per supplied batch shall be taken.
(b) The sample shall be tested for reaction test. If the reaction is normal, the batch
represented by the sample can be used without further tests.
(c) In case the reaction is found to be quiet or boiling, a test joint should be made from
one more sample selected from the batch. Following tests should be conducted on
the test joints.
(i) Weld Metal Chemistry Test
(ii) Load deflection test: These tests should be conducted at Zonal CMTs
organisation and/or the Flash Butt Welding Plant. If the values obtained in above
tests are within the specified values as given in “Indian Railway Standard
Specification for Fusion Welding of Rails by Alumino – Thermic Process” , the
batch represented by the sample can be used, otherwise batch should be
rejected.
(d) The rejected portions are to be disposed-off by igniting five portions at a time in pit
away from the store.
305 Storage and transportation of Portions:-
The manufacturer of portion shall provide guidelines containing best safety practices
with every package for guidance of the user covering various aspects in safe handling,
storage, transportation and disposal of Thermit Materials. Tubes of igniters should be
stored in a locked steel cupboard, or other secure steel container. On no account
must these be stored in the same building as the portions.
Page 78 of 417
AT Portion should not be transported in passenger coaches. The package containing
igniters should be kept in tin cases/steel containers.
For detailed guidelines on storage and transportation, AT Welding Manual may be
referred.
306 Equipment, staff and Traffic block for welding:-
(1) The list of one set of AT welding equipment by short pre-heating process is given in
Annexure - 3/2.
(2) The composition of Thermit welding team is given in Annexure - 3/3.
(3) A minimum traffic block of 70-75 minute duration, depending upon the type of
preheating technique adopted, should be obtained for complete operation of welding
and to ensure good quality of AT weld.
(4) The traffic can be allowed only after 30 minutes have elapsed after welding of the
joint. Suitable speed restriction shall be imposed until the grinding operation is
completed.
307 Execution of Welding and other precautions:-
(1) Alumino Thermic Welding of rails may be carried out in accordance with the detailed
procedure laid down in the ‘Manual for Fusion Welding of Rails by Alumino
Thermic Process’. A Thermit welding done in-situ shall be joggled fish plated with
two clamps and supported on wooden blocks of length 300-450 mm until tested as
good by USFD.
(2) Joggled fishplates with far end bolts shall be provided on AT welds, which have
undertaken traffic equal to or more than 50% of stipulated fatigue life (GMT) of the
rail.
(3) Joggled fishplate with clamps or two far end bolts on good AT welds shall be provided
on banks having height 5 m or more.
(4) Joggled fish plate with clamps or two far end bolts on good AT welds shall be provided
on bridges (having length of waterway as 100 m or more) and on its approaches upto
100 m length.
(5) Joggled fishplate with clamps or two far end bolts on good AT welds shall be provided
on curves of 3° or sharper.
308 Tolerances on finished welds: - All the finished joints shall be checked to ensure
that the joint geometry is within the following tolerances: (Back to Para 311(2))
(1) Vertical alignment: Variation not more than +1.0 mm, − 0.0 mm measured at the end
of one metre straight edge.
(2) Lateral alignment: Variation not more than ± 0.5 mm measured at centre of one-metre
straight edge.
(3) Finishing of top surface: + 0.4 mm, − 0.0 mm measured at the end of 10 cm straight
edge.
(4) Head finishing on sides: ± 0.3 mm over gauge side of the rail head measured at the
centre of 10 cm straight edge.
Note: In specific cases for joint geometry in case of old rails, dispensations may be
permitted by Chief Track Engineer. The method of checking the geometry of welded
joints is illustrated in Fig. 3.3 of Annexure - 3/1.
309 Record of joint geometry:-
(1) In case of welding by outsourced agency, the details of geometry of each joint shall
be jointly signed by the firm’s and Railway’s representative and kept as record.
(2) In case of welding by outsourced agency, any joint found not conforming to the above
stipulations should be cut and re-welded, free of cost, by the firm.
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(3) JE/SSE/P.Way shall maintain ‘Thermit Weld Register’ as per proforma given in
Annexure - 3/4 & shall make entries in TMS.
(4) The welded joints shall be serially numbered in a kilometre.
(5) The Repair welds/additional welds done at a later date may be given continuing weld
number in that kilometre. For example, the last Thermit weld number in a particular
kilometre was 88 and subsequently a Thermit weld has been executed, it shall be
numbered 89, irrespective of its location in that kilometre.
(6) Each joint shall have a distinctive mark indicating month, year of welding, agency and
welder/supervisor identification code number (as appearing on his competency
certificate) at non-gauge face side of AT weld on head as detailed in AT welding
Manual.
310 Painting of Thermit welds:-
(1) Painting of weld collar should be done on all welds to protect them against corrosion
immediately after the welding.
(2) In service painting (maintenance painting) of Thermit welds should be carried as per
following frequency:
(a) Once in four years in areas not prone to corrosion.
(b) Every year at locations prone to corrosion as defined in Para 612 (1).
(c) The frequency may be increased depending on the site conditions.
(d) On condition basis at locations which are prone to severe corrosion (areas of
severe corrosion to be decided by Chief Track Engineer).
(3) The procedure for painting of weld collar for Thermit welded rail joints to protect
against normal corrosion and severe corrosion is outlined in AT Welding Manual.
311 Acceptance tests:-
(1) Visual inspection:
All the welded joints shall be cleaned and examined carefully to detect any visible defect
like cracks, blow holes, shrinkage, mismatch, surface finish (smooth surface finish
required) etc. Any joint, which shows visible defect, shall be declared defective. The
bottom of the joint shall be checked by feeling with fingers as well as inspected with the
help of a mirror for presence of ‘fins’ at the parting line of the mould. If fin is observed in
any joint, the joint shall be declared defective.
(2) Dimensional check:
All finished joints shall be checked for dimensional tolerances, which should be within
the tolerances as specified in Para 308 above.
(3) Ultrasonic flaw detection test:
All the welded joints shall be ultrasonically tested as per the provisions of 'Manual for
Ultrasonic testing of rails and welds' as early as possible in any case not later than 30
days and record maintained as per Annexure - 3/5.
The cumulative number of AT welds found defective in ultrasonic testing and in other
criteria shall be limited as per clause 7.3.1 of AT welding Manual.
For upgraded AT welding techniques approved in terms of Part E of IRS: T-19,
cumulative number of failed AT welds in ultrasonic testing and in other criteria shall be
limited as per clause 7.3.1.1 of AT welding Manual.
Subsequent USFD testing of AT welds shall be done as per the provisions given in
“Manual for Ultrasonic Testing of Rails and welds”.
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PART – ‘B’
FLASH-BUTT WELDING OF RAILS
312 General: - Flash butt welding uses the principle of softening of interface by electric
current and then butting the rail ends under pressure for welding. In Indian Railways, flash
butt welding is done by Stationary flash butt welding plant or by mobile flash butt welding
plant.
Weld Parameters for different rail sections/chemistry have been prescribed by
manufacturers and are unique to the particular welding plant. These shall be approved by
RDSO in accordance with Para 5.6 of “Manual for flash butt welding of rails”. Should any
change in these Parameters be considered necessary, it shall be approved by RDSO. The
welding operators are also to be certified by prescribed authority.
313 Rail Welding by Stationary Flash Butt Welding plant:-
These are used in rail manufacturing plants and in Flash Butt welding Depots of Indian
Railways. It is necessary to get requisite approval from RDSO for the QAP and welding
Parameters for the rail section and plant being used. Competency certificate to welding
operators shall be granted by Chief Track Engineer.
314 Rail Welding by Mobile flash butt welding plant:-
(1) Flash butt welding of new or second hand rails shall be carried out as per detailed
procedure given in “Manual for Flash Butt Welding of Rails”, which gives the details
of type and suitability of rails to be welded, pre-welding inspection, preparation of rail
ends, procedure of execution of welding, finishing of welded joints, acceptance tests
etc.
(2) Quality Assurance Program for mobile flash butt welding shall be got approved from
RDSO as detailed in Annexure - X of Manual for Flash Butt Welding of Rails. After
having obtained approval of QAP from RDSO, approval for field welding shall be
granted after execution of 30 welds on track (carried out in two shifts), if they satisfy
the weld acceptance criteria defined in Para 5.6.4.1, 5.6.4.4, 5.6.4.5, 5.6.4.6, 5.6.4.7,
5.6.4.8 and 5.6.4.10 of Manual for Flash Butt Welding of Rails, (visual, dimension,
ultrasonic, hardness, transverse testing, macro and micro examination). In case of
Flash butt welding work of Zonal Railway, this shall be carried out in presence of
Engineer in-charge and the approval shall be granted by Chief Track Engineer/ Chief
Engineer Construction. The welding operators are also to be certified by prescribed
authority.
315 Suitability of rails for welding:-
For suitability of old/new rails for flash butt welding, “Manual for Flash Butt welding of
Rails" should be referred.
316 Acceptance Tests:-
(1) Visual Inspection:
All welds and rails shall be inspected visually for welding, trimming, clamping or profile
finish imperfections, such as tears, cavities, cracks, damage and thermal damage, in
particular, in the electrical contact areas.
(a) There shall be no sign of tearing, chisel mark or cavity in weld metal due to trimming
and upset shall not be raised more than 3 mm and there shall be no depression in
accordance with Annexure - IV-A & B of Manual for Flash Butt Welding of Rails, as
applicable.
(b) Step across the weld: All the welds shall be measured in as welded condition to
determine step across the weld. No step shall be permitted except as provided in Para
3.3.3 and 3.3.4 of Manual for Flash Butt Welding of Rails.
(2) Dimensional Check:
Finished weld samples shall be checked for weld geometry and shall conform to
tolerance laid down as per following.
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Finishing Tolerances for Welds with New Rails
Sl.
Parameter Value
No.
At the centre of a 1 m straight edge
1 Vertical misalignment +0.3mm
- 0.0 mm
2 Lateral misalignment ± 0.3 mm at the centre of a 1 m straight edge
Side of rail head should be finished to
3 Head finishing (in width) ± 0.25 mm on gauge side at the centre of 10
cm straight edge
At the centre of 10 cm straight edge
4 Finishing of top table surface + 0.2 mm
- 0.0 mm
Web zone (under side of head web, + 3.0 mm of the parent contour
5
top of base, both fillet each side) - 0.0 mm
Upper sides, under surfaces and edges of rail foot shall be ground smooth. The edges
of foot should be rounded and bottom of rail foot ground smooth without any minus
6 tolerances to ensure proper seating on sleepers, unhindered movement of welded
panels on end unloading rakes, avoid damage to elastic rail pads and eliminate stress
riser.
Finishing Tolerances for Welds with Old Rails
Sl.
Parameter Value
No.
1 Vertical misalignment ± 0.5 mm at the centre of a 1 m straight edge
2 Lateral misalignment ±0.5 mm at the centre of a 1 m straight edge
± 0.3 mm on the gauge side at the centre of a
3 Head finishing (on sides)
10 cm straight edge
± 0.2 mm at the centre of a 10 cm straight
4 Head finishing (on top table)
edge
Web zone (under side of head,
5 web, top of base and both fillets on + 3.0 mm ,-0.0 mm of parent contour
each side)
Upper sides, under surfaces and edges of rail foot shall be ground smooth. The
edges of foot should be rounded and bottom of rail foot ground smooth without any
6 minus tolerances to ensure proper seating on sleepers, unhindered movement of
welded panels on end unloading rakes, avoid damage to elastic rail pads and
eliminate stress riser.
Note: The above tolerances are finished tolerances of welds inclusive of tolerances of rail.
(3) Ultrasonic test:
All Flash Butt welds shall be subjected to ultrasonic testing for detecting presence of internal
defects in the weld. This test shall be done manually with USFD machine by trained
personnel as per the procedure laid down in “Manual for Ultrasonic testing of rails and
Welds”. Welds having defects shall be rejected. Results shall be maintained as per
proforma given in Annexure - 3/5 and entries made in TMS. Defective joint shall be
distinctly marked and shall be cut & removed before the panel is laid in the track.
(4) Lab tests:
Hardness test, Transverse load test, Macro examination and Micro examination shall
be conducted as per procedure and frequency prescribed in the “Manual for Flash
Butt Welding of Rails”.
Note: In case a sample joint does not comply with the requirements of the test, two more
sample joints will be made and tested. If both the sample joints meet the requirements
of the tests, welding may continue. In case of failure of any of the retest joints, RDSO
should be consulted for investigation and fixing revised welding Parameters for the
F.B welding plant.
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Annexure - 3/1 (Para 303, 308)
Page 83 of 417
Page 84 of 417
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List of Equipment for Alumino – Thermic Welding of Rail Joints by Short Preheating
Process per Welding Team
Quantity Life in
Sl. terms of
Description Mass Repair
No. No. of
welding welding
joints
A. PRE-HEATING EQUIPMENT
A1. Air- Petrol Pre-heating
1. Pressure tanks with pressure gauges complete 2 Nos. 1 No. 500
2. Vaporisers (burner) complete 2 Nos. 1No. 500
3. Nozzle prickers 4 Nos. 2 Nos. 50
4. Nozzle keys 1 No. 1 No. 500
5. Vaporiser stand 2 Nos. 1 No. 1000
6. Goose neck attachment to vaporiser 4 Nos. 2 Nos. 50
A2. Compressed Air-Petrol Pre-heating
Periodical
maintenance
1. Suitable compressor system with pressure gauges 2 Nos. 1 No.
half yearly
500
2. Torch (Burner) complete 2 Nos. 1 No. 300
3. Torch (burner) keys 1 No. 1 No. 500
4. Torch (burner) stand 2 Nos. 1 No. 1000
5 Goose neck attachment to vaporiser 4 Nos. 2 Nos. 50
A3. Oxy- LPG Pre-heating
1. Oxy- LPG torch (burner) 2 Nos. 1 No. 150-200
2. Oxygen cylinder with pressure gauge 2 Nos. 1 No. 100
3. LPG cylinder with pressure gauge 2 Nos. 1 No. 100
4. Torch (burner) stand 2 Nos. 1 No. 500
5. Connecting Hose pipe 4 Nos. 2 Nos. 75-100
B. OTHER EQUIPMENT
1. Crucible complete- Crucible shell & Crucible lining 2 Nos. 1 No. 500 & 50
2. Crucible caps 2 Nos. 1 No. 50
3. Crucible forks 2 Nos. 1 No. 500
4. Crucible stands 2 Nos. 1 No. 1000
5. Crucible rings 2 Nos. 1 No. 500
6. Mould pressure (clamp) 2 sets 1set 1000
7. Cleaning rod round 2 Nos. 1 No. 500
8. Tapping rod 1 No. 1 No. 1000
9 Straight edge 1 m long 2 Nos. 1 No. --
10. Straight edge 10 cm. long 2 Nos. 1 No. --
11. Aluminium/steel rod for thermal plugging 2 Nos. 2 Nos. --
12. Leather washers for pump 4 Nos. 2 Nos. 100
13. Gap gauges and height gauge 2 Nos. 1 No. --
14. Filler gauge 2 Nos. 1 No. --
15. Tools for punching the marking 2 Sets. 1 Set --
16. Mould shoes 6 Pairs 2 Pairs 100
17. Stop watch 1 No. 1 No. --
Pyrometer/Thermal chalk for measurement of rail
18. 1 No. 1 No. --
temperature
19. Wooden wedges for rail alignment 24 Nos. 12 Nos. --
First aid box filled with medicines bandages, cotton
20. 1 No. 1 No. --
etc.
21. Mirror 150 x 100 mm with handle 2 Nos. 1 No. --
22. Tool box containing –
i) Hot sets (chisels) (for Emergency use only) 2 Nos. 2 Nos. --
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ii) Funnel tin (for pouring petrol ) 1 No. 1 No. --
iii) Adjustable spanner 1 No. 1 No. --
iv) Hammer 1 kg 1 No. 1 No. --
v) Sledge hammer double panel 5 kg. 2 Nos. 2 Nos. --
vi) Steel wire brush 1 No. 1 No. --
vii) Blue goggles 2 Pairs. 1 Pair. ---
viii) Paint brush 50mm 1 No. 1 No. --
ix) Slag container (bowl) 2 Nos. 1 No. 500
x) Asbestos gloves 4 Pairs. 2 Pairs. 500
xi) Hose clips 4 Nos. 4 Nos. --
xii) Pliers 1 No. 1 No. --
xiii) Rail file 350 × 40 × 6 mm (For Emergency use only) 4 Nos. 2 Nos. --
23. Weld trimmer(Cutter) 1 No. 1 No. 100
Insulation hood for control cooling(for 110 UTS rail
24. 1 No. 1 No. --
welding)
25. Rail profile guided grinding trolley (Grinding wheel). 1 No. 1 No. 50
26. To ensure quality, protective clothing, shoes gear & Leather gloves.
Note:
1. For crucible lining, Magnesite powder and sodium silicate should always be available.
2. Expected life of the equipment has been given as guide lines for initiating action for
procurement by zonal railways depending upon their requirement. The expected life of
various equipment may vary depending upon site conditions and its use.
3. The items for which, expected life has not been given, they should be replaced on condition
basis.
4. Tools and equipment viz. Pre-heating arrangement, Crucible and Mould used for A.T welding
shall be as per the Approved A.T welding technique of a particular firm by RDSO. Also,
critical process timing viz. Preheating time, tapping time, mould waiting time, time for
passage of First train on AT weld etc. shall be followed as per the approved AT welding
technique.
Page 87 of 417
Composition of Thermit Welding Team (Compressor Tank- Wise)
Sl. No. Designation Numbers
1 Welder Grade I/Grade II 1
2 Welder Grade III/Skilled Artisan 2
3 Helper Khalasi/Khalasi 5
4 Trackman As per work load
Note: The composition of welding team has been framed taking into account that trimming
and grinding operation would be done by weld trimmer and rail profile grinder .

Proforma for Thermit Weld Register
Sl. Date of Location details Rail Bolt hole distance
No welding Block Stn. Cess / Situ Km TP U/D L / R Section UTS (mm)
1 2 3 4 5
Portion details Welding details

Agency Batch Portion Date of Agency Process Supervisor Welder code
code No. No. Manufacturing code code
6 7
Weld Block Average rail If rail tensor is Date of Dimensional tolerances USFD testing
No. time temperature used for finish on finished joint after welding
From To during creation of gap grinding
welding for welding, On 1m On 10cm
Date Result
whether (Pass/
equalization of Lateral Vertical Top Side
Failed)
forces done
(Yes/No)
8 9 10 11 12 13 14
In service failure Test joint Replacement Weld Reference Sign. of Date of sending
details date Weld1 Weld 2 JE/SSE test joint with
removed S. No. Date S. No. Date P.Way reference
Welding
Date Type
15 16 17 18 19
Test joint results Chainage Reference

Date of Hardness (BHN) Transverse load Porosity Date of of weld point for
receipt of % marking ‘X’ Chainage
results Rail Weld HAZ Load Deflection for
with (mm) extended
reference guarantee
Remarks
20 21 22
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Ultrasonic Testing of Welded Joints
1. Date/Month/year
2. Details of Weld
(Joint No, Km / Chainage / LR / RR /
UP / DN / Line No etc.)
3. Name of Operator
4. USFD testing Machine used (make, model, serial number)
5. Rail section & chemistry
6. Day / Night shift
7. Result of testing
8. If defective, details of flaw Defective zone Head/Web/Foot
9. Probe wise USFD peak pattern.
10. Remarks
11. Signature
Summary (at the end of the month)

No. of joints welded during the month (Rail section-wise)
No. of joints tested (Rail section-wise)
No. of joints found defective (Rail section-wise)
Page 89 of 417
PART – ‘C’
SHORT WELDED RAILS
317 General –
SWR shall be laid generally on stable and efficiently drained formation. 100 mm extra width
of shoulder ballast over and above the standard ballast section on tangent track shall be
provided on outside of curves upto 875 metre radius. In case of sharper curves, the extra
width shall be 150 mm. In case of 60 kg/m Rails, LWR profile shall be adopted.
318 Condition of Laying –
(1) Alignment – SWR on PSC sleepers shall not be laid on curves sharper than 440 metre
radius.
Existing SWR laid on sharper curves may, however, be allowed to continue if there is
no difficulty experienced in maintaining these lengths. Chief Track Engineer’s
approval should be taken in such cases.
(2) Junction with insulated joints and points and crossings – SWR butting against
insulated joints, heel of crossing and stock rail joints, shall be anchored for a length
of 39 metre on the approach effectively to arrest creep in either direction.
(3) Regarding laying of SWR in Level Crossings and Bridges refer Para 918 and Para
226.
319 Laying of Short Welded Rails – The gaps to be provided for SWR at the time of
laying shall be in accordance with Table 1 depending on the installation temperature (ti) and
the Zone in which the rails are laid. (Back to Para 226 (3) (c), 320(5), 715)
TABLE 1
Initial Laying Gaps for SWR for Various Installation Temperatures
For Zone I and II
Rail temperature at the time of Initial laying gaps (in mm)
installation (ti) For 39 m panels For 26 m rolled rails
tm- 17.5°C to tm- 12.6°C 12 10
tm- 12.5°C to tm- 7.6°C 10 9
tm- 7.5°C to tm- 2.6°C 8 7
tm- 2.5°C to tm+ 2.5°C 6 6
tm+ 2.6°C to tm+ 7.5°C 4 5
tm+ 7.6°C to tm+ 12.5°C 2 3
For Zone III and IV
tm- 22.5°C to tm- 17.6°C 12 10
tm- 17.5°C to tm- 12.6°C 10 9
tm- 12.5°C to tm- 7.6°C 8 7
tm- 7.5°C to tm- 2.5°C 6 6
tm- 2.4°C to tm+ 2.5°C 4 5
tm+ 2.6°C to tm+ 7.5°C 2 3
Note:
If the laying has to be done outside the temperature range given in table above, or whichever
joint gaps could not be provided as per the table, readjustment of gap shall be carried out
within two days of laying before the track consolidates. Along with the gap adjustment, any re-
spacing of sleepers, if required, must be carried out.
320 Gap Survey and Adjustment of Gap – (Back to Para 226 (3), 620)
(1) General – Gap survey and rectification of gaps is to be carried out, in stretches where
track develops excessive creep, jammed joints, sun kinks, misalignment, wide gaps,
battered and hogged joints, fractures at joints and bending of bolts etc. In SWR, the
gap survey and adjustment should normally be done before the end of February once
a year (i.e. before onset of summer).
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(2) Gap survey – (Back to Para 322(3)(c))
(a) The gap survey shall be conducted on a clear and sunny day in the cool hours of
the day in rising rail temperature trend.
(b) The length over which gap survey is to be done should, wherever possible, be
divided into suitable sub-sections, each bounded by fixed points such as level
crossings, points and crossings etc. The survey should be completed during as
short a time as possible, by employing adequate number of parties so that the rail
temperature is not likely to vary appreciably.
(c) The joint gaps shall be measured by taper gauge in mm (shown below) and the
readings entered in the proforma as shown in Annexure - 3/6.
Fig. 3.4
(3) Recommended range of value of gaps – The recommended range of value of gaps
(in mm) during service for various ranges of rail temperature is indicated in the Table-
2 given below:
Table – 2
For Zone I and II
Rail Temperature During Gap Permissible Values of gaps (in mm)
Survey For 39 m panels For 26 m rolled rails
tm - 17.5°C to tm - 12.6°C 11-14 8-13
tm - 12.5°C to tm - 7.6°C 9-13 6-11
tm - 7.5°C to tm - 2.5°C 7-11 5-10
tm - 2.4°C to tm + 2.5°C 5-9 3-8
tm + 2.6°C to tm + 7.5°C 3-7 2-7
tm + 7.6°C to tm + 12.5°C 1-5 1-5
For Zone III and IV
tm - 12.5°C to tm - 7.6°C 11-14 8-13
tm - 7.5°C to tm - 2.6°C 9-13 6-11
tm - 2.5°C to tm + 2.5°C 7-11 5-10
tm + 2.6°C to tm + 7.5°C 5-9 3-8
tm + 7.6°C to tm + 12.5°C 3-7 2-7
tm + 12.6°C to tm + 17.5°C 1-5 1-5
(4) Calculations for adjustment –
The average of the measured gaps is worked out as shown in the proforma for gap
survey (Annexure - 3/6). A comparison of the results of the gap measurements
recorded and the permissible values of gap (concerned range for gap) given above
will lead to one of the following cases:
Case 1 – Average gap is within the recommended range, but some of the
individual gaps fall outside the range.
Case 2 – Average gap falls outside the recommended range.
Case 3 – Average gap as well individual gaps fall within the range.
(5) Action to be taken – The action to be taken is as follows –
Case 1 –
Rectification work should be restricted to correcting the individual gaps,
Page 91 of 417
which falls outside the recommended range.
Under no circumstances, adjustment shall be done by cutting a rail or
introducing a longer rail.
Case 2 –
The joint gaps shall be systematically adjusted from one end to the other end
of the sub-section.
The rails shall be unfastened over convenient length, the gaps adjusted to
the initial laying gaps as per Para 319 and rails fastened.
In this case, introduction of a longer or shorter rail might be required.
Case 3 –
No action is to be taken
(6) As far as possible, the day chosen for rectification should be a day on which the rail
temperature is not likely to vary much during rectification period.
Page 92 of 417
Page 93 of 417
321 Counteraction and Adjustment of Creep –
(1) General –
Rails have a tendency to move gradually in the direction of the dominant traffic. It is
believed to be caused by the ‘ironing out’ of yielding track by the moving load, augmented
by braking loads, and by the impact of the wheels on the running-on ends of the rails,
particularly at times when they are in a state of expansion or contraction. Among the
troubles caused by ‘creep’ are –
(a) Sleepers getting out of square.
(b) Distortion of gauge.
(c) Loosening of joints.
(d) Shearing and breaking of bolts and fishplates.
(e) Buckling in extreme cases.
(2) Causes for creep in track –
The following are some of the avoidable causes to which creep is attributed:
(a) Inadequate toe loads of the fastening and rails not secured properly to sleeper.
(b) Inadequate ballast resistance to the movement of sleepers due to poor or
insufficient ballast or other causes.
(c) Inefficient or badly maintained rail joints.
(d) Improper expansion gaps.
(e) Damaged sleepers, uneven spacing of sleepers.
(f) Lack of proper drainage.
(g) Yielding formation.
(h) Loose/uneven packing.
(3) Precautions to reduce creep – (Back to Para 322 (3) (d))
The PSC sleepers with effective elastic fastenings are considered as creep resistant and
therefore no other creep anchors are required. In case, excessive creep is observed on PSC
sleeper road, the condition of elastic fastenings, sleepers and adequacy of ballast resistance
should be examined. Action for replacement/ renewal of fittings, sleepers and providing
adequate ballast resistance etc. should be taken as necessary.
(4) Creep Record –
Creep records should be maintained in the proforma given in Annexure - 3/7. Entries
should be complete as regards kilometerage, section and length of rail, sleeper density.
Periodical readings of creep should be recorded in TMS in the prescribed pro forma.
Frequency of recording of creep should be specified by the Divisional Engineer taking into
consideration the rate of creep. The Assistant Engineer should test check the record
frequently, particularly sections which are prone to creep.
(5) Creep indicator posts – (Back to Para 715)
Creep indicator posts, square to the track should be erected on either side of the track on
the cess at suitable intervals of not more than one km apart. These may be unserviceable
rail posts with chisel mark square to the joints. The top of the post should be about 25 mm
above the rail level and the amount of creep one way or the other measured with a fishing
cord stretched over the chisel marks.
(6) Permissible amount of creep –
Creep in excess of 150 mm shall not be permitted.
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(7) Adjustment of creep –
Adjustments of creep should be carried out in the following manner:
(a) It is a good practice to adjust creep before the commencement of summer. It is
desirable to pull back the rails during the cool hours of the day.
(b) Careful measurement of expansion gaps, as existing, should be done and
appropriate length, which can be dealt with in one operation should be chosen.
The total amount of gap in the length should be equal to the standard expansion
gap required for the temperature at the time, multiplied by the number of joints in
the length.
(c) Work should start at the running-on end of the length, commonly just beyond the
points and crossings or level crossings. The work of creep adjustments should be
carried out under the protection of engineering signals by the JE/SSE/P.Way as
envisaged in Para 806 (1) or under traffic block, on busy routes.
(d) When the value of total gap existing is more than the standard expansion gap
required for the temperature at the time of adjustment multiplied by the number of
joints, it is necessary to provide closure rails. When closure rails are put in, a
speed restriction of 30 Kmph should be imposed, which should be removed, when
closure rail is changed.
Page 95 of 417
Page 96 of 417
322 Buckling of Track (other than LWR) –
(1) General – Buckling of track occurs when high compressive forces are created in the
rails associated with inadequacy of lateral resistance in the track at the place. A
special watch should be kept on the junction of two stretches of track, one liable to
creep and the other held against creep. As one side of such a junction point is held
firmly against creep, the movement of rails due to creep from the other side is
resisted resulting in heavy compressive force being exerted, which will tend to buckle
the track. Jammed rail joints at such junctions are therefore an indication of the track
being subjected to undue strain.
(2) Conditions, which induce Buckling –
(a) The following conditions create high compressive forces in the rail:
(i) Inadequate expansion gaps,
(ii) Failure to counteract creep in time.
(iii) Non-lubrication of rail joints,
(b) The lateral resistance gets impaired due to inadequacy of ballast and due to
carrying out of operations such as deep screening, lifting of track and slewing of
track, without adequate precautions.
(3) Precautions against Buckling – It should be seen that –
(a) Operations, which impair the lateral resistance of track, are not carried out when
rail temperatures are high.
(b) The greasing of fishplates is done before the hot weather sets in.
(c) The joint gap survey is done in the case of SWR and adjusted before the onset of
hot weather as per Para 320(2). Similarly, in case of free rail track, joint gaps
should be adjusted wherever necessary.
(d) Adequate precautions are taken to reduce creep as detailed in Para 321(3).
(e) Over tightening of fish bolts is avoided, but they should be reasonably tight.
(f) Particular attention is also paid to stretches of track, one liable to creep and the
other held against creep (refer Para above). Jammed joints at such junctions call
for remedial measures.
(g) Adequate shoulder ballast should be provided at all places.
(4) Action on buckling of track –
If a buckling does occur or appears imminent, the track should be protected
immediately with hand signal flags and detonators as per the protection rules laid
down. The buckled rails shall preferably be cut adequately apart not less than 6.5
metres. The track shall then be slewed to the correct alignment and cut rails of the
required length shall be inserted to close the gaps making due provision for welding
of joints on both rails.
The cut rails shall then be connected by use of special fishplates and screw clamps
and the line opened to traffic with speed restriction. It may not be possible to do any
more until the temperature drops when the joints must be adjusted. Particular care
must be taken to see that the factors, which contributed to the buckling i.e. jammed
joints, seized fishplates or shortage of ballast, receive appropriate attention without
delay.
323 Conversion of SWR into LWR – Wherever conditions permit, conversion of SWR
into LWR should be considered. The following additional precautions should be observed
when converting SWR into LWR –
(1) The anticipated residual life of rails shall be at least10 years.
Page 97 of 417
(2) The rails shall be tested ultrasonically and all defective rails replaced before
conversion into LWR.
(3) Rail ends which are hogged or battered or have a history of cracks in bolthole region,
shall be cropped before conversion into LWR.
324 Maintenance of Short Welded Rails – (Back to Para 609)
Regular maintenance operation –
(1) Regular track maintenance operations like packing, lifting, aligning, local adjustment
of curves, screening of ballast other than deep screening and scattered renewal of
sleepers may be carried out without restriction when the rail temperature is below tm
+ 25°C in the case of zone I & II and tm + 20°C in the zone III and IV. However, on
curves of less than 875 metre radius in Broad Gauge or yielding formation, the above
temperature limit shall be restricted to tm + 15°C in the case of Zone I and II and t m
+10°C in the case of Zone III and IV.
(2) If the maintenance operations have to be undertaken at temperature higher than that
mentioned above in Sub-Para (1) above, not more than 30 sleeper spaces in one
continuous stretch shall be opened, leaving at least 30 fully boxed sleeper spaces
between adjacent lengths which are opened out. Before the end of the day’s work, it
shall be ensured that the ballast is boxed up.
(3) As an additional precaution, during summer months, to be specified by the Chief
Engineer, for attention to run down track, even if temperature is less than the
temperature specified in Sub-Para (1) above, not more than 30 sleeper spaces in
one continuous stretch shall be opened, leaving at least 30 fully boxed sleeper spaces
between adjacent lengths which are opened out. Further, if joint gaps are not available
at the time of opening of the track even when rail temperature are less than those
specified in clause Sub-Para (1) above not more than 30 sleepers in one continuous
stretch should be opened leaving at least 30 boxed sleeper spaces between adjacent
length which are opened up.
(4) Major lifting, major alignment of track, deep screening and renewal of sleepers in
continuous length- Each of these operations shall be done under suitable precautions
and normally when the rail temperature is below tm + 15°C in the case of Zone I and
II, and tm + 10°C in the case of Zone III and IV. If it becomes necessary to undertake
such works at rail temperature exceeding the above values, adequate speed
restrictions shall be imposed.
(5) Adequate number of joggled fishplates with special clamps shall be provided to the
gangs for use in emergencies.
(6) In the case of any fracture in the weld or in the rail, the portion of rail with fracture is
cut, and removed for a length of not less than 5.5m to carry out the re-welding duly
introducing a rail piece of equivalent length, also ensuring that no weld lies closer than
4 m from the fish- plated joint.
Page 98 of 417
PART – ‘D’
LONG WELDED RAILS
325 Long Welded Rail (LWR) is a welded rail, the central part of which does not
undergo any longitudinal movement due to temperature variations. A length of welded rail
greater than 250m on Broad Gauge will normally function as LWR.
326 Permitted Locations for LWR/CWR:
(1) General Considerations for laying LWR/CWR:
(a) All new constructions/doublings/gauge conversions, permanent diversion shall be
opened with LWR/CWR.
(b) All CTR/TSR/TRR (Primary) shall provide for LWR/CWR, wherever permissible.
(c) The existing rails on permitted locations may also be converted into LWR/CWR,
provided they meet the requirements for Welding of Rail Joints by Alumino Thermic
(SKV Process)/Flash Butt Process, as the case may be.
(d) In yard lines, rail joints may be welded to form LWR if the condition of all the
components of track is generally sound and without any deficiency, subject to such
relaxation as may be approved by Chief Track Engineer, in each specific case.
(2) Alignment:
(a) LWR/CWR shall not be laid on curves sharper than 440 m radius. However, in
temperature Zone-I, LWR/CWR may be laid on curves up to 350 m radius (5 o
Curve) with following additional precautions:
(i) Minimum track structure should be 52 kg/m rails on PSC sleeper 1540 sleeper
density with 300 mm clean ballast cushion.
(ii) Shoulder ballast for curves shaper than 440m radius should be increased to 600
mm on outside of curve and should be provided for 100m beyond the tangent
point.
(iii) Reference marks should be provided at every 50 m interval to record creep.
(iv) Each curve of length greater than 250 m should preferably be provided with SEJ
on either side. SEJ should be located in straight track at 100 m away from the
tangent point.
(b) LWR/CWR may be continued through reverse curves. Shoulder ballast of 600mm
over a length of 100 m on both side of the common point of a reverse curve would
be provided. In case there is a straight track between the reverse curves, this 100m
would be considered from the center of the straight track. No such measure would
be required if the length of straight track between the reverse curves is more than
50 m.
(3) Gradient:
The steepest permitted grade for LWR/CWR shall be 1 in 100.
(4) Approvals & deviations:
Installation of LWR/CWR, or change in its constitution at a later stage shall have the
approval of the Chief Track Engineer in each case, on a detailed plan prepared in
accordance with Para 336 (1) (c). However, for any deviation from this provision,
approval of Principal Chief Engineer shall be obtained.
(5) Track structure for LWR/CWR:
(a) LWR/CWR shall be laid on stable formation having stipulated formation width and
ballast cushion (below the bottom of the sleeper); and with approved PSC sleepers
and its matching fastening system.
Page 99 of 417
(b) The minimum rail section to be used shall be of 52 kg/m.
(c) In a LWR/CWR, two different rail sections are not permitted.
(d) In case of LWRs laid on concrete sleepers having different rail section on either
side of SEJs, combination SEJ to RDSO Drg. No T-6782 (52kg / 60 Kg) shall be
provided. Alternatively, two 3 rail panels (39 m), one of each rail section shall be
provided with combination fish plated joint, between the two panels.
(e) New rails used in LWR/CWR shall, as far as possible, be without fish-bolt holes.
Joining of rail ends temporarily during installation of LWR/CWR shall be done by 1
m long fishplates with special screw clamps/joggled fish-plates having slotted
grooves & bolted clamps as in Fig. 3.9, 3.10, 3.11, 3.12, 3.13 with speed
restrictions indicated in Annexure - 3/8.
(f) Bolt holes, if any, shall be chamfered.
(6) Continuity of track structure:
Wherever LWR/CWR is followed by fish-plated track/SWR, the same track structure
as that of LWR/CWR shall be continued for at least three rail lengths (39 m) beyond
SEJ.
(7) Level Crossings:
Level crossings situated in LWR/CWR territory shall not fall within the breathing
lengths.
(8) Points and Crossings:
(a) In case, LWR is terminated near Points & Crossings, one three rail panel (39 m)
shall be provided between stock rail joint (SRJ) and SEJ as well as between the
crossing and SEJ. This length shall be provided with elastic fastenings with
adequate toe load to arrest creep.
(b) In case, LWR/CWR is taken through Points & Crossings, the provisions contained
in RDSO report no. CT-48 shall be followed.
327 Provision of Glued Joints:
All insulations for track circuiting in LWR/CWR shall be done by providing glued joints of
G3(L) type.
328 Location of SEJ:
The exact location of SEJ shall be fixed taking into account the location of various obligatory
points such as level crossings, bridges, points and crossings, gradients, curves and
insulated joints.
The various designs of SEJs in use on Indian Railways are as per Para 225
(1) The conventional SEJ (RT-4160 and RT-4165) with straight tongue and stock shall
not be located on curves sharper than 0.5° (3500 m radius).
(2) The improved SEJs (RT-6902, RT-6914, RT-6922, RT-6930) may be located on
curves up to 2°. SEJ beyond 2° and up to 4° shall be laid with approval of PCE in
consultation with RDSO
(3) The SEJ shall not be located on transition of curves.
329 Bridges with Ballasted Deck (without bearing): (Back to Para 226 (4))
LWR/CWR can be continued over bridges with ballasted deck without bearings like slabs,
box culverts and arches.
Page 100 of 417

330 Bridges with Ballasted Deck (with bearing): (Back to Para 226 (4))
Detailed calculations shall be done by the Design office of Chief Bridge Engineer / CAO(C)
to ascertain the effect of LWR of such bridges and its effect on the Sub-structure of the
bridge as per Para 2.8.1.2 of “Bridge Rules”.
The LWR/CWR may be permitted on a case-to-case basis based on the above calculations.
In case detailed calculations are not done, LWR may be permitted as per Para 331 below
for bridges with un-ballasted deck.
331 Bridges with Un-Ballasted Deck: (Back to Para 226 (4), 630)
LWR/CWR shall be continued over such bridges with overall length as specified in sub-Para
(1) to (3) below:
(1) Bridges provided with rail-free fastenings (single span not exceeding 30.5 metre and
having sliding bearings on both ends)
Overall length of the bridge should not exceed the maximum as provided in Table-1
with following stipulations:
(a) Rail-free fastenings shall be provided throughout the length of the bridge between
abutments.
(b) SEJ of the LWR should be located such that bridge does not fall in the breathing
length of the LWR. The approach track upto 50 m on both sides shall be well
anchored by providing PRC sleepers with elastic rail clips with adequate toe load
so as to arrest creep.
(c) The ballast section of approach track upto 50 metre shall be heaped upto the foot
of the rail on the shoulders and kept in well-compacted and consolidated condition
during the months of extreme summer and winter.
(2) Bridges provided with rail-free fastenings and partly box-anchored (with single span
not exceeding 30.5 metre and having sliding bearings at both ends)
Overall length of the bridge should not exceed the maximum as provided in Table-1
with following stipulations:
(a) Central sleepers shall be anchored with anchoring arrangement (two each in end
spans and one each in the middle spans) as per RDSO Drg. No. M-10920(1) (Fig
3.25) and the remaining sleepers shall be provided with rail-free fastenings.
(b) The track structure in the approaches shall be laid and maintained to the standards
as stated in (1) (b) & (c) above.
(c) The girders shall be centralized with reference to the location strips on the bearing,
before laying LWR/CWR.
(d) The sliding bearings shall be inspected during the months of March and October
each year and cleared of all foreign Materials. Lubrication of the bearings shall be
done once in two years.
TABLE - 1
Maximum Overall Length of Bridges Permitted on LWR/CWR (in m) Para – 331(1) & 331(2)
Tempe Rail-free fastenings on bridges Rail-free fastenings on bridges and
Rail
rature as per Para 331(1) with PRC partly box-anchored as per Para 331(2)
section
zone sleepers on approaches and with PRC sleeper on approaches
60kg/m 30 77
I
52kg/m 45 90
60kg/m 11 42
II
52kg/m 27 58
60kg/m 11 23
III
52kg/m 27 43
60kg/m 11 23
IV
52kg/m 27 43
Page 101 of 417

(3) LWR/CWR may also be continued over a bridge with the provision of SEJ at the far
end approach of the bridge using rail-free fastenings over the girder bridge (Fig.
3.5(b)). The length of the bridge in this case, however, will be restricted by the capacity
of the SEJ to absorb expansion, contraction and creep, if any, of the rails. The length
of the bridges with the above arrangement that can be permitted in various rail
temperature zones for LWR/CWR with SEJs having maximum movement of 120 mm
and 190 mm are as under:
Rail temp Max. movement of Overall length of Initial gap to be provided at td
zone SEJ used (mm) bridge (Para331(3) With PRC approach sleepers
IV 55 m 7.0 cm
III 70 m 7.0 cm
190
II 110 m 6.5 cm
I 160 m 6.5 cm
II 20 m 4.0 cm
120
I 50 m 4.0 cm
Note:
(i) SEJ is to be installed 15 metre away from the abutments.
(ii) Improved SEJ with 2 gaps of 65 mm (max.) each (Drawing no. RDSO/T-6922 and
RDSO/T-6930) may also be used for laying at far end approach of bridges in lieu of IRS
design SEJ with 120 mm max gap.
(4) Welded rails may be provided from pier to pier with rail-free fastenings and with SEJ
on each pier. The rail shall be box-anchored on four sleepers at the fixed end of the
girder if the girder is supported on rollers on one side and rockers on other side. In
case of girder supported on sliding bearings on both sides, the central portion of the
welded rails over each span shall be box-anchored on four sleepers. See Fig. 3.5 (a).
(5) Welded rails may be provided over a single span bridge with rail free fastenings and
SEJs with 190 mm gap at 30 m away from both abutments. The rail shall be box
anchored on four sleepers at the fixed end of the bridge if bridge is supported on
rollers on one side and rockers on other side. In case of bridge supported on sliding
bearings on both sides, the central portion of the welded rails shall be box anchored
on four sleepers. The approach track upto 50 m on both sides shall be well anchored
by PRC sleepers with elastic rail clips with minimum toe load as specified. The
installation temperature of such welded panels shall be equal to t m. The length of
single span bridge permitted temperature zone-wise shall be as under:
Temperature zone Maximum length of single span girder bridge
IV 75 m
III 87 m
II 110 m
I 146 m
(6) Bridges on which LWR/CWR is not permitted/provided as per above shall be isolated
by a minimum length of 30 metre of well anchored PSC sleeper track on either side.
(7) In case of LWR is continued over bridges as per Sub Para (3) above, the
measurement of gaps of stock rail / tongue rail tip of SEJ provided at bridge approach
from the reference post shall be compared with the theoretical gaps as prescribed in
Annexure - 3/9A.
(8) In case welded rails are provided as per Sub Para (4) or (5) above, these shall not be
entered in TMS as LWR and accordingly, measurement of gaps of at such SEJs of
welded panels is not warranted.
Page 102 of 417

Fig 3.5 Welded Rail on Bridge
Back to Para 331(3)
Page 103 of 417

332 Measurement of Rail Temperature:
(1) Thermometer:
The following are the types of approved thermometers for measuring rail temperature:
(a) Embedded type:
This is an ordinary thermometer inserted in a cavity formed in a piece of railhead,
the cavity filled with mercury and sealed. The rail piece is exposed to the same
conditions as the rail inside the track. This type of thermometer takes 25 to 30
minutes for attaining temperature of the rail.
(b) Dial type:
This is a bi-metallic type thermometer, which is provided with magnet for attaching
it to the rail. The thermometer is attached on the shady side of the web. A steady
recording of the rail temperature is reached within 8 minutes.
(c) Continuous recording type:
It consists of a graduated chart mounted on a disc, which gets rotated by a winding
mechanism at a constant speed to complete one revolution in 24 hours or 7 days
as applicable giving a continuous record of rail temperature. The sensing element
is attached to the web of the rail and connected to the recording pen, through a
capillary tube, which is filled with mercury.
(d) Any other type of thermometer approved by RDSO/Chief Engineer.
(2) Where a number of thermometers are used to measure the rail temperature at one
place, as in case of laying of LWR, de-stressing etc. or during routine tools inspection
at office of SSE/ P.Way, any of the thermometer showing erratic readings, appreciably
different from the other adjoining thermometers, shall be considered as defective.
333 Temperature Measurements:
(1) The existing SSE/P.Way (In-charge) shall record rail temperature using preferably a
well-calibrated continuous recording type thermometer and data to be updated in
TMS.
(2) The maximum and minimum rail temperature for a continuous period of at least 5
years shall be ascertained and the mean rail temperature (tm) for the region arrived
at.
(3) These temperature records shall be analysed to assess the probable availability of
time periods during different seasons of the year for track maintenance, de-stressing
operations and requirements of hot/cold weather patrolling etc.
(4) The rail thermometer shall also be available with each Gang and sectional
JE/SSE/P.Way to enable the Gangs to work within the prescribed temperature
ranges.
334 Temperature Records:
(1) The maximum daily variation of rail temperature and the mean rail temperature (t m)
for the section shall be ascertained from the temperature records available with the
SSE/P.Way(In-charge) or as built up as per Para 333.
(2) If rail temperature records of preceding five years are not available, the mean and
range of rail temperatures shown in the ‘Map of India showing Rail Temperature
Zones’ (Fig. 3.6 below), shall be adopted.
Page 104 of 417

Fig. 3.6 (Back to Para 334 above)
Page 105 of 417

335 Thermal Forces in LWR/CWR: (Back to Para 338)
Temperature changes cause movement of the ends of LWR/CWR in the breathing lengths
but the central portion of LWR/CWR does not expand/contract. This results in building up
of thermal forces in the central portion. The thermal force (P) calculated by
P= EAαt
Where,
P= Thermal force in the rail (kg)
E= Modulus of elasticity of rail steel, (2.15 x 106 kg/cm2)
A= Area of cross section of the rail (cm2)
Rail Section Cross-sectional Area (cm2)
60 kg/m 76.86
52 kg/m 66.15
α= Coefficient of linear expansion of steel, (1.152 x 10-5/0C)
t= Variation of rail temperature from td /to (°C)
The Range of td or t0 shall be within the limits of rail temperature shown below:
Temperature Zone Rail Section Range
I, II, III All Sections tm to tm+ 50 C
IV 52 kg/m & heavier tm+50 C to tm+100 C
Usual breathing lengths on PSC sleepers for different temperature zones and sleeper
density is shown in Annexure - 3/16.
The level of maximum thermal stresses in LWR depends upon variation of Rail temperature
from the stress free temperature. The thermal force diagram in LWR is shown as under (Fig
3.7):
Fig. 3.7: Force Diagram in LWR / CWR
Page 106 of 417

336 Laying of LWR / CWR
(1) Survey:
(a) A foot by foot survey of the sections where LWR/CWR is proposed to be laid shall
be carried out in regard to the Locations over which LWR/CWR cannot be carried
through on account of constraints such as bridges having
substructure/superstructure in a distressed condition, curves, gradients, points and
crossings, unstable formation etc. Such stretches of track shall be isolated from
the remaining portion of LWR/CWR by provision of SEJs at either end.
(b) Locations where following preliminary works are required to be carried out shall be
identified for completion before laying of LWR/CWR:
(i) Replacement of insulated joints by glued joints
(ii) Realignment of curves
(iii) Lifting or lowering of track to eliminate sags and humps
(iv) Introduction and improvement of vertical curves
(v) Stabilisation of troublesome formation
(vi) Rehabilitation of weak bridges involving removal or lifting of rails or introduction
of temporary arrangements.
(vii) Deep screening of ballast along with lifting or lowering of track, if required.
(c) A detailed plan shall be made showing the exact locations of SEJs and of various
other features mentioned in Sub-Para (a) and (b) above. A sample of the detailed
plan may be seen at Fig. 3.8. The plans may be prepared to a horizontal scale of
1:5000. (Back to Para 326(4))
(2) Materials Required:
Following Materials are required for laying one LWR:
(a) Four numbers of 4 metre or longer rail pieces of the same rail section as LWR
(b) Two sets of SEJs with sleepers and fastenings
(c) Adequate numbers of 1 metre long fishplates with special screw clamps/ joggled
fishplates with slotted grooves & bolted clamps as in Fig. 3.9, 3.10, 3.11 & 3.12.
Note: Slotted fishplates as in Fig. 3.13 with fish-bolts may be used in exceptional cases.
(d) Rail closures of suitable sizes
(e) 1 metre and 10 cm straight edges
(f) Callipers and feeler gauges (2 mm to 0.1 mm)
(g) Rail cutting equipment
(h) De-stressing equipment i.e. rollers, mechanical/hydraulic rail tensor, mallets and
side rollers for curves, Fig. 3.14, & 3.15.
(i) Alumino-thermic welding equipment and consumable Materials
(j) Equipment for protection of track.
Page 107 of 417

Fig 3.8 Proposal for laying LWR / CWR
Back to Para 336 (1) (c)
Page 108 of 417

Fig. 3.9 - 1 m LONG SLOTTED FISH PLATE FOR CLAMPED JOINTS /SUPPORT ARM
Back to Para 326(5) (e), 336, 337, 349
Page 109 of 417

Fig. 3.10 SCREW CLAMP FOR FIXING 1 m LONG FISH PLATE
Back to Para 326(5) (e), 336, 337, 349
Page 110 of 417

Fig. 3.11 M.S. CLAMP FOR FIXING 1 m LONG FISH PLATE
Back to Para 326(5) (e), 336, 337, 349
Page 111 of 417

Fig. 3.12 DETAILS OF JOGGLED FISH PLATE WITH CLAMP / SUPPORT ARM
Back to Para 326(5) (e), 336, 337, 349
Page 112 of 417

Fig. 3.13 SLOTTED FISH PLATE
Back to Para 326(5) (e), 336
Page 113 of 417

Fig. 3.14 ROLLER
Back to Para 336, 340
Page 114 of 417

Fig. 3.15 SIDE ROLLER / SUPPORT ARM
Back to Para 336
Page 115 of 417

337 Welding of Rails to form LWR:
(1) Rails shall normally be welded into sufficiently long panels of 10 to 20 rail lengths or
more by flash butt welding, either in the welding depot or on cess or in-situ. The joints
in between only shall be welded by Alumino-Thermic welding (SKV process)/flash butt
welding (using mobile FBW plant).
(2) Before laying long welded panels and/or before welding of rails, two complete sets of
SEJs, one at either end of the proposed LWR/CWR shall be inserted at pre-
determined locations with gaps in mean position as per Para 338 below. Closure rails
of suitable length (refer Para 340 / 341) shall be provided at LWR side/sides of SEJs
to facilitate adjustment of gaps during de-stressing operation.
(3) Laying of welded panels and/or welding of joints at site can be done at any time of the
year. However, after welding into sufficiently long panels of about 1 km or longer, de-
stressing as per Para 340 / 341 shall be undertaken as soon as possible.
(4) Under unavoidable circumstances where de-stressing could not be done soon after
and not likely to be done within a reasonable period, a strict vigil shall be maintained
on the prevailing rail temperatures, and if the rail temperature rises more than 20 °C
above the rail temperature at which welding of rails/laying of welded panels was done
temporary de-stressing shall be undertaken at a rail temperature of 10 °C below the
maximum rail temperature likely to be attained until final de-stressing. If the rail
temperature comes down appreciably, cold weather patrolling as per Para 1005(3)
should be introduced. Final de-stressing shall be done after consolidation of track has
been achieved.
(5) Consolidation of track can be achieved by the following:- (Back to Para 117(4)(a))
(a) For Existing track where maintenance activity involving disturbance to
ballast compaction (tamping operation) has been undertaken.
(i) For the track structure consisting of concrete sleepers, passage of at least
50,000 gross tonnes of traffic or a period of two days whichever is later.
(or)
(ii) At least one round of stabilisation by Dynamic Track Stabiliser (DTS).
(b) For newly laid track (CTR/TSR) or freshly deep screened Track
Three rounds of packing, last two of which should be by on-track tamping machines
(6) Temporary speed restriction as indicated in Annexure - 3/8 shall be imposed on the
length of track where welded panels are joined by 1 m long fishplates with special
screw clamps or joggled fishplates with slotted grooves & bolted clamps as in Fig.
3.9, 3.10, 3.11 & 3.12.
338 Gaps at SEJ: (Back to Para 341(10))
(1) (a) The thermal force in a LWR as shown in Para 335 is to be resisted by suitable
track structure. Accordingly, the Gap at SEJ depends on following factors:
(i) Longitudinal Ballast Resistance of sleepers (taken as 13.28 or 13.74 kg / cm / rail
per sleeper for PSC sleeper of density 1540 or 1660 per km respectively, which is
indicative and can vary as per site conditions)
(ii) Area of rail section
(iii) Modulus of Elasticity (E) for rail steel
(iv) Coefficient of linear expansion (α) for rail steel
(v) Difference between the De-stressing temperature and prevailing rail temperature
of LWR
(vi) Initial gap at SEJ at de-stressing temperature.
Page 116 of 417

(b) Gaps at SEJ shall be adjusted at the time of de-stressing of LWR/ CWR as under:
(Back to Para 340)
Rail section laid Gap to be provided at ‘td’
52 kg/m
40 mm
60 kg/m
(c) For Gaps at different types of SEJ and its laying and measurement, Fig No 3.17,
3.18, 3.19, 3.20 may be referred to:
(2) Hysteresis Curve:
(a) In service, the change in gap at SEJ due to rail temperature variations is in the
form of a Hysteresis Curve. Therefore, for any given rail temperature, the
measured gap at the SEJ may fall within the range defined by the Hysteresis curve.
A typical hysteresis curve for Zone – IV with 52 Kg/m rail on PSC sleeper with 1540
density is as under in Fig 3.16 below:
Fig 3.16
(b) The gaps between the reference mark and tongue rail tip/stock rail corner, which is
attached to the LWR/CWR side at various rail temperatures, shall not differ by more
than ±10 mm from the theoretical range as shown in Annexure - 3/9.
(c) Where fish-plated or SWR track is joined on one side of SEJ, the gap between the
reference mark and tongue rail tip/stock rail corner on SWR/Fish plated track side
shall not be measured.
Page 117 of 417

Fig 3.17 Setting of Gap at SEJ (IRS Design) to Drawing nos. RDSO/T-412,
RDSO/T-4160, RDSO/T-4165, RDSO/T-5478, RDSO/T-5586, RDSO/T-
5748, RDSO/T-6257, RDSO/T-6782 at De-stressing temperature (td)
Back to Para 338
Page 118 of 417

Fig 3.18 Setting of Gap at Improved SEJ with double gap of max. 65mm each (DG
65 Design) to Drawing no. RDSO/T-6922 (60 Kg) & RDSO/T-6930 (52 Kg)
(Applicable for both rails) at De-stressing temperature (td)
Back to Para 338
Page 119 of 417

Fig 3.19 Setting of Gap at Improved SEJ with Single gap of max. 80mm (SG 80
Design) to Drawing no. RDSO/T-6902 (60 Kg) & RDSO/T-6914 (52 Kg)
(Applicable for both rails) at De-stressing temperature (td)
Back to Para 338
Page 120 of 417

Fig 3.20 Illustration for measurement of gap at SEJ for observation of
movement of LWR/CWR
Back to Para 338
Page 121 of 417

339 De-stressing Operation of LWR:
The work of de-stressing shall be done during a traffic block under the personal supervision
of JE/SSE/P.Way.
De-stressing shall be done when rail temperature falls between the range provided for t d. If
required temperature cannot be obtained in field, de-stressing can be done at a little lower
temperature than the targeted stress-free temperature to with the use of rail tensors.
340 De-stressing without Rail Tensors: (Back to Para 337, 346, 351)
In case rail temperature at the time of de-stressing is within the range specified for td,
detailed procedure as given below may be adopted.
(1) The LWR, if longer than manageable lengths that cannot be de-stressed at a time,
then, the LWR shall be de-stressed in parts by tackling manageable lengths
depending on the availability of Block, labour etc.
(2) Remove impediments to free movement of rail such as rail anchors, guard rails, check
rails etc.
(3) A traffic block of adequate duration should be arranged at such a time that the rail
temperature will be within the temperature range specified for t d during the fastening
down operations of fittings.
(4) Before the traffic block is actually taken, a speed restriction of 30 Kmph should be
imposed and fastenings on alternate sleepers loosened.
(5) When the traffic block is taken, a closure rail near the SEJ shall be cut and removed,
the SEJs adjusted as per Para 338(1) (b) and fastened.
(6) The remaining fastenings on both running rails shall be loosened/removed starting
from the ends near the SEJs and proceeding towards the centre of LWR. The rail
shall be lifted and placed on rollers Fig. 3.14 at every 15th sleeper to permit the rails
to move freely. While de-stressing on curved track, provision of side rollers as per
Para 341(6) (a) & (b) may be adopted. The rails shall be struck horizontally with
wooden mallets to assist in their longitudinal movement.
(7) The rollers shall then be removed, the rails lowered to correct alignment and
fastenings tightened, starting from the middle of LWR and proceeding towards both
ends simultaneously. The tightening of fastenings shall be completed within the
temperature range for td. The actual range of temperature during the period of
tightening shall be recorded by JE/SSE/P.Way along with the time and date.
(8) Simultaneously with the tightening of fastening, arrangements for insertion of cut rails,
4 metre or longer, between the SEJ and LWR shall be started. The four gaps shall be
measured individually and the rails of required length cut by saw keeping required
gaps for AT welding. The cut rails shall then be placed in position, fastened to the
sleepers and welded at each end. Fastenings for 20 m on each end of the LWR shall
be removed before welding.
341 De-stressing with Rail Tensors: (Back to Para 337, 346, 351)
For de-stressing of LWR with the use of rail tensor, the following procedure shall be
adopted:
(1) The LWR, if longer than manageable lengths that can be de-stressed at a time, then,
the LWR shall be de-stressed in parts by tackling manageable lengths depending on
the availability of Block, labour and the capacity of the tensor available etc.
(2) Remove impediments to free movement of rail such as rail anchors, guard rails, check
rails etc.
Page 122 of 417

(3) During the traffic block, create a gap of 1 m at location ‘B’ i.e. centre of the first
segment of the LWR (Fig. 3.21).
(4) Mark the anchor length A1 A2 and C1 C2 each equal to la at either end of the length
A2 C2 to be de-stressed (Fig. 3.21 (a)).
Note: The anchor length ‘la’ should be determined on the basis of the lowest value of tp at
which the de-stressing is likely to be carried out. Anchor length shall be increased
suitably based on the condition of the fastenings, rubber pads, liners or ballast
(5) Erect marker pillars W0 W1 etc., on each of the length A2 B and C2B. Transfer the
marks W0 onto the rail foot (Fig: 3.21 (a)).
Note: The distances W0 W1, W1 W2 etc. shall be marked at about 100 m intervals, the
distance from the previous pillars and the last pillar WB may be less than 100 metre.
(6) when tP is less than the desired to (Fig. 3.21 (b)), de-stressing operation shall be
carried out for the lengths A2 B and C2 B as described below:- (Back to Para 340(6))
(a) Unfasten and mount on rollers the portion from A2 C2.
Note: Side rollers on the inside of curve shall also be used while undertaking de-
stressing on curved track these should be spaced at every n th sleeper,
Where, n = Radius of curve (R) x No. of sleepers per rail length
50 x (to-tp)
(b) Outside supports shall be used in addition at the rate of one for every three inside
supports.
(c) Fix the rail tensor across the gap at ‘B’ and apply tension so as to obtain some
movement at W0 to remove any kinks or misalignment and to minimize the friction
in the rollers etc. Release the tension and note the movement Y 0 at W0.
(d) Transfer marks W1, W2,....... onto the rail foot and note temperature tp.
(e) Calculate the required movement at W1 = Yo + elongation of length W0 W1 (L) due
to temperature difference (to - tp) = Y0+ Lα (to - t p)
(f) Calculate the required movement at W2 = Movement at W1 + elongation of length
W1W2 (L) due to temperature difference (to - tp). Similarly, calculate the required
movements successively at each of the remaining points.
(g) Mark the above calculated extensions with respect to the transferred marks
referred at (d) above on the rail foot on the side away from the tensor.
(h) Apply the tension by means of rail tensor till the mark of required extension comes
opposite to the mark on the marker pillar W1. Fasten down the segment W0W1
(i) Then check at W2, bring the mark of required extension at this location opposite to
the mark on the marker pillar W2, by adjusting the tensor either by reducing or
increasing tension and fasten down the segment W1W2. Similarly, check the
remaining marks, adjust the tension as required and fasten down each segment
before proceeding to the next segment.
Note:
(i) Annexure - 3/11 gives the value of Lα (to - tp) for different values of L and (to - tp).
(ii) Only one value of tp has to be taken at the time of marking W1, W2 etc. on the rail foot.
The values of tp is not required to be taken thereafter. The variation of temperature, if
any during the de-stressing operation shall automatically be taken care of by reducing
or increasing the tensile force from the tensor, while coinciding the reference mark on
rail with the corresponding mark on pillars.
(iii) If for any reason, both the lengths A2B and C2B cannot be fastened down
simultaneously, the final adjustment in pull and fastening down of the individual
segments may be done in series, first from A2 to B and then, from C2 to B.
Page 123 of 417

(j) After the fastening down of the last length A2B and C2B is completed, make a paint
mark near free end of one rail at a distance of (X metre + 2 x 25 mm -1 mm),
measured from the end of the other rail across the gap spanned by the rail tensor.
(k) Remove the tensor, close the 1 m gap temporarily and allow traffic at restricted
speed (Fig. 3.21 (c)).
(7) During traffic block, cut the rail at the paint mark, insert a rail closure of length exactly
equal to X metre and weld one end thereof (Fig. 3.21 (d)). If the gap at the other end
is also 25 mm, it can be welded in the same block. Otherwise, fasten with special
fishplates and clamps and allow traffic at restricted speed. In the latter case, during a
subsequent block, when tp is not greater than to, release rail fastenings on either side
to the required extent of about 50 to 75 m and pull the rails with rail tensor to get the
desired gap of 25 mm (Fig. 3.21 (e)); refasten the rail and weld the joint. Release the
tensor after a lapse of a minimum of 30 minutes after pouring of the weld metal.
Note: - (i) X=4 metre or longer
(ii) In case gap at the time of the second weld as above is less than the
desired welding gap, additional cutting of rail shall NOT be done to create
correct gap for welding. In such cases, the welding should be done below td and
the requisite gap for welding shall be created by using rail tensor and
equalization of forces as described below shall be done.
(8) During a traffic block, when tp is less than td, equalize the forces in the rail by releasing
the fastenings over a length of minimum 125 m on either side of location ‘B’ and
tapping with wooden mallets etc. (Fig. 3.21 (f)). Fasten down the rail and allow traffic.
(9) The above procedure should be repeated for the remaining segments, if the entire
LWR is to be de-stressed.
(10) During another traffic block, when tp is within the range of temperature specified for
td, destress the end 125 metre from SEJ. Thereafter, weld the closure rail next to SEJ
duly ensuring setting of the gaps at SEJ as per Para 338.
Page 124 of 417

Fig 3.21 Destressing of LWR using Rail Tensor
Back to Para 341
Page 125 of 417

342 Joining of LWRs: (Back to Para 346)
Detailed procedure for joining of LWRs is as given below (Fig. 3.22 (a) to (f)):-
(1) During traffic block, replace the existing SEJs between the LWRs with ordinary rails,
of which there should be two temporary rails about 4 metre or longer for each of left
and right sides. Leaving the temporary rails fish-plated, weld the other rails and traffic
passed.
Note: Where fluctuations of temperatures during the period of joining are likely to be small, only one
temporary rail instead of two may suffice.
(2) Provide W0 marker pillars for each of the LWRs at a distance of 100 m from the centre
of temporary rails, to mark the ends of the breathing lengths.
(3) Keep ready two rails of standard length. Measure their lengths ‘l’ correct to the nearest
mm.
(4) Transfer the marks W0 to the rail flange for both the LWRs.
(5) During the traffic block when tp is less than desired t0,remove the fishplates and fish-
bolts connecting the temporary rails to the breathing lengths, release the fastenings
of LWRs between the W0 marks, mount the rails on rollers and note the movements
Y0 and Y'0 at the marker pillars W0, for LWRs 1 and 2 respectively.
Note: The movements of Y0 and Y'0 should be away from the ends of LWR, if the LWRs are in a
state of correct de-stressing.
(6) Note tp and mark the anchor length on either side as shown Fig. 3.22 (b).
(7) Make a paint mark near the end of either of the LWRs at a distance of l + Lα(t0-tp) +
Y0 + Y'0 + 2 x 25 -1 mm measured from the end of other LWR. Here L = 200 m, 25
mm is the allowance for each Thermit weld and 1 mm is the allowance for a saw cut.
The value of L α (t0-tp) may be read from Annexure - 3/11.
(8) Remove the rollers, fasten down the length ‘L’, cut the rail at the paint mark, remove
the temporary rails, insert the rail of length ‘l’ and weld one end of it. If the gap at the
other end is 25 mm, it can also be welded during the same block. If the required 25
mm gap is not available, fasten the rails with fishplates and clamps and allow traffic
at restricted speed.
(9) During the next traffic block (Fig. 3.22 (e)), weld the other joint if the gap is 25 mm. If
the gap is more than 25 mm, release the rail fastenings on either side to the required
extent and pull the rails with rail tensor to get the desired gap of 25 mm. Re-fasten
and weld the rail. Release the tensor after the lapse of a minimum of 30 minutes after
pouring of the weld metal.
(10) During the block (Fig. 3.22 (f)), equalize the forces in the rail by releasing the
fastenings over the portion marked ‘L’ and over the anchor lengths on either side and
tapping with wooden mallets, etc. Fasten down the rail and restore traffic.
Page 126 of 417

Fig 3.22 JOINING OF LWR (Back to Para 342)
Page 127 of 417

343 Reference Marks:
(1) Reference marks shall be fixed at each SEJ and at the centre of LWR/CWR, on the
reference pillars erected for this purpose.
(2) While the reference marks on the reference pillars shall be saw marks, corresponding
marks on the running rails shall be paint marks on the non-gauge face of the rail.
(3) In no case, a saw mark shall be made on the running rail. Reference marks are
required to be fixed immediately after de-stressing of LWR/CWR and shall not be
shifted or tampered with thereafter.
(4) Additional reference marks in fixed portion and breathing length may be provided to
know the behaviour of LWR/CWR.
344 Maintenance of LWR/CWR:
An important prerequisite for proper functioning of LWR/CWR is its initial laying to a high
standard and its subsequent maintenance by trained personnel possessing valid
competency certificates as per Annexure - 14/2 and level of authorization not lower than
what is laid down in Annexure - 3/10.
345 Regular Track Maintenance: (Back to Para 609)
Regular track maintenance in LWR/CWR includes following operations:-
(i) Tamping/packing
(ii) Lifting
(iii) Aligning including minor realignment of curves
(iv) Shallow screening/shoulder cleaning
(v) Renewal of fastenings requiring lifting
(vi) Maintenance of SEJ
(1) General: (Back to Para 345(2))
(a) The regular track maintenance in LWR/CWR shall be confined to hours when the
rail temperature is between td+10°C and td-30°C and shall be completed well before
onset of summer.
(b) If rail temperature after the maintenance operation exceeds td+20°C during the
period of consolidation, then the speed restriction of 50 Km/h shall be imposed.
(c) Ballast section shall be properly maintained, especially on pedestrian & cattle
crossings, curves and approaches to level crossings and bridges. Cess level
should be correctly maintained. Dwarf walls may be provided on pedestrian and
cattle crossings to prevent loss of ballast.
(d) Replenishment of ballast shall be completed before onset of summer. Shortage of
ballast in the shoulder at isolated places shall be made up by the Gang Mate by
taking out minimum quantity of ballast from the centre of the track between the two
rails over a width not exceeding 600 mm and a depth not exceeding 100 mm.
(e) Sufficient quantity of ballast shall be collected to provide full ballast section before
commencing any maintenance operation, specially lifting.
(f) When crowbars are used for slewing, care shall be taken to apply these in a
manner so as to avoid lifting of track. In this connection, the instructions in Para
607 (d) shall be followed.
(g) Special attention shall be paid to maintenance of track at following locations:
• SEJs/breathing lengths
• Approaches of level crossings, points & crossings and un-ballasted deck
Page 128 of 417

bridges
• Horizontal and vertical curves
(h) All fastenings shall be complete and well secured in position.
(2) Mechanised Maintenance:
(a) Tamping in LWR/CWR with general lift not exceeding 50 mm including correction
of alignment shall be carried out during the period when prevailing rail
temperatures are as per Para 345 (1) (a) & (b) together with precautions laid down
therein.
(b) Lifting where needed, in excess of 50 mm shall be carried out in stages with
adequate time gap in between successive stages such that full consolidation of the
previous stage is achieved prior to taking up the subsequent lift.
(c) Mechanised cleaning of shoulder ballast shall be undertaken when prevailing rail
temperatures are within the limits prescribed together with the precautions
mentioned therein.
(3) Manual maintenance:
(a) At no time, not more than 30 sleepers spaces in a continuous stretch shall be
opened for manual maintenance or shallow screening with at least 30 fully boxed
sleeper spaces left in between adjacent openings. Maintenance of in between
lengths shall not be undertaken till passage of traffic for at least 24 hours in case
of BG carrying more than 10 GMT or 2 days in case of other BG routes.
(b) For correction of alignment, the shoulder ballast shall be opened out to the
minimum extent necessary and that too, just opposite the sleeper end. The ballast
in shoulders shall then be put back before opening out crib ballast for packing.
(c) In exceptional circumstances when more than 30 sleeper spaces have to be
opened for any specific work, like through screening of ballast etc. during the period
of the year when minimum daily rail temperature is not below td-30°C or maximum
does not go beyond td+10°C, upto 100 sleeper spaces may be opened under the
direct supervision of JE/SSE/P.Way.
(d) It should however, be ensured that rail to sleeper fastenings on the entire length of
LWR including SEJs are functioning satisfactorily.
(4) Casual renewal of sleepers:
Not more than one sleeper in 30 consecutive sleepers shall be replaced at a time.
Should it be necessary to renew two or more consecutive sleepers in the same length,
they may be renewed one at a time after packing the sleepers renewed earlier duly
observing the temperature limits specified in Para 345 (1) (a) & (b) together with
precautions mentioned therein.
(5) Renewal of fastenings:
The work of renewal of fastenings shall be carried out when rail temperature is within
the limits specified in Para 345 (1) (a) & (b) with following additional precautions:-
(a) Renewal of fastenings not requiring lifting of rail: (Back to Para 116 (7) (b))
Fastenings not requiring lifting of rails, shall be renewed on not more than one
sleeper at a time. In case fastenings of more than one sleepers are required to be
renewed at a time, then at least 15 sleepers in between shall be kept intact. Work
shall be done under supervision of Keyman.
(b) Renewal of fastenings requiring lifting of rail:
Fastenings requiring lifting of rails i.e., grooved rubber pads, etc. shall be renewed
on not more than one sleeper at a time. In case fastenings of more than one
sleeper are required to be renewed at a time, then at least 30 sleepers in between
Page 129 of 417

shall be kept intact. Work shall be done under supervision of Gang Mate.
Alternatively, if prevailing rail temperature is lower than td-10, fastening up to 5
sleepers on either side may be removed for replacement of rubber pad under the
rail.
(6) Maintenance of SEJs:
(a) Once in a fortnight SEJs shall be checked, packed and aligned if necessary. Oiling
and greasing of tongue and stock rails of SEJ and tightening of fastenings shall be
done simultaneously.
(b) During his daily patrolling, Keyman shall keep special watch on the SEJs falling in
his beat.
(7) Renewal of defective rails/welds:
The procedure laid down in Para 349(2) of this manual for repairs to track after rail
fracture shall be followed.
346 Special Track Maintenance: (Back to Para 347, 628, 638, 639, 714)
Special track maintenance in LWR/CWR includes following operations:-
(a) Through fittings renewal
(b) Deep screening/mechanised cleaning of ballast
(c) Lowering/Lifting of track
(d) Major realignment of curves
(e) Sleeper renewal other than casual renewals
(f) Rehabilitation of bridges and formation causing disturbance to track
(1) Through fittings renewal:
Whenever it is decided to carry out through renewal of fittings, the LWR shall be de-
stressed immediately after the TFR is completed of complete or part LWR.
(2) Deep screening/mechanised cleaning of ballast:
(a) Provisions laid down in Para 637 (2) shall apply to LWR/CWR regarding the
sequence of operations of Ballast Cleaning Machine (BCM).
(b) Ballast Cleaning Machine (BCM), tamping machine and Dynamic Track Stabilizer
(DTS) shall, as far as possible, be deployed in one consist.
(c) Temperature records of the sections where deep screening is to be undertaken,
shall be studied for the previous and the current year. The maximum and minimum
rail temperature attainable during the period of deep screening and during the
period of consolidation shall be estimated. Any of the following two methods may
be adopted for carrying out the work of deep screening/mechanised cleaning:
(i) If range of rail temperature falls within td+10°C to td-20°C, deep screening may
be done without cutting or temporary de-stressing.
(ii) If range of rail temperature falls outside (a) above, temporary de-stressing shall
be carried out 10°C below the maximum rail temperature likely to be attained
during the period of work.
(d) Constant monitoring of rail temperature shall be done during the progress of work.
Should the temperature rise more than 10°C above td / temporary de-stressing
temperature, adequate precautions shall be taken including another round of
temporary de-stressing as required.
Note: Deep screening shall be undertaken within a reasonably short period of temporary
de-stressing so as to ensure that the temperature range as prescribed at Sub-Para (2)
(c) (ii) above is ensured, failing which temporary de-stressing may become due again.
Page 130 of 417

(e) During the period of deep screening, if there is any possibility of minimum
temperature falling 20°C below td / temporary de-stressing temperature, cold
weather patrol as per Para 1005 (3) should be introduced to detect / guard against
rail fractures.
(f) Sequence of operation: -
(i) Deep screening of LWR may be done from one end of LWR to other end.
(ii) After deep screening and consolidation, de-stressing of LWR shall be
undertaken as per Para 340 / 341.
(3) Other special maintenance
(a) Other types of special track maintenance constitute jobs like lowering of track,
major realignment of curves, renewal of large number of sleepers or rehabilitation
of formation/ bridges causing disturbance to track.
(b) For carrying out such maintenance, the affected length of track may be isolated
from LWR/ CWR by introducing SEJs as needed.
(c) After completion of work, the affected length of track shall be de-stressed at the
required de-stressing temperature and joined with rest of the LWR/CWR in
accordance with Para 342.
347 Destressing during Maintenance: (Back to Para 714)
(1) Abnormal behaviour of LWR/CWR can be inferred by observing one or more of the
following:
(a) When the gap observed at SEJ
(i) Differs beyond limits specified in Annexure - 3/9.
(ii) Exceeds the maximum designed gap of SEJ
(iii) When tip of tongue rail/corner of Stock Rail crosses the reference line
(b) In case of excessive creep of more than 20 mm in the central portion of LWR is
noticed.
(2) In such cases as in Sub Para (1) above, LWR/CWR shall be inspected by ADEN for
(a) deficiency of ballast,
(b) poor compaction / consolidation of ballast,
(c) deficiency of fittings,
(d) poor toe load of ERC
(e) formation trouble if any,
(f) whether procedures as per Para 349 were followed during permanent repairs after
earlier rail fracture(s),
(g) the possibility of defective thermometers being used by the staff.
After the above inspection, the deficiency shall be made good at the earliest by
suitable corrective action, to improve the track resistance. Thereafter, the SEJ/LWR
shall be kept under close observation by active monitoring by the JE/SSE/P.Way. If
LWR/CWR still behaves abnormally, a decision shall be taken by ADEN for de-
stressing of LWR/CWR.
(3) After special maintenance operations mentioned in Para 346, de-stressing shall be
undertaken.
(4) After restoration of track following an unusual occurrence mentioned in Para 348, de-
stressing shall be undertaken.
(5) If number of locations where repairs by way of replacement of rail / weld have been
done, exceed three per km, de-stressing of affected portion of LWR / CWR shall be
done.
Page 131 of 417

348 Unusual Occurrences: List of unusual occurrences: (Back to Para 347)
(a) Rail fractures or replacement of defective rail/ glued joint.
(b) Damage to SEJ.
(c) Buckling or tendency towards buckling.
(d) Factors causing disturbance to LWR/CWR such as accidents, breaches etc.
349 Rectification of Rail Fractures: (Back to Para 347, 351)
(1) Equipment required:
(a) Special 1 m long fishplates with screw clamps and joggled fishplates with bolted
clamps (for fractures at welded joints) as per arrangement shown in Fig. 3.9, 3.10,
3.11 & 3.12.
(b) Steel tape capable of reading upto one mm
(c) Alumino-thermic welding and finishing equipment
(d) Equipment for de-stressing
(e) 4 metre or longer sawn rail cut piece of the same section as LWR duly tested by
USFD
(f) Rail closures of suitable lengths
(g) Equipment for protection of track
(2) Procedure for repairs: (Back to Para 345)
If any fracture takes place on LWR/CWR, immediate action shall be taken by the
official who detected the fracture to suspend the traffic and to protect the line. He shall
report the fracture to the Gang Mate /Keyman/JE/ SSE/P.Way. Repairs shall be
carried out in four stages as described below:
(a) Emergency repairs
(b) Temporary repairs
(c) Permanent repairs
(d) De-stressing.
(3) Emergency repairs:
The fractured rails shall be joined by using the arrangements shown in Fig. 3.9, 3.10,
3.11 & 3.12. with or without insertion of closure rail piece as per site conditions and
feasibility. The traffic may then be resumed at a speed as mentioned in Annexure -
3/8 and by authority as mentioned in Annexure - 3/10.
(4) Temporary repairs: (Back to Para 351)
If a welding party is not readily available, the fracture shall be repaired by using a cut
rail (4 metre or longer) and clamped/bolted as per arrangement shown in Fig. 3.9,
3.10, 3.11 & 3.12.
(a) A traffic block shall be taken as soon as possible preferably when the rail
temperature is within the range specified for td or as near as possible to td.
(i) Two points on either side of the fracture shall be marked on the rail such that
the length of closure rail to be inserted is equal to the total length of the rail
pieces removed from the track minus allowances for two welds and saw cut
(normally 51 mm). See Fig. 3.23.
(ii) Alternately, two points on either side of the fracture shall be marked on the rail
at a distance equal to the length of the available closure rail. The length of
closure rail should not become less than 4 m at the time of permanent repairs.
See Fig. 3.23.
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(b) The rails shall then be cut through at these points simultaneously, if possible. The
closure rail shall then be inserted and joined See Fig. 3.24. After joining, the traffic
shall then be resumed at restricted speed in accordance with Annexure - 3/8.
(c) In case closure rail as per Sub Para (4) (a) (i) above is inserted, one of the joints
may have to be provided with closure piece of adequate width and joined by one
metre fishplate and clamps.
(5) Permanent Repairs: (Back to Para 351)
(a) If the fracture is such that, wide gap AT welding can be adopted, then the total
length of fractured ends to be cut shall be equal to the gap required for wide gap
welding. Once the two ends are cut, a gap required for wide gap welding will be
created by using rail tensors and joint welded by wide gap AT welding technique.
(b) In case rail closure as per Sub Para (4) (a) (i) has been provided for temporary
repairs, one joint of the closure rail shall be welded without rail tensor after setting
correct gap for welding. However, to ensure correct gap during welding of the other
joint, tensor shall be used.
(c) In case rail closure as per Sub Para (4) (a) (ii) has been provided at the time of
temporary repairs, the rail closure shall be suitably cut such that the length of the
rail to be finally inserted in track is equal to length of rail removed from track after
fracture minus allowances for two welds i.e. 50 mm. Once the closure rail is cut,
the closure rail will be welded as given in Sub Para (5) (b).
(d) It is necessary to carry out local destressing of 125 m on either side for equalization
of stresses, induced in LWR due to permanent repair. Explanatory note is given in
Annexure - 3/17. After welding of joints, at rail temperature below td, a length of
track equal to 125 m on either side be unfastened and tapped to ensure
equalization of stress and then refastened. The details of equalization of forces
shall be entered in to TMS under local destressing in weld fracture report.
Page 133 of 417

3.23 TEMPORARY AND PERMANENT REPAIRS OF RAIL FRACTURE WITH USE OF RAIL
TENSOR (Back to Para 349)
Page 134 of 417

350 Damage to Switch Expansion Joint:
(1) The damaged/broken SEJ shall be replaced with a new SEJ. The gap at the new SEJ
shall be adjusted to the mean gap as provided in Annexure - 3/9 depending of the
rail temperature prevailing at the time of replacement.
(2) If another SEJ is not available for replacement, both the damaged SEJ and the
undamaged SEJ on the opposite rail at the same location, shall be replaced by a
closure rail and connected to LWR/CWR with special clamps and fishplates.
The traffic over the clamped joints may be permitted at a restricted speed as per
Annexure - 3/8. The restriction may be relaxed only after the new SEJ has been
inserted in the correct position and the clamped joint has been replaced with in-situ
weld.
351 Buckling of Track
(1) General:
Buckling or a tendency towards buckling may occur, among others, in the following
circumstances:
(a) Failure to adhere to the temperature ranges specified for various laying and
maintenance activities on LWR/CWR.
(b) Inadequate resistance to longitudinal, lateral and vertical movement of track due
to deficiencies in ballast section or/and inadequate ballast consolidation.
(c) Use of ineffective fastenings or missing fastenings resulting in loss of creep
resistance and torsional resistance.
(d) Excessive settlement of formation.
(e) Repair to fractures or replacement of defective rails not as per procedure
prescribed in Para 349, which can lead to the disturbance to the force diagram in
the LWR as explained below (fig. 3.24 (a), (b) (c)).
(i) Normal Force diagram in a good LWR:
Fig. 3.24 (a)

(ii) In case rail fracture occurs, the force diagram gets altered instantaneously as
under:
Rail fracture with a gap
Creation of two Temporary Breathing Lengths
Fig 3.24 (b)
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(iii) If rail introduced during repairs to rail fracture is not as per the provisions of Para
349 the force diagram is altered as under:
Additional Force added due to introduction of longer Rail
Fig 3.24 (c)

(2) Buckling and its investigation:
(a) Tendency towards buckling will usually manifest itself through kinks in track. Kinks
may also arise from incorrect slewing or lifting operations. By tapping sleepers for
hollowness, it may be possible to notice if there is any tendency towards vertical
buckling.
(b) As soon as the tendency for buckling is detected, the traffic shall be suspended
and the track protected. The track shall then be stabilized by heaping ballast on
the shoulders upto the top of the web of the rail obtaining the ballast from inter-
sleeper spaces between the rails. Thereafter full investigation shall be made to find
out the cause of the tendency for buckling.
(c) Each case or buckling shall be investigated by ADEN soon after its occurrence and
a detailed report submitted to DEN/Sr. DEN.
(3) Repairs to buckled track:
(a) When the track actually buckles, the traffic shall be suspended and the cause of
buckling ascertained.
(b) The rectification shall normally be carried out in the following stages under the
supervision of JE/SSE/P.Way:-
(i) Emergency repairs:
The buckled rails shall preferably be gas cut adequately apart not less than 6.5
m. The track shall then be slewed to the correct alignment and cut rails of the
required lengths shall be inserted to close the gaps making due provision for
welding of joints on both sides. The cut rails shall then be connected by use of
special fishplates and screw clamps and the line opened to traffic with speed
restriction as indicated in Annexure - 3/8.
(ii) Permanent repairs:
As soon as possible, the clamped joints shall be welded adopting the same
procedure as in Para 349(4) and (5). Additional pair of cut rails and rail cutting
equipment shall also be required to adjust the gaps in case they have been
disturbed in the intervening period.
The speed restriction shall be removed after welding.
(iii) The length of track of minimum 500 m on either side of the location of buckling
of the affected LWR shall be de-stressed as soon as possible as per Para 340
/ Para 341 and complete LWR shall be inspected by ADEN and further action
as deemed necessary shall be taken.
Page 136 of 417

352 Breaches, Temporary Girders and Diversions:
(1) The affected portion shall be isolated by insertion of SEJs preferably within the
temperature range specified for td.
(2) The track thus isolated shall be replaced by fish plated / SWR track, which shall be
provided with ERC with adequate toe load to arrest creep.
(3) In the breached sections where the new banks are constructed, the formation shall
be fully consolidated before laying LWR again.
(4) In case of diversions and insertion of temporary girders, SEJ shall be inserted to
isolate the portion where such work is required to be done.
(5) The LWR panels in the affected portion shall be de-stressed immediately after the
LWR are restored.
353 Hot and Cold Weather Patrolling:
Hot and Cold Weather Patrolling shall be introduced and carried out in accordance
with the provisions contained in Para 1005.
354 Inspection and Records:
(1) Inspection:
While requiring less maintenance, LWR/CWR necessitate intensive inspection at
supervisory and officer’s level.
(a) The profile of the ballast section shall always be as per Para 212. This should be
checked, especially at pedestrian / cattle crossings, curves, approaches of level
crossings, points and crossings and bridges. Cess level should be correctly
maintained. Replenishment of ballast shall be completed before the onset of
summer.
(b) Inspection shall be more frequent in the afternoons during summer months. During
inspections, look out shall be kept for kinks, incipient buckles and checks made on
functioning of the patrols.
(c) Knowledge of staff in regard to prescribed maintenance practices shall be
periodically checked and it shall be ensured that the work is done accordingly.
(d) Ultrasonic examination of rails should not be in arrears. Defective rails/welds
should be replaced expeditiously.
(e) Inspections of gaps at SEJ and creep/movement at central portion of LWR/CWR
by Permanent Way officials would be done as per prescribed schedule by
JE/SSE/P.Way (Sectional), SSE/P.Way (In-charge) and ADEN.
(2) RECORDS
(a) The Record of LWR/CWR shall be maintained by the JE/SSE/P.Way in TMS
database. Format is as per Annexure - 3/12, 3/13, 3/14 and 3/15.
(b) An indication plate similar to that suggested in Para 661 (6) shall be fixed on the
cess at each SEJ showing the date of de-stressing, de-stressing temperature td/to
and length of LWR/CWR.
(c) ADEN will analyse the observation of each LWR/CWR and give a certificate before
onset of summer regarding satisfactory behaviour of all LWR/CWR.
(d) The DEN/Sr.DEN will scrutinise TMS records and shall countersign certificate
given by ADEN and send to Chief Track Engineer.
Page 137 of 417

Annexure - 3/8
(Para 326, 337, 349, 350, 351, 618)
SCHEDULE OF SPEED RESTRICTIONS
S Conditions of track Restriction imposed
No in Km/h
1 When 1 metre long slotted fishplates (Fig. 3.9) with screw clamps (Fig. 30
3.10) & M.S. clamp (Fig. 3.11) or joggled fishplates with bolted clamps
(Fig. 3.12) are used at a temporary rail joint and there is 24 hrs. watch.
However, if the above arrangement is not under round the clock
watch, speed restriction of 20 Kmph should be imposed, as
mentioned in drawings.
2 When sleeper fastenings on alternate sleepers are loosened before 30
de-stressing
3 At fracture after emergency repairs are completed
i First train STOP DEAD &
10
ii Subsequent trains 20
4 After emergency repairs to track after buckling
i First train STOP DEAD &
10
ii Subsequent trains 20
5 Speed restriction during consolidation period of track, after regular
track maintenance operations when rail temperature exceeds td +
20°C:
i When shoulder and crib compaction has been done:- 50
ii When shoulder and crib compaction has not been done 30
Page 138 of 417

Annexure - 3/9
(Para 338, 347, 350)
Gaps at SEJ for various Rail Temperatures and PSC Track
ZONE -I
Rail 60 kg/m 52 kg/m
Sleeper Density 1660 1540 1660 1540
13.74 13.28 13.74 13.28
Ballast Resistance
kg/cm/rail kg/cm/rail kg/cm/rail kg/cm/rail
td + 20° - - - -
td + 15° 18 18 18 18
td + 10° 18 to 20 18 to 20 19 to 20 1 8 to 20
td + 05° 19 to 22 19 to 22 19 to 22 19 to 22
td 19 to 23 19 to 23 19 to 23 19 to 23
td - 05° 20 to 25 20 to 25 20 to 24 20 to 24
td - 10° 21 to 26 21 to 26 21 to 25 21 to 25
td - 15° 22 to 27 22 to 27 22 to 26 22 to 26
td - 20° 23 to 27 23 to 28 23 to 26 23 to 26
td - 25° 25 to 28 25 to 28 24 to 27 24 to 27
td - 30° 26 to 28 27 to 28 25 to 27 26 to 27
td - 35° 28 28 27 27
td - 40° - - - -
ZONE-II
13.74 13.28 13.74 13.28
Ballast Resistance
td + 25° - - - -
td + 20° 17 17 17 17
td + 15° 17 to 19 17 to19 17 to 19 17 to 19
td + 10° 17 to 21 17 to 21 18 to 21 18 to 21
td + 05° 18 to 23 18 to 23 18 to 23 18 to 23
td 18 to 25 18 to 25 19 to 24 19 to 24
td - 05° 19 to 26 19 to 27 19 to 25 19 to 26
td - 10° 20 to 28 20 to 28 20 to 27 20 to 27
td - 15° 22 to 29 22 to 29 21 to 27 22 to 28
td - 20° 23 to 30 23 to 30 23 to 28 23 to 29
td - 25° 25 to 30 25 to 31 24 to 29 24 to 29
td - 30° 27 to 31 27 to 31 26 to 29 26 to 30
td - 35° 29 to 31 29 to 31 28 to 30 28 to 30
td - 40° 31 32 30 30
td - 45° - - - -
Note: The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Page 139 of 417

Annexure - 3/9
(Para 338, 347, 350)
GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURES AND PSC TRACK
ZONE-III
13.74 13.28 13.74 13.28
Ballast Resistance
td + 25° 15 15 16 16
td + 20° 15 to 18 15 to 18 16 to 18 16 to 18
td + 15° 15 to 20 15 to 20 16 to 20 16 to 20
td + 10° 16 to 23 16 to 23 17 to 22 16 to 22
td + 05° 17 to 25 16 to 25 17 to 24 17 to 24
td 18 to 27 17 to 27 18 to 26 18 to 26
td - 05° 19 to 28 19 to 28 19 to 27 19 to 27
td - 10° 20 to 30 20 to 30 20 to 28 20 to 29
td - 15° 21 to 31 21 to 31 21 to 29 21 to 30
td - 20° 23 to 32 23 to 32 23 to 30 23 to 31
td - 25° 25 to 33 25 to 33 24 to 31 24 to 32
td - 30° 27 to 34 27 to 34 26 to 32 26 to 32
td - 35° 29 to 34 30 to 35 28 to 32 28 to 33
td - 40° 32 to 34 32 to 35 30 to 32 31 to 33
td - 45° 35 35 33 33
ZONE-IV
13.74 13.28 13.74 13.28
Ballast Resistance
td + 28° 14 13 15 14
td + 25° 14 to 16 13 to 14 15 to 16 14 to 16
td + 20° 14 to 18 14 to 15 15 to 19 15 to 19
td + 15° 14 to 21 14 to 18 15 to 21 15 to 21
td + 10° 15 to 23 14 to 21 16 to 23 16 to 23
td + 05° 16 to 26 16 to 26 16 to 25 16 to 25
td 17 to 28 17 to 28 17 to 27 17 to 27
td - 05° 18 to 29 18 to 30 18 to 28 18 to 28
td - 10° 20 to 31 20 to 31 20 to 30 20 to 30
td - 15° 21 to 32 21 to 33 21 to 31 21 to 31
td - 20° 23 to 34 23 to 34 23 to 32 23 to 32
td - 25° 25 to 35 25 to 35 24 to 33 24 to 33
td - 30° 27 to 36 27 to 36 26 to 33 26 to 34
td - 35° 29 to 36 30 to 37 28 to 34 29 to 34
td - 40° 32 to 37 33 to 37 31 to 34 31 to 35
td - 45° 35 to 37 36 to 37 33 to 34 33 to 35
td - 48° 37 37 34 35
Note: The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Page 140 of 417

Annexure - 3/9A (Para 331(7))
GAPS AT SEJ PROVIDED AT THE FAR END APPROACH OF BRIDGE USING RAIL FREE
FASTENINGS OVER GIRDER BRIDGE FOR VARIOUS RAIL TEMPERATURES IN MM
Zone-I
Sleeper
1660 1540 1660 1540
Density
Ballast
13.74 kg/cm/rail 13.28 kg/cm/rail 13.74 kg/cm/rail 13.28 kg/cm/rail
Resistance
Initial gap at
65 40 65 40 65 40 65 40
SEJ (mm)
td + 25° (-19)-(-19) 1-1 (-19)-(-19) 0-1 (-18)-(-19) 1-1 (-18)-(-19) 1-1
td + 20° (-7)-(-9) 4-6 (-7)-(-9) 3-6 (-7)-(-9) 4-6 (-7)-(-9) 4-6
td + 15° 0-4 7-10 0-4 7-10 0-4 7-11 0-4 7-11
td + 10° 10-15 10-15 10-15 10-15 10-15 10-15 10-15 10-15
td + 05° 20-26 14-19 20-26 14-19 20-25 14-19 20-25 14-19
td 30-36 18-24 30-36 17-24 30-36 17-23 30-36 17-23
td - 05° 40-46 21-28 40-47 21-28 40-46 21-27 40-46 21-27
td - 10° 51-57 26-31 51-57 26-32 50-56 25-31 50-56 25-31
td - 15° 62-66 30-35 62-67 30-35 61-66 29-34 61-66 29-34
td - 20° 72-76 35-38 73-76 35-39 71-75 33-37 72-75 34-38
td - 25° 83-86 39-41 84-86 39-42 82-85 38-40 82-85 38-41
td - 30° 95-95 44-44 95-95 44-45 94-94 43-43 94-94 43-44

Zone-II
Sleeper
1660 1540 1660 1540
Density
Ballast
13.74 kg/cm/rail 13.28 kg/cm/rail 13.74 kg/cm/rail 13.28 kg/cm/rail
Resistance
Initial gap at
65 40 65 40 65 40 65 40
SEJ (mm)
td + 30° (-13)-(-20) (-1)-6 (-13)-(-20) (-2)-6 (-12)-(-18) 1-7 (-12)-(- 0-7
td + 25° (-4)-(-11) 3-10 (-4)-(-11) 2-9 (-3)-(-9) 4-10 18)
(-3)-(-10) 4-10
td + 20° (-2)-5 6-13 (-2)-5 6-13 (-1)-5 8-13 (-1)-5 7-13
td + 15° 7-13 10-16 7-13 10-16 8-13 11-16 8-13 11-16
td + 10° 16-22 14-19 16-22 14-19 16-21 14-19 16-21 14-19
td + 05° 25-30 18-22 25-30 18-22 25-29 18-22 25-29 18-22
td 34-37 21-25 34-38 21-25 34-37 21-24 34-37 21-24
td - 05° 43-45 25-27 43-45 25-28 42-44 25-26 42-44 25-27
td - 10° 52-52 29-30 52-53 29-30 51-51 28-29 51-52 28-29
td - 15° 60-61 32-33 60-61 32-33 59-59 30-31 59-60 31-32
td - 20° 67-70 33-36 67-70 34-37 65-68 32-35 66-68 33-35
td - 25° 74-78 35-40 74-79 35-41 72-76 34-38 73-77 34-38
td - 30° 80-87 37-44 81-88 37-44 79-85 35-41 79-85 36-42
td - 35° 87-96 38-47 87-97 38-48 85-93 36-45 86-94 37-45
Page 141 of 417

Zone-III
Ballast Resistance 13.74 kg/cm/rail 13.28 kg/cm/rail 13.74 kg/cm/rail 13.28 kg/cm/rail
Initial gap at SEJ (mm) 70 70 70 70
td + 35° (-3)-(-3) (-3)-(-3) (-2)-(-2) (-2)-(-2)
td + 30° 1-4 1-4 2-5 2-5
td + 25° 5-11 5-11 7-11 6-11
td + 20° 10-17 10-17 11-17 11-17
td + 15° 15-24 14-24 16-24 16-24
td + 10° 20-30 19-30 21-29 20-29
td + 05° 25-36 25-36 26-35 25-35
td 30-41 30-42 31-40 31-41
td - 05° 36-47 36-47 36-46 36-46
td - 10° 41-52 41-53 42-51 42-51
td - 15° 47-57 47-58 47-56 47-56
td - 20° 53-62 54-63 53-61 53-61
td - 25° 60-67 60-67 59-65 59-66
td - 30° 66-72 67-72 65-70 65-70
td - 35° 73-76 73-76 72-74 72-75
td - 40° 80-80 80-80 78-78 78-79
Zone-IV
Ballast Resistance 13.74 kg/cm/rail 13.28 kg/cm/rail 13.74 kg/cm/rail 13.28 kg/cm/rail
Initial gap at SEJ (mm) 70 70 70 70
td + 33° 5-6 5-6 7-7 6-7
td + 30° 7-9 7-9 9-10 8-10
td + 28° 9-13 8-12 10-13 10-13
td + 25° 11-16 10-16 12-17 12-17
td + 20° 14-22 14-22 15-22 15-22
td + 15° 18-28 18-28 19-28 19-28
td + 10° 22-34 22-34 23-33 23-33
td + 05° 26-39 26-39 27-38 27-38
td 31-44 31-45 31-43 31-43
td - 05° 35-49 35-50 36-48 36-48
td - 10° 40-54 40-54 40-52 40-53
td - 15° 45-59 45-59 45-57 45-57
td - 20° 50-63 50-63 50-61 50-61
td - 25° 56-67 56-68 55-65 55-65
td - 30° 61-71 61-72 60-69 60-69
td - 35° 67-75 67-76 65-72 66-73
td - 40° 73-78 73-79 71-76 71-76
td - 43° 76-81 77-81 74-78 75-79
td - 48° 82-84 83-84 80-81 80-82
Page 142 of 417

Annexure - 3/10 (Para 344, 349)
WORK CHART AND AUTHORISED LEVEL OF SUPERVISION
Lowest level of
Sl.
Nature of work staff/Supervisor
No
in charge of work
1 Maintenance operation
Mechanised Tamping, Lifting (general lift), Alignment, Minor
(a) JE(P.Way)
alignment of curves, Deep screening etc.
(b) Manual Packing, Alignment Gang Mate
(c) Lifting/Lowering of track JE(P.Way)
Lifting, aligning, packing etc., in case of emergencies at
(d) JE(P.Way)
temperatures higher than those permitted
2 Rails, sleepers and fastenings
Packing or renewal of single isolated sleeper not requiring lifting or

(a) Gang Mate
slewing of track
(b) Renewal of fastenings not requiring lifting Keyman

(c) Renewal/recoupment of fastenings requiring lifting Gang Mate
(d) Casual renewal of sleepers and fastenings over long stretches JE(P.Way)
(e) Renewal of Defective rails JE(P.Way)
(f) Carrying out welding of rail joints at site JE(P.Way)
3 Ballast
(a) Making up of shortage of ballast in shoulders at isolated places Gang Mate
Replenishment of ballast & Checking ballast section before the
(b) JE(P.Way)
onset of summer
(c) Screening of ballast other than Deep screening JE(P.Way)
(d) Deep Screening JE(P.Way)
4 Curve Realignment
(a) Minor Realignment of curves JE(P.Way)
(b) Major realignment of curves under special instructions from ADEN JE(P.Way)
5 Hot weather work
Imposing speed restriction if the temperature exceeds (td + 20°)
(a) Celsius after maintenance work is completed, manually or by Gang Mate
machines
(b) Organizing hot weather patrolling during summer months JE(P.Way)
Ensuring that hot weather patrolman turns out promptly for duty
(c) during the required period of patrolling and during other periods Gang Mate
when rail temperature exceeds (td + 20°) Celsius
Hot weather patrolling, watching stability of track, presence of large
number of sleepers with defective packing, alignment of track, Hot weather
(d)
checking if the profile of ballast is disturbed, tendency for patrolman
lateral/vertical deformation of track
Inspection in summer months and checking on the working of hot
(e) JE(P.Way)
weather patrols
Cold weather
6 Cold weather patrolling
patrolman
7 De-stressing - all operations regarding De-stressing JE(P.Way)
8 Rail fracture
Keyman.
Trackmen with
(a) Emergency repairs
valid competency
Certificate
(b) Temporary repairs JE(P.Way)
(c) Permanent repairs JE(P.Way)
9 Buckling
Protection of track and secure safety of trains in case of buckling,
(a) Patrolman
rail fractures, or any abnormal behaviour of track
(b) Emergency repairs JE(P.Way)
Page 143 of 417

(c) Permanent repairs JE(P.Way)
Emergencies- Action in case of damage to track following
10 JE(P.Way)
derailments, breaches etc.
11 SEJ
Checking of SEJ, oiling and greasing and re-tightening/ renewal of
(a) Keyman
fittings once a fortnight
(b) Inspection of SEJ JE(P.Way)
Annexure - 3/11 (Para 341, 342)

EXTENSION TABLE
(°C) L in metres
t0 -tp 10 20 30 40 50 60 70 80 90 100 200 300 400 500
1 - - - - 1 1 1 1 1 1 2 3 5 6
2 - - 1 1 1 1 2 2 2 2 5 7 9 11
3 - 1 1 1 2 2 2 3 3 3 7 10 14 17
4 - 1 1 2 2 3 3 4 4 5 9 14 18 23
5 1 1 1 2 3 3 4 5 5 6 11 17 23 29
6 1 1 2 3 3 4 5 6 6 7 13 21 28 34
7 1 2 2 3 4 5 6 6 7 8 16 24 32 40
8 1 2 3 4 5 6 6 7 8 9 18 28 37 46
9 1 2 3 4 5 6 7 8 9 10 21 31 41 52
10 1 2 3 4 6 7 8 9 10 11 23 35 48 57
11 1 3 4 5 6 7 9 10 11 13 25 38 50 63
12 1 3 4 5 7 8 9 11 12 14 28 41 55 69
13 1 3 4 6 7 9 10 12 13 15 30 45 60 75
14 2 3 5 6 8 10 11 13 14 16 32 48 64 80
15 2 3 5 7 9 10 12 14 16 17 34 52 69 86
16 2 4 6 7 9 11 13 15 17 18 37 55 74 92
17 2 4 6 8 10 12 14 16 18 19 39 59 78 98
18 2 4 6 8 10 12 14 17 19 21 41 62 83 103
19 2 4 6 9 11 13 15 18 20 22 44 66 87 109
20 2 5 7 9 11 14 16 18 21 23 46 69 92 115
21 2 5 8 10 12 14 17 19 22 24 48 73 97 121
22 3 5 8 10 13 15 18 20 23 25 51 76 101 126
23 3 5 8 11 13 16 19 21 24 26 53 79 106 132
24 3 6 8 11 14 17 20 22 25 28 55 83 110 138
25 3 6 9 12 14 17 20 23 26 29 57 86 115 144
26 3 6 9 12 15 18 21 24 27 30 60 90 120 149
27 3 6 9 12 16 19 22 25 28 31 62 93 124 155
28 3 6 10 13 16 19 23 26 29 32 64 96 129 161
29 3 7 10 13 17 20 23 27 30 33 67 100 133 167
30 3 7 10 14 17 21 25 28 31 34 69 103 138 172
Extension in mm, based on formula e = L α (to-tp)
Page 144 of 417

DETAILS OF STRUCTURE OF LWR/CWR
DIVISION: SUB - DIVISION:

SSE/P.Way (In-charge): LWR/CWR No.:
DETAILS OF STRUCTURE OF LWR/CWR AS LAID:
1. GENERAL
(a) Kilometers to
(b) Between stations and
(c) Up/Down/Single line
(d) Date of laying
2. TRACK STRUCTURE
(a) Rails
(i) Sectional weight
(ii) Rolling mark
(iii) Year of laying
(iv) Length of rails as rolled
(v) Plant where rails welded
(vi) Types of depot welding - Flash Butt
(vii) Length welded into panels at depot
(viii) Whether fish-bolt holes provided Yes/No
(ix) Thermit welding done in-situ/on cess by SKV/ FB by Mobile plant
(b) Sleepers
(i) Type
(ii) Density or No. per km.
(iii) Type of fastenings
(c) Ballast and Sub-Ballast
(i) Size (mm)
(ii) Depth of cushion (mm)
(iii) Date of last deep screening of ballast
(d) SEJ
(i) Location (km)
(ii) Date of laying
(iii) Maximum gap possible (mm)
(iv) Drawing No.
(v) Manufactured by
(vi) Whether joined to LWR/CWR welded joint
(e) Girder Bridges
(i) Location and No.
(ii) Lengths and spans of bridges with LWR/CWR – yes / no
(iii) Type of fastenings used
(iv) Any other remarks
(f) Level Crossings
Location and No.
3. GRADES, ALIGNMENT AND FORMATION:
(i) Steepest gradient
(ii) Maximum degree of curvature
(iii) Formation (indicate type of soil)
(iv) Particulars of trouble with formation and treatment given, if any, at the time of laying.
(Sketch showing grades and curves with locations to be attached)
Page 145 of 417

Annexure - 3/13(Para 354)
ANNUAL RECORD OF LWR/CWR MAINTENANCE AND PERFORMANCE

1. Maintenance Details:
Year/Year/Year/Year
(i) Method of packing at the time of laying, manual/by machines
(ii) If by machine, type of machine/ tamper used
(iii) Packing during maintenance - manual beater/manual MSP/by machines
(iv) If by machines, type of machine/ tamper used
(v) Whether directed maintenance/ systematic through packing is done and if the
latter, the period when it is done
(vi) Location requiring repeated maintenance, if any
(vii) Quantity of ballast recouped
2. Climatic Details: (Measurements shall be taken on representative LWR only)
(i) Maximum daily variation in temperature, vide Para 334
(ii) Max. rail temperature °C
(iii) Max. ambient temperature °C
(iv) Minimum rail temperature °C
(v) Minimum ambient temperature °C
3. Details of Installation, De-stressing etc.:
Items (i) to (iv) to be entered soon after LWR is laid and de-stressed for the first time.
(i) Installation temperature
(ii) Mean rail temperature for the locality
(iii) Temperature at the time of de-stressing td
(iv) Reasons for carrying out the de-stressing
(v) Subsequent de-stressing done - Temperature and date
4. Unusual Occurrences:
(i) Rail fractures
(ii) Buckling (Location and reasons for buckling)
(iii) Replacement of components in SEJ assembly
a) Fastenings
b) Bolts
c) Sleepers
d) Longitudinal ties
e) MS bracket
f) Chairs
g) Rubber pads
h) Tongue rails
i) Stock rails
(iv) Derailments and accidents on the LWR/ CWR portion (give km of the affected
portion)
(v) Replacement of sleepers (give km and the number of sleepers replaced and
reasons)
(vi) Replacement of rails (indicate length, km and reasons)
5. FORMATION:
Any trouble subsequent to laying and the treatment given.
Page 146 of 417

Page 147 of 417

Page 148 of 417

BREATHING LENGTHS ON PRC SLEEPERS
Breathing length(in meters)

Zone Sleeper Density
60 Kg/m (UIC) 52 Kg/m rails
1540 60 52
I
1660 58 50
1540 69 59
II
1660 66 57
1660 74 64
III
1540 77 66
1540 82 71
IV
1660 79 68
Note: Breathing lengths given above are indicative and are likely to vary as per site
conditions.
Page 149 of 417

Need for Equalization of Stresses after Permanent Repair in LWR/CWR
If there is a fracture or rail replacement on any account, the thermal stresses over a length
of two temporary breathing lengths (BLs) will be altered. This will alter the Stress Free
Temperature (SFT) of rail in the affected portion of track. If repairs are done in such a
manner that the length of rail removed from track is exactly same as the length of rail
inserted (including welding), and the equalisation of stresses is done for a length of at least
two temporary BLs (one temporary BL on either side of the location of rail replacement),
then the forces in LWR, and hence the SFT, will get restored to very close to original level
(effect of hysteresis is ignored in this analysis). However, if during rail replacement the
length of rail inserted in track is different from the length of rail removed the pattern of
thermal stresses in the affected portion of LWR will change altering the SFT in the affected
portion. The magnitude of change in SFT can be calculated as below.
If length of rail inserted in track varies by δL from the length of rail removed from track, and
equalization of stresses is done, say over 250 meters (125 metres on either side), then the
force change in LWR would be
F = (δL / 250) * EA (From Hooke’s Law)
The equivalent temperature can be calculated by equating F with AEα δt

Thus, δL can be calculated as under, δt = δL / (250 * α)
If repairs are done, say at prevailing rail temperature of (td – 30), then the length of rail
inserted in track would be more than the length of rail removed by an amount of contraction
of LWR over two temporary BLs corresponding to (td -30).
This can be calculated by formula = 𝑳𝒃 = AEαt / R
Using standard values for 60 kg rail and 60cm sleeper spacing,
𝐿𝑏 = 76.86 ∗ 2.15 ∗ 106 * 1.152 ∗ 10−5 * 30 / 13.74 =4156 cm = 41.56 m
Total contraction of rail (for both temporary BLs) = δL = 2 *(Lb αt)/2
= (2 * 41.56 *100 * 1.152 ∗ 10−5 * 30) /2
= 1.44 cm = 14.4 mm
Therefore, rail replaced at (td – 30) will result in insertion of extra 14.4 mm rail in track. This
extra length may slightly vary on either side due to effect of hysteresis.
The equivalent temperature effect corresponding to 14.4 mm extra length of rail, assuming
equalisation of stresses is done for 125 metre of track on either side of the location of rail
replacement, can be calculated by formula: δt = δL / (250 m * α)
= 14.4/ (250* 1000 * 1.152 ∗ 10−5 )
= 144 / (25 * 1.152) = 5 degrees
Thus, if repairs are done at td – 30, then the effective SFT of rail will get lowered by 5
degree Celsius. If two such overlapping repairs are done, then the effective lowering of SFT
will be about 10 degree Celsius in the overlapping portion. Such situation makes track
vulnerable to buckling. When repairs are done at higher temperature than td, the
corresponding stress free temperature in the affected portion of track would become higher
in a similar manner; and track would become vulnerable to fractures.
If equalisation of stresses is not done (over 125 m on either side) then the SFT at the
location of rail replacement will get altered to the temperature at which repairs are
completed. This makes track much more vulnerable for buckling or fractures depending
upon whether the repairs are done at rail temperature lower than td or higher than td.
In above example the rail replacement being done at td-30 without equalisation of stresses,
hence the SFT at the location of rail replacement would be reduced to (td – 30) degree
Celsius. However, if equalisation of stresses is done over 125 m on either side, the change
in SFT will only be 5 degree Celsius as the effect is distributed over a length of 250 metres.
Page 150 of 417

Fig 3.25 Arrangement for providing LWR on steel girder Bridges using anchor
arrangement (Ref: RDSO Drawing No. RDSO/M-10920/1) (Back to Para 331(2)(a))
Page 151 of 417

CHAPTER – 4
CURVES & TURNOUTS
*********************
PART ‘A’ - CURVES
SECTION – I: GENERAL
401 Determination of Radius:-
(1) The radius of a curve is determined by measuring the versine on a chord of known
length, from the equation,
125 × 𝐶 2
𝑅=
𝑉
Where;
R = Radius in metres;
C = Chord length in metres; and
V = Versine in millimetres.
(2) Curves can be designated by the radius in metres or by its degree. The angle
subtended at the centre by a chord of 30.5 metres, is the degree of the curve.
360 30.5
1° curve is thus of = 1750
metres radius
2
2° curve has a radius of 1750 = 875 metres and so on.

2
(3) Curves shall be described by the radius in metres.

(4) For measuring versines of a curve, 20 metres overlapping chords should normally be
used with stations at 10 metres intervals. For checking the radii of turnout and turn-in
curves overlapping chord of 6 metres should be used and the versine measuring
stations should be located at every 3 metres. (The turnout curve can also be checked
by offsets from the straight).
(5) The versine is obtained by stretching a fishing/ nylon cord or wire stretched between
the end of chord length decided upon, and the measuring distance between the
cord/wire and gauge face of the rail at the middle point of the chord. Care should be
taken that the cord or wire is applied to the side of the head of the rail at the gauge
point.
402 The Reference Rail for Level:-
The level of inner rail of any curve is taken as reference level. The super-elevation is
provided by raising the outer rail. For reverse curves, however, stipulation as laid
down in Para 406(3) shall apply.
403 Safe Speed on Curves:- (Back to Para 409)
(1) Fully transitioned curves – The maximum permissible speed for transitioned curves
should be determined (based on the assumption that the centre-to-centre distance
between railheads is 1750 mm) using the following formulae:
V = 0.27 R  (Ca + Cd )
Where,
V = Speed in Kmph.
R = Radius in metres.
Ca = Actual cant in mm.
Cd = Permissible cant deficiency in mm.
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(2) Non transitioned curves with cant on virtual transition – (Back to Para 405)
The determination of the maximum permissible speed on curves without transition
involves the concept of the virtual transition.
The change in the motion of a vehicle from straight to curve conditions takes place
over the distance between the bogie centres, commencing on the straight at half the
distance before the tangent point and terminating on the curve at the same half
distance beyond the tangent point.
Normally, the length of virtual transition is taken as 14.785 m over which Super-
elevation is gained with maximum permissible cant gradient as per Para 405.
(3) For curves laid with inadequate length of transition or without transition, the safe
permissible speed should be worked out on the basis of actual cant/cant deficiency,
which can be provided taking into consideration the limiting values of cant/cant
deficiency gradient and the rate of change of cant and cant deficiency.
(4) The speed as determined above shall not exceed the maximum permissible speed of
the section.
404 Super-elevation, Cant Deficiency and Cant Excess:-
(1) Super-elevation/cant –
(a) The equilibrium super elevation/cant necessary for any speed is calculated from
the formula.
𝐺 × 𝑉2
𝐶=
127 × 𝑅
Where,
C is cant /Super-elevation in mm,
G is the dynamic gauge (nominal gauge of track + width of railhead) in mm;
R is the radius of the curve in metres.
(b) The equilibrium speed for determination of cant to be provided shall be decided by
the Chief Engineer, after taking into consideration the maximum speeds which can
be actually attained by fast and slow trains, the proximity of permanent speed
restriction in the route, junctions, stopping places, gradients which may reduce the
speeds of goods trains, without appreciably affecting the speed of fast trains and
their relative importance.
For this purpose, the entire section may be divided into certain number of sub
sections with a nominated equilibrium speed for each sub section, fixed on the
basis of speeds which can be actually attained by fast or slow trains over the sub
section, so that the need for imposing any speed restrictions for limiting the cant
excess for slow trains and cant deficiency for fast trains is avoided.
On sections where all trains run at about the same maximum permissible speeds
like suburban section, it will be preferable to provide cant for that speed.
(c) The amount of Super-elevation to be actually provided will be calculated by the
formula given in Sub-Para (a) for the equilibrium speed determined on the basis of
Sub-Para (b) above. The calculated cant shall be rounded off in the multiple of 5
mm.
(d) Maximum cant on curved track shall be as under – (Back to Para 405)
(i) Broad Gauge – Group ‘A’, ‘B’ and ‘C’ routes-165 mm.
Note – Maximum cant of 185 mm may be assumed for the purpose of
locating all permanent structures etc., by the side of the curves on new
constructions and doubling on group ‘A’ routes having potential for increasing the
speed in future. The transition length should also be provided on the basis of 185
mm cant for the purpose of planning and layout of the curve.
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(ii) Broad gauge – Group ‘D’ and ‘E’ routes-140 mm.
(e) In every case, the Super-elevation to be provided should be specified when the
line is originally laid and thereafter altered only with the prior approval of the Chief
Engineer.
(2) Cant Deficiency – Maximum value of cant deficiency:
(a) On routes with sectional speed more than 100 Kmph for nominated rolling stock
with permission of Principal Chief Engineer 100 mm
(b) For Broad Gauge routes not covered by above 75 mm
(3) Cant Excess-The cant excess should not be allowed to exceed 75 mm for all types
of rolling stock. The cant excess should be worked out taking into consideration
the booked speed of goods trains on a particular section.
In the case of a section carrying predominantly goods traffic, the cant excess
should be preferably kept low to minimize wear on inner rail.
405 Length of Transition Curve and Setting-out Transitions:- (Back to Para 403,
410, 419)
(1) The desirable length of transition ‘L’ shall be maximum of the following three values
–
(a) L= 0.008 Ca × Vm
(b) L= 0.008 Cd × Vm
(c) L= 0.72 × Ca
Where,
L = the length of transition in metres.
Vm= max. permissible speed in Kmph.
Cd= cant deficiency in mm.
Ca= actual Super-elevation on curve in mm.
The formula (a) and (b) are based on rate of change of cant and of cant deficiency
of 35 mm per second. The formula (c) is based on the maximum cant gradient of
1 in 720 or 1.4 mm per metre. The length of transition so calculated should be
rounded off to the next higher value in multiple of 10 m.
(2) For the purpose of designing future layouts of curve, future higher speeds (such
as 160 Kmph for Group ‘A’ routes and 130 Kmph for Group ‘B’ routes) may be
taken into account for calculating the length of transitions. The provision given in
Para 404 (1) (d) may also be considered while deciding the transition length.
(3) In exceptional cases where room is not available for providing sufficiently long
transitions in accordance with the above, the length may be reduced to a minimum
of 2/3 of the desirable length as worked out on the basis of formula (a) and (b)
above or ½ of the desirable length as worked out on the basis of (c) above
whichever is greater. This is based on the assumption that a rate of change of
cant/cant deficiency will not exceed 55 mm per second and the maximum cant
gradient will be limited to 2.8 mm per metre or 1 in 360.
(4) At locations where length of transition curve is restricted, and therefore, may be
inadequate to permit the same maximum speed as calculated for the circular curve,
it will be necessary to select a lower cant and/or a lower cant deficiency which will
reduce the maximum speed on the circular curve but will increase the maximum
speed on the transition curve. In such cases, the cant should be so selected as to
permit the highest speed on the curve as a whole.
(5) In case of doubling and New lines, if a curve is not possible to be designed for 160
Kmph for Group ‘A’ and 130 Kmph for Group ‘B’ routes, approval of PCE shall be
obtained.
Page 154 of 417

An example is illustrated with calculations below –
A curve of 600 metres radius has a limited transition of 40 metres length, the
calculation of maximum permissible speed and super-elevation is as follows –
Speed on transition curve = Speed on circular curve
Rate of change of cant × L × 3.6 = 0.27 R  (C a + C d )
Ca
(3.6 is a factor used for converting m/sec to Kmph)
Best values of speed are obtained when Ca = Cd
Adopting the same units and the maximum value of rate of change of cant of 55
mm per second for Broad Gauge –
55 X 40 X 3.6
Ca = 0.27 600  2Ca
Solving Ca = 89.50 or 90 mm
Limiting the value of Cd to 75 mm
Maximum speed = 0.27 R  (C a + C d )
= 0.27 × √600 × (90 + 75)

= 84.95 say 85 Kmph
Cant gradient = (90/40000) = 1/444, which is within the permissible limits
The rate of change of cant at 85 Kmph works out to 53.12 mm/second, which is
also within the permissible limits.
(6) Laying Transition –
(a) A transition curve is laid out as a cubic Parabola and to accommodate this, the
main circular arc is moved inwards by an amount called the “Shift”.
The “Shift” is calculated from the formula: L2
S=
24R
Where,
S = shift in metres
L & R being in metres.
(b) The offset in metres from the straight to any point on the transition curve is
calculated from the formula – X3
Y=
6 RL
Where,
Y= offset from the straight in metres.
X= distance from the commencement of the curve in metres, and
L & R length of transition and radius of curve respectively in metres.
Page 155 of 417

(c) The arrangement of a transition curve is shown in the figure below –
The original circular curve TC is tangential to the straight at T. The curve is shifted
to ZY and TZ is the amount of shift. The transition curve MNP bisects the shift TZ
at N.
(7) When realigning old curves, transition curves on approaches should invariably be
provided wherever feasible. It should be ensured that there is no change of grade
over the transition.
(8) Compound Curves – In case of a compound curve, which is formed, by two circular
curves of different radii but curving in the same direction, common transition curve
may be provided between the circular curves. Assuming that such compound curve
is to be traversed at uniform speed, the length of the common transition connecting
the two circular curves can be obtained from –
(a) L = 0.008 (Ca1- Ca2) x Vm
(b) L = 0.008 (Cd1-Cd2) x Vm
Whichever, is greater.
Where,
Ca1 and Cd1 are cant and cant deficiency for curve No.1 in mm;
L is length of common transition in metres; and
Vm is max. permissible speed in Kmph.
The Cant gradient should be within the permissible limits as stated in Sub Para (1)
& (3) above. Common transition may be provided when the length of common
transition as worked out above is more than the length of virtual transition as
specified in Para 403 (2).
(9) Reverse Curves –
(a) In case of a reverse curve, which is formed by two circular curves in opposite
directions, common transition curve may be provided between circular curves.
The total length of common transition, i.e., from first circular curve to second
circular curve, may be obtained from –
(i) L = 0.008 (Ca1+Ca2) x Vm
(ii) L = 0.008 (Cd1+Cd2) x Vm
Whichever is greater;
Where,
L is length of transition in metres; and
Vm is max. permissible speed in Kmph.
Cant gradient should be within the permissible limits as stated in sub Para (1) &
(3) above.
Page 156 of 417

(b) For high speeds, in Group ‘A’ and ‘B’ routes, a straight with a minimum length
of 50 m shall be kept between two transitions of reverse curves.
(i) On groups ‘A’ and ‘B’ routes on straights less than 50 metres between
reverse curves should be eliminated by suitably extending the transition
lengths.
In doing so, it should be ensured that the rate of change of cant and versine
along the two transitions so extended is kept the same.
(ii) Whenever such straights between reverse curves can neither be eliminated
nor the straight length increased to over 50 metres, speed in excess of 130
Kmph should not be permitted.
406 Running out Super-elevation:- (Back to Para 402)
(1) On transitioned curves, cant should be run up or run out on the transition, not on the
straight or on the circular curve, increasing or decreasing uniformly throughout its
length.
(2) On non-transitioned curves, cant should be run up or run out on the ‘virtual transition’.
(3) Longitudinal profile of transition on the reverse curve may be from one of the following
two alternatives-
(a) In case I, the level of one of the rails is maintained and the super elevation is run
out on the other rail by lowering it over half the transition length and raising it to the
required amount of cant over the remaining half portion of the transition.
(b) In case II, the level of the centre line of the track is maintained the same throughout,
and the cant is provided by raising one rail by half the amount of cant and lowering
the other rail by the equal amount. Cant is run out or gained over the length of the
transition by raising and lowering both the rails by equal amount symmetrically,
with respect to the level of the centre line track.
In case I, the level of the centre of the track gets disturbed whereas in case II, it is
maintained the same throughout.
VERSINE OR CANT DIAGRAM
RAIL 1
CENTRE LINE OF
THE TRACK
RAIL 2
CASE: I
LONGITUDINAL
CASE: II PROFILE
(4) Special cases of Super-elevation run out may be approved by the Chief Track
Engineer.
407 Indicators/Boards Provided in Curves:-
(1) Curve Board – Each approach of a curve should be provided with a curve board at
the tangent point fixed on the outside of the curve. This Board should indicate the
radius of the curve, the length of the curve, length of transition in metres and the
maximum cant provided on the circular portion of curve in millimetres.
(2) Rail Posts Indicating Tangent Points – On the inside of the curve, rail posts should be
erected on each approach of the curve, to indicate the positions of the beginning and
Page 157 of 417

end of transition curves. These rail posts may be painted in red and white colours
respectively. In the case of non-transitioned curve, similar rail post should be erected
on the tangent track and on the circular curve over which the cant is run out, indicating
the beginning and end of the virtual transition.
(3) Indication of cant on track – Super-elevation or cant should be indicated by painting
its value on the inside face of the web of the inner rail of the curve and at every versine
station, beginning with zero at the commencement of the transition curve.
The value of cant should be indicated on the circular curve at its beginning and at the
end. In the case of long circular curve, the cant value should be indicated at
intermediate stations at a distant not exceeding 250 metres.
(4) When curves are realigned, the repositioning of the curve boards and posts and
repainting of values of Super-elevation at intermediate points should be done, as
required.
408 Speed over Turnout on Curves:- (Back to Para 426)
(1) Provision in General Rules – Relevant Para 4.10 of “General Rules, 1976 Edition”
is reproduced below –
(a) The speed of trains over non-interlocked facing points shall not exceed 15 Kmph
in any circumstances and the speed over turnout and crossovers shall not exceed
15 Kmph, unless otherwise prescribed by approved special instruction, which may
permit a higher speed.
(b) Subject to provision of sub-rule (a) above, a train may run over interlocked facing
points at such speed as may be permitted by the standard of interlocking.
(2) Turnouts on Running Lines with Passenger Traffic – (Back to Para 408)
(a) Turnouts in running lines over which passenger trains are received or dispatched
should be laid with 1 in 12 curved switch or flatter.
(b) 1 in 8.5 turn out with curved switches can be laid in exceptional circumstances
taking off from straight track with the approval of PCE.
(c) Emergency crossovers between double or multiple straight lines, which are laid
only in the trailing direction, may be permitted to be laid with 1 in 8½ crossings
(d) For snag dead end, 1 in 8½ symmetrical split turnouts may be used.
(e) The turnouts have inbuilt curvature as a part of the design. Therefore, it is desirable
that laying of turnouts should normally be avoided on curved main line from the
consideration of maintainability & comfort. If the laying of turnout on curved main
line is inevitable due to site constraints, following stipulations shall be followed:
(i) for laying of turnouts with 1 in 12 or flatter crossings taking off from curve, it shall
be ensured that the resultant lead curve radius as well as the radius of main line
curve shall not be less than 350m.
(ii) 1 in 8.5 turnout shall not be laid from inside of a curved track
(iii) 1 in 8½ turnout with curved switches may be laid from outside of a curve up to
five degree in exceptional circumstances with the approval of PCE, where due
to limitation of room it is not possible to provide 1 in 12 turnout.
Note: The existing turnouts not conforming to the stipulations given in Sub-Para (e)
above may continue. However, efforts shall be made to eliminate such layouts
in a planned manner.
(f) Radius of turn-in-curve should generally be not less than 350 metre however,
where it is not practicable to achieve the radius of curvature of turn-in curves as
350 m on account of existing track centres for the turnout taking off from curves,
the turn-in curves may be allowed upto a minimum radius of 220 m subject to the
Page 158 of 417

following –
(i) such turn-in curves are provided on PSC sleepers only, with sleeper spacing
same as that for the main line.
(ii) full ballast profile, same as that for the main line, is provided.
(3) Speed over interlocked turnouts –
(a) Speed in excess of 15 Kmph may be permitted for straights of interlocked turnouts
only under approved special instructions in terms of Para 4.10 of “General Rules,
1976 Edition”.
(b) In the case of 1 in 8½, 1 in 12 and flatter turnouts provided with curved switches,
higher speeds as permitted under approved special instructions may be allowed
on the turnout side, provided the turn-in curve is of a standard suitable for such
higher speeds. While permitting speed beyond 15 Kmph, provisions of Para 408
(4) below may be kept in view.
(c) The permissible speed on turnouts taking off on the inside of the curve should be
determined by taking into consideration the resultant radius of lead curve which
will be sharper than the lead curve for turn-outs taking off from the straight.
(4) Up-gradation of Speeds on Turnouts and Loops to 30 Kmph-
(a) Length of Section – Up-gradation of speeds on turnout should cover a number of
contiguous stations at a time so as to derive a perceptible advantage of the higher
speed in train operation. The works described below should cover all the running
loops on the stretch of line taken up.
(i) Turnouts – Speed, in excess of 15 Kmph, should be permitted on turnouts laid
on PSC sleepers only. All turnouts on the running loops shall be laid with curved
switches, with minimum rail section being 52 kg/m. All rail joints on these
turnouts should also be welded to the extent possible.
For different type of curved switches permissible speed are as under –
Sl. No. Type of Turnout Permissible speed
1. 1 in 8½ curved switch 15 Kmph
2. 1 in 8½ symmetrical split with curved switches 30 Kmph
3. 1 in 12 curved switch 30 Kmph
Note: The permissible speed for 1 in 12 TWS is 50 Kmph
(ii) Track on Running Loops – The minimum track structure on the running loops
should be 52 Kg/m rails laid as Short Welded Panels, sleeper density 1540 Nos.
per km and 150 mm clean ballast cushion. Proper drainage of the area should
also be ensured.
(iii) Turn-in curves – Turn-in curves should be laid with the same rail section as on
the turnout with PSC sleepers with sleeper spacing being 65 cm centre to centre
(maximum).
Turn-in curve should conform to Para 408(2) and especially so in respect of curvature
of the lead curve. Extra shoulder ballast of 150 mm should be provided on outside of
the turn-in curve.
The frequency of inspection of turn-in curves should be same as that for main line
turnouts.
409 Permissible Speed over Curved Main Line at Turnouts: - Subject to the
permissible run through speed governed by the interlocking standard, speed over the
main line will be determined taking into consideration the maximum cant that can be
provided on the main line and the permissible amount of cant deficiency.
Page 159 of 417

(1) In the case of turnout of similar flexure, the maximum cant that can be provided, on
the main line will be the sum of equilibrium cant for the turnout and permissible cant
excess.
(2) In the case of turnouts of contrary flexure, the maximum cant on the main line
(negative Super-elevation on turnout) will be the difference between the maximum
permissible cant deficiency and cant determined for turnout from the formula given in
Schedule of Dimensions as indicated in Para 411 below.
(3) In both the cases, the permissible speed on the main line will be worked out by the
formula as given in Para 403(1).
410 No Change of Super-elevation over Turnouts:-There should be no change of
cant between points 20 metres outside the toe of the switch and the nose of the
crossing except in cases where points and crossings have to be taken off from the
transitioned portion of a curve.
Normally, turnouts should not be taken off the transitioned portion of a main line curve.
However, in exceptional cases, when such a course is unavoidable a specific
relaxation may be given by the Chief Track Engineer of the Railway.
In such cases, change of cant and/or curvature may be permitted at the rates specified
in Para 405 or such lesser rates as may be prescribed.
411 Curves of Contrary Flexure: - (Back to Para 429)
On the main line curve from which a curve of contrary flexure takes off, the cant of the
main line (which is the negative Super-elevation on the turnout), should be calculated
from the formula given in the Schedule of Dimension and the permissible speed on
the main line determined from the allowable cant deficiency and cant on the main line.
The speed so determined shall be subject to limitations governed by the standard of
interlocking and the sectional speed.
412 Curves of Similar Flexure:- (Back to Para 429)
(1) Not followed by reverse curves – On a main line curve from which a curve of similar
flexure takes off, not followed immediately by a reverse curve, the turnout curve shall
have the same cant as the main line curve.
(2) Followed by reverse curves – A change of cant on the turnout may be permitted
starting behind the crossing (after the last exit sleeper) and being run out at a rate not
steeper than 2.8 mm per metre and subject to the maximum cant on the main line
turnout being limited to 65 mm.
The permissible speed on the main line is then determined from the allowable cant-
deficiency and subject to limitations governed by the standard of interlocking and the
safe speed limit.
413 Curves with Cross Overs: - On curves on double line connected by cross over
road, the speed and the cant for both roads are governed by the inner road to which
the cross over road is a curve of contrary flexure. On the outer road, it is a curve of
similar flexure.
The permissible speed and the necessary cant on the inner road shall be calculated
in accordance with Para 411 above. The same speed and the same cant shall be
allowed on the outer road.
The outer track shall be raised so that both roads lie in the same inclined plane in
order to avoid change in cross level on the cross over road. Where this is not possible,
both main line and the turnout should be laid without cant and suitable speed
restriction imposed.
414 Curves with Diamond Crossing: - Normally straight diamond crossings should
not be provided in curves as these produce kinks in the curve and uniform curvature
cannot be obtained.
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However, where provision of such diamonds cannot be avoided or in case where such
diamonds already exists in the track, the approach curves of these diamonds should
be laid without cant for a distance of at least 20 metres on either side of the diamond
crossings.
The cant should be uniformly run-out at the rate specified in Para 405 beyond 20
metres.
The speed restrictions on the approach curve shall be decided in each case by the
Chief Track Engineer taking into consideration the curvature, cant deficiency and lack
of transition but shall in no case be more than 65 Kmph.
In the case of diamond crossings on a straight track located in the approach of a
curve, a straight length of minimum 50 m between the curve and the heel of acute
crossing of diamond is necessary for permitting unrestricted speed over the diamond,
subject to maximum permissible speed over the curve from considerations of cant
deficiency, transition length etc.
415 Extra Clearance on Curves: - On curves, additional lateral clearances, in excess
of the fixed dimensions should be provided as laid down in the Schedule of
Dimensions –
(1) Between adjacent tracks and
(2) Between curved track and fixed structure.
416 Compensation for Curvature on Gradient: - Compensation for curvature
should be given in all cases where the existing gradient when added to the curve
compensation exceeds the ruling gradient.
The compensation to be allowed should ordinarily be (70/R) %. (i.e., 0.04% per
degree of curvature), where R is the radius of curvature in metres.
Thus, for a ruling gradient of 0.5% or 1 in 200, the gradient for 583 metre radius of
curvature should be flattened to 0.5% - {(70/583)or(3° x 0.04 %)} = 0.38% or 1 in 264.
417 Vertical Curve: - (Back to Para 657)
A vertical curve shall be provided only at the junction of the grade when the algebraic
difference between the grades is equal to or more than 4 mm per metre or 0.4%.
The minimum radius of the vertical curve shall be kept as under:
Group A Group B Group C, D & E
4000 metres 3000 metres 2500 metres
Page 161 of 417

SECTION – II: RE-ALIGNMENT OF CURVES
418 Running on Curves:-
(1) For smooth and satisfactory running on curves –
(a) There should be no abrupt alteration of curvature and/or Super-elevation (cant),
and
(b) The Super-elevation should be appropriate to the curvature, at each point.
(2) The versines, Super-elevation and gauge should be checked by the
JE/SSE/P.Way(Sectional), SSE/P.Way(In-charge) and ADEN as per prescribed
schedule for inspection and also whenever the running over curves is found to be
unsatisfactory as a result of inspection by locomotive or by carriage or as a result of
Track Recording.
(3) The results of the inspections shall be recorded as per the proforma given in
Annexure - 4/1 and necessary entries made in TMS.
(4) Based on the results of the inspections the decision to realign should be taken by the
SSE/P.Way in-charge or Assistant Divisional Engineer.
(5) The criteria for realignment of a Curve, based on service limit for station to station
versine variation, shall be as per Para 524.
419 String lining Operations:-
(1) The work of realigning and transitioning curves consists of the following three main
operations –
(a) Survey of the existing curve by measurement of versines.
(b) Determination of the revised alignment and computation of slews, including
provision of correct Super-elevation.
(c) Slewing of the curve to the revised alignment.
(2) Operation No. 1 – Versine survey of curve –
(a) Versine readings shall be taken along the gauge face of the outer rail.
(b) To ensure inclusion of the point of commencement of the curve, a mark is made
on the gauge face of the outer rail at a distance of at-least 30 m (three stations)
behind the beginning of curve, and at the end of curve as indicated by station
markings on the rails. i.e., station number zero/last station (or apparent tangent
point, if no such markings exist on track).
(c) If station markings at every 10 m interval are not available on track, it shall be
marked at every 10 m (half-chord distance) interval beginning from the marking
made before beginning of the curve (vide Sub-Para (b) above) till the marking
beyond end of the curve (vide Sub-Para (b) above),
(d) These “stations” should be marked and numbered in white paint on the rail.
(e) With a fishing cord or wire stretched out over the full length of the cord, the versines
are measured to 1 mm accuracy serially at each station from one end of the curve
to the other with the rule held normal to the line and recorded.
(f) Certain features, which restricts slewing of the track either inwards or outwards
should also be recorded, indicating the maximum extent inwards or outwards to
which slewing is possible-
(i) under existing circumstances; and
(ii) if a moderate expenditure could be incurred in removing the “restriction”.
(g) The existing Super-elevation should also be measured and recorded against each
“Station”.
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(h) The record obtained would be in the following form:
Curve from km............................to km............………………................
Between station..................................…and station......................................
Date of survey...............................................................................................
Jurisdiction of JE/SSE/P.Way (In-Charge) / (Sectional) ………………………..
Station Versine (mm) Cant Existing Remarks regarding
No restrictions to Slewing
0 0 Zero
1 2 5 mm
2 4 10 mm
3 4 20 mm
4 10 25 mm
5 11 28 mm 1.6 metres
6 23 25 mm G B obligatory point
7 30 28 mm High Bank, Moorum etc
(i) In the case of reverse curves, the versine survey should be continuous, but
transferred to the outer rail at points where the curvature changes sign.
It is probable that the exact point will not be definite; it is therefore, desirable to
keep the original rail face as the base until the change is certain to enable plus or
minus versines to be read from the same rail, it is only necessary to hold the fishing
cord or wire 20 mm clear of the rail edge at each end by using special gadget and
subtracting 20 mm from the reading at the centre.
(j) Where there are two or more lines, track centres should also be recorded at every
station. After the versine-survey, the curve alignment shall not be disturbed until
the realignment is commenced.
(3) Operation No. 2 – Determination of revised alignment and computation of slews –
(a) The basic principles of string lining are as follows –
(i) the chord length being identical, the sum total of the existing versines should be
equal to the sum total of the proposed versines.
(ii) the slew in any direction at a station affects the versine values at the adjacent
stations by half the amount in the opposite direction, when the track is not
disturbed at the adjacent stations.
(iii) the second summation of versine difference between proposed versine and
existing versine represents half the slew at any station.
(iv) at the first and at the last station, the slews should be zero.
(b) The calculations for obtaining a realignment solution are carried out in the following
manner (Refer Table-1);
(i) after recording the versines in mm, proposed versines are selected in such a
way as to obtain uniform rate of change of versines over the transition curve;
and uniform versines over the circular portion of the curves.
(ii) the difference between the proposed and the existing versines are worked out
for each station, the positive sign being used, if the proposed versine is greater
than the existing versine and negative sign if it is less (Ref. Col. 4 -Table 1), at
the end of this Sub-Para (4), wherein a solution to a realignment of curve is
worked out.
(iii) first and second summations of the differences of proposed and existing
versines are then worked out (Ref. Col. 5 & 6).
(iv) the first summation at any station, gives the cumulative versine difference at
each station. To begin with this value for station ‘0’ is the same as the versine
difference (Col. 4).
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To obtain the corresponding value for station No. 1 the cumulative versine difference
of station ‘0’ (Col. 5) is added to the versine difference of station No. 1 (Col. 4)
diagonally downward as shown by the arrow indication and the resultant value is
written against Station No. 1 (Col. 5).
Similarly, the cumulative versine difference is calculated at each station till the last
station is reached. Since the sum total of the existing and the proposed versines is
the same, the figure against the last station will be ‘0’ (Col. 5).
(v) the second summation at any station gives the cumulative effect of the figures
of first summations upto the previous station. It can be proved theoretically that
this represents half the slew required at each station to obtain the proposed
versine.
To start with, this value for station no. ‘0’ is taken as zero. To obtain the
corresponding value of Station No.1, the second summation value of the station
‘0’ (i.e., the previous station) is added to the first summation value of the same
station ‘0’, as shown by horizontal arrow. This value is shown against Station
No. 1 (Col. 6).
Similarly, the second summation for Station No. 2 is the sum of the figures of
the first summation and second summation of Station No. 1 (Col. 5 and 6).
The second summation is obtained against each station till the last station is
reached. The slew at the last station should be zero. Otherwise, the track
beyond the last station will be affected by the slew at the last station.
Normally this figure at the last station may not be zero. To make it zero
correcting couples are applied.
(vi) Method of applying correcting couples – For correcting the half throws to zero
the procedure shall be as follows –
When the final half-throw is negative, add to the versines having the lower
station numbers and subtract an equal amount from the versines having the
higher station numbers, selecting “station” in pairs such that the sum of the
products of the difference of the “station” numbers taken in pairs and the amount
added to the versines, equals the numerical amount of the negative half-throw
to be cleared.
When the final half-throw is positive, subtract from the versines having the lower
station numbers and add an equal amount to the versines having the higher
station numbers, selecting the stations in pairs such that the sum of the product
of differences of the station numbers in pairs and the amount subtracted from
the versines, equals the numerical amount of the positive half throw to be
cleared.
(c) For computing slews when realigning and/or transitioning a complete curve the
following procedure should be adopted –
(i) calculate the length of transition from Para 405. This determines the versine
gradient on the transition.
(ii) work out versine difference, first and second summations as discussed above
at the initial stations with a view to foreseeing and exercising due control over
the slews (col. 4, 5 and 6).
(iii) review the figures of proposed versines (col 3), if necessary and continue the
process until the transition at the other end on which the specific versine
gradient should be observed.
(iv) in the process, it must be ensured that difference of versines (col. 4) should sum
up to zero.
(v) apply correcting couples to control the slew at obligatory points and to close the
slew at the end to zero.
(vi) the slews must be limited to the minimum possible.
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(vii) determine correct cant to be provided, points of zero and maximum cant and
the cant run-off.
(viii) alternatively, suitable computer softwares, where available may be used to
determine the final values of slew.
(d) Maximum Slew – Maximum slew at any station is usually limited by practical
considerations. The distance between tracks and adequate clearance to existing
structures must be maintained and track must not be slewed too near the edge of
the formation. At certain locations like bridges, it may not be possible to slew the
curve at all.
(e) In carrying out the calculations for the realignment of a long curve of more than 50
stations, it is best to write down values of about 10 proposed versines at a time
and see that the sum is approximately the same as that of the corresponding old
versines and then workout the second summation to ensure that slews are
minimum. A final adjustment to ensure that the sum of the existing and proposed
versines is equal and that the slew at last station is zero can then be made.
(f) For obtaining a suitable re-alignment solution, the proposed versines should be
selected carefully.
(g) A numerical example is given in Table 1, which will illustrate the method of working
out the solution for realignment of a curve.
(4) Operation No. 3 – Slewing the curve to revised alignment –
(a) The revised alignment of the curve should be staked out with a steel tape by using
the pegs cut from the bars (or wooden stakes with tack marks). These are fixed on
the cess on the inner side of the curve square to the track and at such a distance
according to the value of the slews, so that the final alignment of the track is at one
gauge distance from the face of the pegs (or the tacks on wooden pegs) to the
outer edges of the inner rail.
(b) In narrow cuttings with sharp curves or in tunnels it may not be possible to measure
versines on the pegs driven on the inner cess of the curve due to the face of the
cutting fouling the fishing cord. In such cases, the pegs may be driven on the outer
cess. The correctness of the peg locations should be checked, by measuring the
versines on these pegs and, verifying that they correspond to the final versines (of
the re-alignment solution).
(c) In no case should these be fixed on formation that is not firm or at locations where
they are liable to the disturbed or tampered with.
(d) The curve should then be correctly slewed with reference to the pegs.
(e) Along with slewing of the curve to the revised alignment correct Super-elevation
should be provided at each station to accord with the curvature, particular attention
being paid to the run-off on the transition. Repositioning of posts on the cess to
indicate zero and maximum Super-elevation and remarking of cant values on the
inside web of the inner rail should be done.
420 Realigning Curves on Double or Multiple Lines:-On double or multiple tracks,
each curve should be string-lined independently. No attempt should be made to realign any
curve by slewing it to a uniform centre to centre distance from the realigned curve as –
(1) The existing track centres may not be uniform and relatively small slew on one may
entail a much larger (even prohibitively large) slew on the adjacent track.
(2) The transitions at the entry and exit may be of different lengths, which make it
impracticable to maintain uniform track centres on them even though the degree
of the circular curves may be nearly the same.
421 Cutting of Rails on Curves:- (Back to Para 715)
Rails are usually laid with square fish plated joints on curve. On curved track the inner rail
fish plated joints gradually lead over the outer rail joints. When the inner rail of the curve is
ahead of the outer rail by an amount equal to half the pitch of boltholes, cut rails should be
Page 165 of 417

provided to obtain square joints. Cut rail is a rail, which is shorter than the standard length
of rail by an amount equal to the pitch of the boltholes. The excess length ‘d’ by which the
inner rail gains over the outer rail is calculated by the formula –
LG
d =
where, R
‘d’ is the length in mm by which the inner rail joint is ahead of the outer rail joint
over the entire length of the curve, if cut rails are not provided.
L = length of the curve in metre
R = radius of the curve in metre
G = the gauge + width of the rail head in mm
422 Joints on Curves:- (Back to Para 715)
(1) It must be ensured that fish plated rail joints are square at beginning and at the end
of the curve.
(2) On the sharp curves less than 400 metres the rail joints may be staggered, where
elbows/kinks are likely to develop if rail joints are laid square.
423 Check Rails on Curves:-
Check rail reduces the risk of derailment on the sharp curves.
(1) Check rail should be provided on the inside of the inner rail of the curve, with
appropriate clearances between the checkrail and the running rail, as stipulated in the
“Schedule of Dimensions”.
(2) Locations where checkrail should be provided shall be decided by the Divisional
Engineer taking into consideration the negotiability of the rolling stock and the curve
geometry.
424 Wear on Outer Rail of Curves:- (Back to Para 613)
(1) The wear on the outer rail on the curve can be reduced effectively by-
(a) Lubricating the gauge face of outer rails on the curves.
(b) Maintaining correct curve geometry and Super-elevation.
(c) Provision of suitable checkrail.
(d) Adopting slack gauge PSC sleeper as per RDSO drawings depending on curvature
of track.
(2) Track mounted automatic Gauge Face Lubricators should be provided on curves of
radius 875 m (2°) and sharper to reduce rail gauge face wear.
On routes where rail grinding is in practice, track mounted automatic Gauge Face
lubricators should be provided on curves of radius 1400 m (1.25°) and sharper.
Lubrication should be done on new rails or on old rails, which do not have Gauge
Corner Cracking or head checks.
While deciding the location of lubricators, following should be considered:-
(a) It is located on tangent track at the beginning of transition curve where wheel
flanging is just beginning to occur.
(b) On single lines, the lubricator shall be located in the direction of heaviest traffic.
(c) Lubricators should be located away from switches, crossings and other areas
where discontinuity in LWR track may exist.
425 Measurement of Rail Wear on Sharp Curves: -The wear of rails of curves
having radius of 600 m or less shall be recorded periodically as specified by the zonal
railway. The lateral wear, vertical wear and total loss of section should be recorded
and proper record of measurements maintained.
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Page 167 of 417
Page 168 of 417

PART – ‘B’
POINTS & CROSSINGS
426 (1) Turnout:-It is a geometrical installation of track to allow movement of train from
one track to another track. The turnout consists of following sub-assemblies:
(a) Switch assembly
(b) Lead assembly
(c) Crossing assembly
(2)Turn in Curve: The curve connecting the turnout curve after heel of crossing and the
adjoining track is called turn in curve. (Refer Para 408)
Turn in Curve
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427 Assembly drawings:-The turnout and its sub-assembly drawings numbers
commonly being utilized on Indian Railways are as under:
RDSO Drawing No.
Sl. Switch Crossing
Rail Section and sleeper Angle of Crossing Complete
No. sub sub
Layout
Assembly Assembly
1 52 Kg/m Rail on PSC sleeper 1 in 8½ RT-4865 RT-4866 RT-4867
2 60 Kg/m Rail on PSC sleeper 1 in 8½ RT-4965 RT-4966 RT-4967
3 52 Kg/m Rail on PSC sleeper 1 in 12 RT-4732 RT-4733 RT-4734
60 Kg/m Rail on PSC sleeper Thick
7 1 in 8½ RT-6279 RT-6280 RT-4967
web Switch with Zu – 1 – 60 rails)
8 1 in 12 RT-5268 RT-5269 RT-4734
9 1 in 12 RT-6154 RT-6155 RT-4220
1 in 8½
10 52 Kg/m Rail on PSC sleeper RT-5353 RT-5354 RT-4867
symmetrical split
1 in 8½
symmetrical split
1 in 12
symmetrical split
1 in 12
symmetrical split
428 LWR through Points and Crossings: - The turnouts shall be isolated from
LWR/CWR by provision of SEJs on either side. However, in case of LWR/CWR taken
through turnouts the provisions contained in RDSO report no. CT-48 shall be followed.
However, before permitting LWR through turnouts, specific approval of RDSO is required
till the trials are completed.
429 Inspection and Maintenance of Points and Crossings:-
(1) Maintenance – General
(a) Points and crossings should be laid without the 1 in 20 cant unless otherwise
specified in the drawing.
(b) There should be no junction fishplates at stock rail joints or at the heel of crossings.
(c) At least one rail on either side of the Points and Crossings should have the same
section as the Points and Crossings assembly rail section.
(d) It is desirable to weld stock and lead joints on the Points and Crossings assembly.
(e) The use of spherical washer is necessary, where the shank of the bolt is not at
right angles to the axis of the rail to obtain flush fit of the head of the nut of the bolt
with the web of the rail. The spherical washers are used on skew side.
(f) Notwithstanding the provisions of Sub-Para (e) above, the spherical washer should
invariably be provided on the left side in switch assembly; as the orientation of fish-
bolt hole is made accordingly. On crossing tapered washers are to be used on both
sides.
(g) Correct spacing of sleepers should be ensured according to the standard layout
drawings. The standard spacing of sleepers for turnout for 1 in 8.5 and 1 in 12
turnouts are given in Annexure - 4/2.
(h) The track geometry at the turnout should not be inferior to that applicable for the
route.
(i) The clearance, at the toe, heel of switch, at checkrail and wing rail must be
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maintained within the tolerances prescribed in the schedule of dimensions.
(j) The chairs and fastenings and all other fittings must be properly secured.
(k) Packing under the sleepers must not be loose/ defective especially under crossing
and the switch.
(l) Cess should be low enough to permit efficient drainage and adequate depth of
ballast cushion should be provided.
(m) In case creep is observed at such layouts, the condition of elastic fastenings may
be examined and suitable action be taken.
(n) Where large number of Points and Crossings are being maintained within a specific
area such as marshalling yards, large layouts of sidings, terminal stations etc.,
regular cycle of maintenance covering all Points and Crossings should be
organized.
(2) Maintenance of Switches –
(a) The tongue rail and stock rail shall be fabricated in workshop as per standard
RDSO drawings. Field officials should check the curvature of Stock Rail and
Tongue Rail before laying. In case of Turn out taking off from curve suitable
curvature as per resultant lead radius to be provided both in Stock Rail and Tongue
Rail.
(b) For information of field officials, the location of 13 mm head of tongue rail, Junction
of head (JOH), location of level point of stock rail and tongue rail and its head
thickness from ATS is given in Annexure - 4/5
(c) The condition of stock & tongue rails should be carefully examined and badly worn
and damaged stock and tongue rails should be replaced. A tongue rail may be
classified as worn/ damaged when- (Back to Para 717)
(i) it is chipped/cracked over small lengths aggregating to 200 mm within a
distance of 1000 mm from its toe. Chipped length will be the portion where
tongue rail has worn out for a depth of more than 10 mm over a continuous
length of 10 mm.(The tongue rail can, however, be reused after reconditioning
of the broken/worn/ damaged tip by welding)
(ii) it is badly twisted or bent and does not house properly against the stock rail
causing a gap of 5 mm or more at the toe, the limit described in the IRSEM.
(iii) wear on stock rail shall not exceed the limits laid down in Para 702 (1) (b).
However, proper housing of tongue rails is to be ensured. Burred stock rail likely
to obstruct the lock bar, should be replaced, if necessary.
(d) Rail Gauge ties, rodding etc. hinder proper packing and hence at the time of
packing points and crossing the signal staff should take out the rods and stretcher
bars etc.to facilitate proper tamping.
(e) To check the housing of the tongue rail and also the throw of the switch, all non –
interlocked points should be operated by hand lever and other Points from the
signal frame, when traffic permits doing so.
(f) If the tongue rail is found to be not housing properly against the stock rail, the
defect must be rectified by the Permanent Way Staff in case of non- interlocked
points and jointly with signal and telecommunication staff, in case of interlocked or
partially interlocked points.
(g) Tongue rail should, preferably bear evenly on all the slide chairs.
(h) When the tongue rail is in closed position, it must bear evenly against slide blocks.
(i) Slight wide gauge at the toe of switch over and above the required widening to
house the tip of the tongue rail, may be adjusted by providing suitable steel packing
between the web of the stock rail and the lug of the slide chair wherever feasible.
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(j) The Stretcher bar connected to the pull rod shall be maintained jointly by the
Permanent Way Staff and the Signalling Staff. The gap between the top of the
leading stretcher bar and bottom of stock rail should be between 1.5 mm to 5 mm.
(k) All other stretcher bars shall be maintained by the JE/SSE/P.Way. Stretcher bars
insulated for track circuit purposes shall not be interfered with unless signal staff
are present.
(l) Wear on switches can be reduced by lubrication of the gauge face of tongue rail.
(3) Maintenance of Crossings –
(a) If any damage to the nose of crossing is noticed, its cause must be traced, which
might be due to tight gauge or due to excessive clearance at the checkrail.
(b) To avoid hitting of nose, it shall be ensured that the checkrail clearance should be
between 41 to 45 mm for fan-shaped turnout.
(c) In obtuse Crossings, the distance between the throat and the nose must be
maintained correctly.
(d) In diamond crossings, obtuse crossings should be laid square to each other with
respect to the centre line of the acute Crossings.
(e) Maximum permissible vertical wear on wing rails or nose of crossing shall be 10
mm. However, on Rajdhani/ Shatabdi routes, as a good maintenance practice,
crossing and the wing rails should be planned for reconditioning/resurfacing by
welding on reaching the following wear limits: (Back to Para 717)
(i) Built up/Welded Crossing – 6 mm
(ii) CMS crossings – 8 mm
Note –
In case of CMS crossings, following dimensions should be deducted (to account for
slope in casting of wing rails to 1 in 20 cant) from the wear measurements to find out
the actual wear of wing rails and nose of crossing.
(a) for 52 kg section – 2.0 mm.
(b) for 60 kg section – 2.5 mm.
(c) for heat-treated welded crossing – 3.5 mm.
(4) Maintenance of lead portion and turn-in curve –
(a) At the time of laying, the correct sleeper spacing should be ensured to achieve
correct alignment of the lead curve. During maintenance, stations at 3.0 m intervals
should be marked, versines checked, and track attended as necessary. The
versine at each station in lead curve and turn in curve should not be beyond 3 mm,
from its design value, as a good maintenance practice.
(b) The versines of turn-in curves on loops should be recorded at stations at 3.0 m
intervals on 6.0 m chord length during the inspection of points and crossings to
check the sharpness of the curve and rectified as necessary.
(c) The turn-in curve should also be checked for condition of sleepers and fastenings.
(5) Inspections of Points and Crossings –
(a) For Points and Crossings on PSC sleepers, the detailed inspection as per proforma
given in Annexure - 4/3 should be done once in a year and all other intermediate
inspections should be carried out as per proforma given in Annexure - 4/3 (A).
The format for inspection of Diamond Crossings, Diamond Crossings with single and
double slip are at Annexure - 4/4, 4/4(A), 4/4(B)
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(b) The Divisional Engineer may inspect, at his discretion, a certain number of points
and crossings particularly in running lines and those recommended for renewals.
(c) All points inspected as per proforma mentioned in Sub-Para (a) above and entries
to be made in TMS.
(6) Cleaning and Lubrication of Points - At all interlocked and partially interlocked
stations, the Signal staff will be responsible for the periodical cleaning and lubrication
of those slide chairs in which signaling and interlocking gears are connected
(generally upto third sleeper from toe of switch) in all points interlocked with signals
or provided with locks. The SSE/JE/P. Way shall be responsible for the cleaning and
lubrication of slide chairs of all hand operated points on their sections and remaining
slide chairs of all points interlocked with signals or provided with locks.
(7) Alterations of Points – The position of points and crossings should not be changed
without the written authority of the Divisional Engineer. The sanction of the
Commissioner of Railway Safety is necessary in the case of
alterations/insertion/removal of points and crossings in existing running lines,
however, shifting of points, which does not affect nature of signalling, will not require
CRS sanction.
(8) Gauge and Super-elevation in Turnouts –
(a) It is a good practice to maintain reasonable uniform gauge over turnouts. Tolerance
in gauge at various portions of turnout during new laying/renewal and maintenance
shall be as given in Para 520 (3) (a) & Para 525 (1) respectively.
(b) The gauge in crossing portion shall be 0 mm to 4 mm with respect to gauge
prescribed in standard drawing, i.e., 1673 mm, both in case of New Laying/
Renewal and during service.
(c) If gauge of track on either side of the points and crossings is maintained
wider/tighter than the gauge on the points and crossings, the gauge on either side
of the track should be brought to same gauge as in the points and crossings, as a
good maintenance practice.
(d) Super-elevation on turnouts with curve of similar or contrary flexure should be
provided in accordance with Para 411 & 412.
(9) Interlocking of Points – Before interlocking work is taken in hand, the JE/SSE/P.Way
should –
(a) Bring the rails to correct level and alignment.
(b) Fully ballast and pack the points to be interlocked.
(c) Mark the locations where the rods and wires have to cross the lines.
(d) To avoid future adjustments of gear, see that the track at turnout, is laid to correct
gauge so that switches, fittings and locks may be correctly put together.
(e) Clear cess and bring it to the correct level and section where rods and wires have
to be run.
(f) Fit gauge ties wherever provided correctly to all switches.
(10) Maintenance of Interlocked points- In the case of interlocked points, the JE/SSE
(Signal) will be responsible for keeping the interlocking parts and apparatus in working
order. As the slewing of the track at points is likely to throw them out of adjustment,
such work should not be undertaken except in the presence of the Signal staff. On the
advice of track defects from JE/SSE (Signal), JE/SSE/P.Way should promptly attend
to them.
(11) Date of Laying Points and Crossings – The month and year of laying a new or second
hand points and crossings should be painted in white block letters on the webs of
switches about 500 mm from the heel joint and the webs of crossings about 500 mm
from the joint connected to the lead rails.
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When second hand points and crossings are subsequently laid at another site, the
dates previously marked should not be obliterated; an indication of the total life will
then be available. In the case of reconditioning of switches and crossings, the date of
reconditioning should also be painted.
430 Reconditioning of Switches and Crossing:-
(1) General-There are two welding techniques used for reconditioning of crossings.
Manual method consisting of H3B and H3C type of electrodes is used for
reconditioning of switches and crossings. The reconditioning of switches shall be
done on cess outside the track, Built-up crossings on cess or in-situ and CMS
crossings in the depot / mobile depot. Robotic Welding Technology is used for in-situ
reconditioning of CMS crossing on all routes having traffic density more than 30 GMT.
On routes having traffic density up to 30 GMT and loop lines of all routes, decision
regarding type of electrode / technology to be used for reconditioning of crossing is to
be taken by CTE keeping in view local requirement and other relevant factors giving
due consideration to the requirement that departmental workshops for reconditioning
have to be kept functional with sufficient work load so that in-house capacity remains
available and track maintenance does not suffer in case of failure / problems in
contract awarding / execution.
(2) Selection of Points and Crossings for Reconditioning.
(a) Points and crossings to be reconditioned by welding should be in good condition
and certified by the Sectional JE/SSE/P.Way for their suitability for reconditioning
and should normally not have exceeded specified limit of wear.
(b) Points and Crossings containing cracks on the worn-out portion having depth more
than 3 mm (as determined by gouging) beyond the condemning size shall not be
selected for further reconditioning.
(c) Ultrasonic testing should be carried out to detect the serviceability. The Points &
Crossings having internal defects should not be reconditioned.
(d) Reconditioning of tongue rail shall be done on level cess / depot along with stock
rail.
(3) Competency of welder: Only skilled or highly skilled welder who has been trained
and certified by competent authority in resurfacing of the crossings by welding shall
be engaged.
The competency of welder should be checked by Chemist and Metallurgist of Railway
or officer nominated by CTE of the concerned Railway in case of departmental
welders and by RDSO in case of non-departmental welder. A copy of competency
certificate with identity card should be available with welder at the site of
reconditioning. Competency given by OEM of the firm approved by RDSO will be
accepted.
(4) Welding Electrodes:
(a) Electrodes of H3B and H3C class may be used for reconditioning, which have a
minimum service life of 35 GMT and 50 GMT respectively.
(b) Electrodes shall be sourced from RDSO approved vendors only.
(5) Precautions for using electrode:
(a) Welding should be done using 4 mm diameter electrodes only.
(b) The electrode shall be stored in a dry storeroom.
(c) Electrodes having cracked and damaged flux covering shall be discarded.
(d) Electrodes shall be dried at 130° C to 170° C for at least one hour immediately
before use. In case, the packing of electrodes is absolutely intact and all the
electrodes are consumed within six hours after the opening of the packing, then
preheating of electrodes may be dispensed with.
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(6) Equipment for reconditioning:
All the equipment as laid down in Para 6 of “Manual for reconditioning of medium
manganese (MM) steel points and crossings, switch expansion joints and cast
manganese steel (CMS)”should be available for reconditioning.
(7) Reconditioning procedure: The procedure given in “Manual for reconditioning of
medium manganese (MM) steel points and crossings, switch expansion joints and
cast manganese steel (CMS)”should be followed.
431 Periodical Inspection of Reconditioned Points and Crossing:-
After laying in track, the resurfaced points and crossing shall be inspected quarterly in order
to record the amount of wear on the nose, left wing and right wing rail as well as stock and
tongue rail and also for the structural soundness, presence of disintegration or any other
defects.
The wear shall be recorded in crossing at ten different locations marked (A1, A3, B1, B3,
C1, C2, C3, D1, D2 & D3) as shown in Fig: 4.1 and in tongue rails at seven different
locations starting from one at toe to places each 100 mm away towards heel side and up to
600 mm from the toe.
Fig: 4.1
432 Robotic Reconditioning:-

(1) The Robotic Welding technique uses a computer-controlled arc-welder that utilizes a
coated wire without gas to eliminate operator exposure to weld fumes. The records of
all welding Parameters and events are stored in memory for later reference.
(2) For detailed welding process the manufacturer's manual may be referred to.
Page 175 of 417

Table for spacing of Sleepers in 1 in 12 fan shaped Turnout
(Taking off from Straight)
Sleeper Spacing on gauge face on tongue rail for ML Spacing on gauge face of stock rail for ML
No. side side
Spacing Cumulative From SRJ Spacing Cumulative from SRJ
150 150
1 150 150
457 457
2 607 607
510 510
3 1117 1117
695 695
4 1812 1812
537 537
5 2349 2349
550 550
6 2899 2899
550 550
7 3449 3449
550 550
8 3999 3999
550 550
9 4549 4549
550 550
10 5099 5099
550 550
11 5649 5649
550 550
12 6199 6199
550 550
13 6749 6749
550 550
14 7299 7299
550 550
15 7849 7849
550 550
16 8399 8399
550 550
17 8949 8949
550 550
18 9499 9499
550 550
19 10049 10049
550 550
20 10599 10599
526 550
21 11125 11149
549 550
22 11674 11699
549 550
23 12223 12249
549 550
24 12772 12799
549 550
25 13321 13349
549 550
26 13870 13899
549 550
27 14419 14449
549 550
28 14968 14999
549 550
29 15517 15549
549 550
30 16066 16099
549 550
31 16615 16649
549 550
32 17164 17199
Page 176 of 417

549 550
33 17713 17749
549 550
34 18262 18299
549 550
35 18811 18849
549 550
36 19360 19399
548 550
37 19908 19949
549 550
38 20457 20499
549 550
39 21006 21049
549 550
40 21555 21599
549 550
41 22104 22149
549 550
42 22653 22699
549 550
43 23202 23249
549 550
44 23751 23799
549 550
45 24300 24349
549 550
46 24849 24899
549 550
47 25398 25449
549 550
48 25947 25999
549 550
49 26496 26549
549 550
50 27045 27099
549 550
51 27594 27649
549 550
52 28143 28199
549 550
53 28692 28749
549 550
54 29241 29299
549 550
55 29790 29849
549 550
56 30339 30399
549 550
57 30888 30949
549 550
58 31437 31499
549 550
59 31986 32049
549 550
60 32535 32599
548 550
61 33083 33149
549 550
62 33632 33699
549 550
63 34181 34249
549 550
64 34730 34799
549 550
65 35279 35349
550 550
66 35829 35899
550 550
67 36379 36449
550 550
68 36929 36999
550 550
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69 37479 37549
550 550
70 38029 38099
550 550
71 38579 38649
550 550
72 39129 39199
550 550
73 39679 39749
550 550
74 40229 40299
550 550
75 40779 40849
550 550
76 41329 41399
550 550
77 41879 41949
550 550
78 42429 42499
550 550
79 42979 43049
550 550
80 43529 43599
550 550
81 44079 44149
550 550
82 44629 44699
550 550
83 45179 45249
Page 178 of 417

Table for spacing of Sleepers in 1 in 8.5 fan shaped Turnout
(Taking off from Straight)
Sleeper Spacing on gauge face on tongue rail for ML Spacing on gauge Face of stock rail for ML
No. side side
Spacing Cumulative from SRJ Spacing Cumulative from SRJ
268 268
1 268 268
600 600
2 868 868
600 600
3 1468 1468
685 685
4 2153 2153
620 620
5 2773 2773
660 660
6 3433 3433
600 600
7 4033 4033
600 600
8 4633 4633
600 600
9 5233 5233
600 600
10 5833 5833
600 600
11 6433 6433
600 600
12 7033 7033
600 600
13 7633 7633
564 600
14 8197 8233
597 600
15 8794 8833
598 600
16 9392 9433
598 600
17 9990 10033
598 600
18 10588 10633
597 600
19 11185 11233
598 600
20 11783 11833
598 600
21 12381 12433
598 600
22 12979 13033
597 600
23 13576 13633
598 600
24 14174 14233
598 600
25 14772 14833
598 600
26 15370 15433
597 600
Page 179 of 417

27 15967 16033
598 600
28 16565 16633
598 600
29 17163 17233
598 600
30 17761 17833
597 600
31 18358 18433
598 600
32 18956 19033
598 600
33 19554 19633
598 600
34 20152 20233
597 600
35 20749 20833
598 600
36 21347 21433
598 600
37 21945 22033
598 600
38 22543 22633
597 600
39 23140 23233
598 600
40 23738 23833
598 600
41 24336 24433
598 600
42 24934 25033
550 550
43 25484 25583
550 550
44 26034 26133
550 550
45 26584 26683
550 550
46 27134 27233
550 550
47 27684 27783
550 550
48 28234 28333
550 550
49 28784 28883
550 550
50 29334 29433
550 550
51 29884 29983
550 550
52 30434 30533
550 550
53 30984 31083
550 550
54 31534 31633
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Page 183 of 417
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Annexure - 4/3 (A) (Para 429)
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Page 188 of 417
Page 189 of 417
Annexure - 4/4(A) (Para 429)
Page 190 of 417

Page 191 of 417
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Page 193 of 417
Page 194 of 417
Annexure - 4/4 (B) (Para 429)
Page 195 of 417

Page 196 of 417
Page 197 of 417
Page 198 of 417
Page 199 of 417
PARTICULARS OF TONGUE RAILS SHOWING LOCATION AND HEAD THICKNESS
AT LEVEL POINT OF STOCK AND TONGUE RAIL
Location Location Location of Head
of 13 mm of JOH level point of thickness
S
Description of switches Drg. No. of head from from stock & of tongue
No.
tongue rails ATS ATS tongue rail rail at level
from ATS point
mm mm mm mm
6400 mm c/s on PSC RT-4866/2
1 476.5 3023 1512 31.6
BG 52 kg RT-4866
6400 mm c/s on PSC RT-4966/1
2 476.5 3229 2348 48.25
BG 60 kg RT-4966
10125 mm c/s on PSC, RT-4325/1
3 1682 5836 4244 43.4
BG, 60 kg RT-4219
10125 mm c/s on PSC RT-4733/1
4 1682 5540 4029 40.34
BG 52 kg RT-4733
7000 mm c/s on PSC, RDSO/T-5364/1
5 RDSO/T-5364 for 52 kg to RDSO/T- 476 3095 1547.5 32
1 in 8 ½ Diamond 5364/3
7000 mm c/s on RDSO/T-6494/1
6 PSC,RDSO/T-6494 for to RDSO/T- 476 3008 2406 50
60 kg 1 in 8 ½ Diamond 6494/3
Page 200 of 417

CHAPTER – 5
TRACK MONITORING & TOLERANCES
*********************
PART – ‘A’ - TRACK MONITORING
501 General - Inspections by individuals on foot or by trolley, locomotive, and rear vehicle
enable the Permanent Way staff to carry out assessment of the quality of track based
on their expertise and experience. For objective assessment of track quality, the
following mechanized means are being used on Indian Railways.
(1) Track Recording Car
(2) Oscillation Monitoring System
(3) Oscillograph Car
502 Track Recording Cars: - These enable collection of discrete values of various track
geometry Parameters on selected sampling interval under loaded condition. The
TRCs work on inertial principle of measurements for various track geometry
Parameters except Gauge.
(1) Inertial principle of measurements:-
TRC measures lateral and vertical accelerations with the help of accelerometers
placed at coach floor / bogie frame. The acceleration values obtained are integrated
twice to get loci of the location of accelerometers. The relative displacements between
rail and accelerometer locations are obtained from displacement transducers
(LVDT)/LASER based contactless sensors. The loci of accelerometers are combined
with relative displacement between accelerometers and rail obtained from sensors to
derive the vertical and lateral profile of the rail. These measurements are further
corrected for roll and yaw motion of coach using gyroscopes.
(2) Gauge Measurement:-
For measurement of Gauge Parameter, the following types of Gauge sensors are in
use on Indian Railways:
(a) Contact gauge sensor (used up to maximum recording speed of 100 Kmph); and
(b) Contactless laser based gauge sensor (used up to maximum recording speed of
160 Kmph);
503 Quick Calibration, Recording and Speed:-
(1) Before start of any run (day light hours only), it should be ensured that quick calibration
of the system has been done satisfactorily.
(2) The track recording car specials must have a through run over the section between
two major stations and run through main lines only at all stations.
(3) The track parameter recording is independent of speed above a minimum speed of
20 Kmph (needed for inertial platform); however, the Track Recording Cars should be
run at the maximum speed of Section/TRC for objective assessment of ride quality in
terms of acceleration peaks and Ride Index. Any recording done below speed of 20
Kmph is taken as "Non-recorded".
504 Arrangements for Running Track Recording Car:-
(1) On receipt of monthly program for running of TRCs on various zonal railways issued
by RDSO, Zonal Railways shall arrange for suitable power, crew, consumables and
path for an uninterrupted run of the Track Recording Car as per RDSO program.
Page 201 of 417

(2) ADENs & SSEs headquartered at originating / halting stations shall coordinate for
proper placement, watering, charging, and other assistance for the TRC special.
505 Officials to accompany the TRC run:-
Sectional Sr. DEN/DEN, ADEN and SSE/P.Way (In-charge) shall accompany TRC
run in their sections.
Sectional Sr. DEN/DEN shall ensure proper liaison in the control office for suitable
path and monitoring of the TRC special.
The soft copy of TRC recording shall be provided by RDSO officials and the same
shall be uploaded in TMS.
506 Frequency of Track Recording:-
The frequency of Track geometry monitoring by TRC is as under:
Sl. No. Speed Slab Frequency
i) Routes with speeds above 130 Kmph Once in 2 months
Routes with speeds above 110 Kmph and up to 130
ii) Once in 3 months
Kmph
Routes with speeds above 100 Kmph and up to 110
iii) Once in 4 months
Kmph
iv) Routes with speeds up to 100 Kmph Once in 6 months
507 Track Geometry Parameters Recorded by TRC: - The following track geometry
parameters are measured by the Track Recording Cars:
(1) Unevenness of left & right rail (on two selected chords)
(2) Alignment of left & right rail (on two selected chords)
(3) Twist (calculated on two selected bases)
(4) Variation of gauge over nominal gauge, which is 1676 mm for IR.
(5) Vertical and lateral accelerations on coach floor above bogie pivot, in test vehicles
(Locomotive)
(6) Curve details (only in contactless laser based TRCs)
(7) Speed of recording
508 Chords for Measurements/Report:-
Both types of TRCs have the ability to measure and calculate track geometry
parameters on two user selectable chords/bases in the range of 2 to 20 metres. The
shorter one is termed as short chord/base and the other one as long chord/base
(denoted by suffix 1 & 2 respectively). The length of short and long chord/base for
track monitoring are as under:
SN Parameter Short Chord / Base (m) Long Chord/ Base (m)
1 Unevenness 9.0 (UN-1) 18.0 (UN-2)
2 Alignment 9.0 (AL-1) 15.0 (AL-2)
3 Twist 3.0 (TW-1) 15.0 (TW-2)
509 Reporting of TRC Results:-
While recording the track parameters, on-line reports are generated by TRC for each
block of 200 metre and for the entire kilometre:
(1) Details of every block of 200 m:-
(a) Standard Deviation values of Unevenness of left & right rail on short and long chord
(b) Standard Deviation value of Alignment of left & right rail on short and long chord
(c) Average of Variation of gauge over nominal gauge (1676 mm)
Page 202 of 417

(d) Maintenance Instructions corresponding to Gauge (MI-G) based on Need Based
Maintenance Limit (NBML) and Urgent Maintenance Limit (UML) values for
average/mean gauge
(e) Average speed
(f) Vertical and Lateral Ride Index on coach floor above bogie pivot (accelerometer
location) and in test vehicle (Locomotive) in Laser Contact less TRCs
(g) Parameter Index for Unevenness (UNI-1 & UNI-2) and Alignment (ALI-1 & ALI-2)
on short and long chords.
(h) Track Quality Index (TQI) on both short and long chord i.e., TQI-S and TQI-L
(i) Composite Track Quality Index for Sections having Speed > 100 Kmph (TQI-C)
(j) Maintenance Instructions corresponding to SD (MI-SD) based on PML and NBML
for Unevenness and Alignment
(2) Results reported for whole kilometre:
(a) Total number of peaks above Need Based Maintenance Limits (NBML) on long
chord and short chord for Alignment and Unevenness.
(b) Total number of peaks above Need Based Maintenance Limits (NBML) and Urgent
Maintenance Limit (UML) on short base for Twist.
(c) Total number of peaks above Need Based Maintenance Limits (NBML) and Urgent
Maintenance Limit (UML) for Gauge.
(d) Total number of peaks above Urgent Maintenance Limit (UML) for vertical and
lateral acceleration.
(e) Parameter Indices for Unevenness (UNI-1 & UNI-2) and Alignment (ALI-1 & ALI-
2) on short and long chord.
(f) Track Quality Index (TQI) on both short and long chord i.e. TQI-S and TQI-L.
(g) Composite Track Quality Index for sections having speed > 100 Kmph (TQI-C).
(h) Average speed.
(i) Vertical and Lateral Ride Index on coach floor above bogie pivot (at accelerometer
location).
(j) 10 highest peak values of alignment and unevenness Parameters with location on
long and short chord out of the maximum peak values measured for each 50 m
block of a kilometer.
(k) 10 highest peak values of Twist Parameter with location on short base out of the
maximum peak values measured for each 50 m block of a kilometer.
(l)10 highest peak values of variation of gauge (over nominal gauge of 1676 mm)
parameter with location out of the maximum peak values measured for each 50 m
block of a kilometer.
(m) 10 highest peak values of vertical and lateral accelerations with location out of the
maximum peak values measured for each 50 m block of a kilometer.
(n) 10 maximum peak values of Twist on short base exceeding Urgent Maintenance
Limits (UML) with location.
(o) 10 maximum peak values of Gauge (over nominal gauge of 1676 mm) exceeding
Urgent Maintenance Limits (UML) with location.
(p) 10 maximum peak values of vertical and lateral accelerations exceeding Urgent
Maintenance Limits (UML) with location.
(3) SMS alerts would be generated for cases of exceedances of UML during TRC
recordings. These alerts would be sent through TMS to concern JE/P.Way,
SSE/P.Way, ADEN and sectional DEN/Sr.DEN along with Sr.DEN/Coordination.
Page 203 of 417

510 Action to be Taken After Track Recording by TRC:-
(1) Spots/blocks requiring attention as per Parameter limits, and acceleration peak limits
set as UML should be noted by the ADEN and SSE/P.Way accompanying the car for
giving requisite action/attentions as per Para 521.
(2) Track recording results should be uploaded in TMS by SSE/In-charge of TRC after
end of days recording and analyzed in the Divisional Office.
(a) A comparison of the records of each section shall be made with the previous run.
(b) Analysis shall be done for identifying the blocks/locations needing Planned, Need
Based and Urgent attention for onward transmission to concerned maintenance
units.
(c) Analysis of data to generate various reports/charts using TRC offline software or
through TMS to take up the maintenance and precautionary action as detailed in
Para 523. Alerts with respect to UML will also be generated by TMS after uploading
of data in TMS.
(d) Maintenance units shall take action for maintenance as detailed in Para 523.
511 Parameter Indices:-
For characterization of the Track Quality, the Parameter wise Indices viz. unevenness
index (UNI-1 and UNI-2) and Alignment Index (ALI-1 and ALI-2) on short and long
chord for each block of 200 m are computed as under:
(1) Alignment Index:
(a) On Short Chord (ALI1):
((𝑆𝐷 −(𝑆𝐷𝑁𝑇𝐿−𝐴𝐿−1))
−[((1.3×𝑆𝐷𝑀−𝐴𝐴𝐿−1 ]
𝐴𝐿𝐼1 = 100 × 𝑒 𝑁𝐵𝑀𝐿−𝐴𝐿−1−(𝑆𝐷𝑁𝑇𝐿−𝐴𝐿−1))
(b) On Long Chord (ALI2):

((𝑆𝐷 −(𝑆𝐷𝑁𝑇𝐿−𝐴𝐿−2))
−[((1.3×𝑆𝐷𝑀−𝐴𝐴𝐿−2 ]
𝐴𝐿𝐼2 = 100 × 𝑒 𝑁𝐵𝑀𝐿−𝐴𝐿−2−(𝑆𝐷𝑁𝑇𝐿−𝐴𝐿−2))
(2) Unevenness Index:

(a) On Short Chord (UNI1):
((𝑆𝐷 −(𝑆𝐷𝑁𝑇𝐿−𝑈𝑁−1))
−[((1.3×𝑆𝐷𝑀−𝐴𝑈𝑁−1 ]
𝑈𝑁𝐼1 = 100 × 𝑒 𝑁𝐵𝑀𝐿−𝑈𝑁−1−(𝑆𝐷𝑁𝑇𝐿−𝑈𝑁−1))
(b) On Long Chord (UNI2):

((𝑆𝐷 −(𝑆𝐷𝑁𝑇𝐿−𝑈𝑁−2))
−[((1.3×𝑆𝐷𝑀−𝐴𝑈𝑁−2 ]
𝑈𝑁𝐼2 = 100 × 𝑒 𝑁𝐵𝑀𝐿−𝑈𝑁−2−(𝑆𝐷𝑁𝑇𝐿−𝑈𝑁−2))
Where,
ALI1 Alignment Index on short chord i.e. on 9.0 metre chord
ALI2 Alignment Index on long chord i.e. on 15.0 metre chord
UNI1 Unevenness Index on short chord i.e. on 9.0 metre chord
UNI2 Unevenness Index on long chord i.e. on 18.0 metre chord
SDM-AAL-1 Average of measured SD value of alignment of left and right rail on short chord
SDNTL-AL-1 SD value of New Track Limit of alignment on short chord
SDNBML-AL-1 SD value of Need Based Maintenance Limit of alignment on short chord
SDM-AAL-2 Average of measured SD value of alignment of left and right rail on long chord
SDNTL-AL-2 SD value of New Track Limit of alignment on long chord
SDNBML-AL-2 SD Value of Need Based Maintenance Limit of alignment on long chord
SDM-AUN-1 Average of measured SD value of unevenness of left and right rail on short chord
SDNTL-UN-1 SD value of New Track Limit of unevenness of short chord
SDNBML-UN-1 SD value of Need Based Maintenance limit of unevenness on short chord
SDM-AUN-1 Average of measured SD value of alignment of left and right rail on short chord
SDNTL-UN-2 SD value of New Track Limit of unevenness on long chord
SDNBML-UN-2 SD value of Need Based Maintenance Limit of unevenness on long chord
Page 204 of 417

512 Track Quality Index (TQI):-
(1) TQI is prescribed for overall assessment of track quality for IR routes categorized in
four different speed bands. The TQI could be worked out by expressions given in (a)
and (b) below using indices for short chord (for all speeds) as well as long chord (for
speeds more than 100 Kmph) respectively. Additionally, a composite TQI can also be
calculated by expressions given in (c) below.
(a) On Short Chord
𝑈𝑁𝐼1 + 𝐴𝐿𝐼1
𝑇𝑄𝐼𝑆 = ( )
2
(b) On Long Chord (For Speed >100 Kmph only)
𝑈𝑁𝐼2 + 𝐴𝐿𝐼2
𝑇𝑄𝐼𝐿 = ( )
2
(c) Composite Track Quality Index (For Speed >100 Kmph only)
𝑈𝑁𝐼1 + 𝐴𝐿𝐼1 + 𝑈𝑁𝐼2 + 𝐴𝐿𝐼2
𝑇𝑄𝐼𝐶 = ( )
4
(2) The TQI values based on the above expressions are only an indicator; the actual
maintenance of track shall be planned on the basis of SD values and peak values of
different track parameters in comparison to respective benchmark values.
513 Oscillation Monitoring System:-
This equipment measures the track performance by measurement of vehicles
response in terms of vertical and lateral accelerations. The real time output of the
equipment is in the form of value of peaks exceeding the limiting value, their locations,
and Ride index. These values are available for both vertical and lateral accelerations.
(1) The OMS equipment used for oscillation monitoring uses a portable accelerometer
and transducers converting the oscillations into electrical signals, which can be
recorded electronically and processed. The OMS equipment used should preferably
be GPS enabled.
(2) (i) The OMS equipment shall be kept in the rearmost coach of the fastest train in the
section or in a dedicated coach, which shall be attached, as last vehicle, to the fastest
train in the section.
(ii) The OMS equipment shall be kept on the coach floor (as close to the bogie pivot
as possible) on the free end of the coach.
(3) The stored data should be uploaded in TMS for analysis and maintenance planning.
514 Frequency of OMS Recording:-
(1) On routes having speed above 100 Kmph – Once every month
(2) Others routes – Once in two months
515 Recording of Defects:-
To assess the track quality, vertical and lateral acceleration peaks exceeding the values as
below are to be considered.
(1) On routes having speed above 110 Kmph (on A & B routes) – Greater than 0.15 g.
(2) Others routes having speed up to 110 Kmph – Greater than 0.2 g.
Page 205 of 417

516 Classification of Track Quality:-
For judging the track quality, the following criteria could be used (average total number of
peaks per km) to classify a continuous section for track quality (SSE/P Way’s
jurisdiction/Subdivision/division):
Track Quality
Very Good Good Average
Section Speed
Speed Above 110 Kmph Less than 1.0 1-2 Greater than 2
Others Less than 1.5 1.5-3.0 Greater than 3
517 Oscillograph Car:-

(1) Brief Description of the Car –
The Oscillograph cars monitor riding quality of track at Maximum Sanctioned Speed
of the section with the help of an accelerometer that digitally records the accelerations.
The vertical and lateral accelerations at the vehicle floor level are recorded by keeping
the accelerometer as close to the bogie pivots as possible.
(2) Frequency of Recording – The frequency of recording shall be as under:
(a) On routes having speed above 110 Kmph and up to 130 Kmph – Once in 6 months
(b) On routes having speed above 130 Kmph and up to 160 Kmph – Once in 4 months
(3) Analysis of Oscillograph Car results –
Vertical and lateral accelerations above the threshold values, mentioned hereunder,
are separately counted.
(a) Loco Cab floor:
In vertical mode - 0.20 g for all locos (Diesel and Electric)
In Lateral mode - 0.20 g for diesel and electric locos (with double stage
suspension)
In Lateral & Vertical mode- 0.30 g (for Locos with single stage suspension)
(b) Passenger Coach Floor:
In vertical and lateral modes - 0.15 g.
(4) Reports and Interpretation of Results –
The km wise analysis and results are given in Annexure - 5/1 under the following
heads (In addition the Speed grouping table) on the basis of the number of peaks
counted above threshold values for a particular locomotive:
(a) Station Yards
(b) Other than Station Yards (Isolated locations)
(c) Active continuous stretches
518 Use of Oscillograph Car Recordings:-
(1) Threshold values of acceleration are given in Para 517 (3). The track should be
attended to at all such locations where peaks above threshold values are reported so
as to ensure good riding.
(2) Efforts should be made not only to check the extent of defect but also to find out
whether it is occurring in an active patch (defined as per Statement A, B and C of
Oscillograph Results)as it may lead to excessive oscillations.
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PART – ‘B’
TRACK TOLERANCES
519 General - The track deteriorates structurally and geometrical Parameters de-grade
with the passage of traffic resulting in decline in ride quality. The rate of deterioration of the
track depends on the quality of track at that point in time. Various limits for track geometrical
Parameters are laid down to assess the ride quality of track and to plan necessary
maintenance interventions during the service life.
520 New Track Tolerances:- (Back to Para 716)
(1) Utmost care should be taken during linking of track to ensure good quality of work. As
a good practice, the laying standards of track geometry for track laid with new Material
are as under: (To be measured three months after speed is raised to normal).
(2) For measurements recorded by TRC.
(a) SD Values for Unevenness and Alignment:
Sl. Speed upto 100 Speed above 100 Kmph; and
Parameter
No. Kmph up to 160 Kmph
1. UN-1 2.0 mm 1.4 mm
2. UN-2 - 1.9 mm
3. AL-1 1.4 mm 1.1 mm
4. AL-2 - 1.3 mm
(b) Peak Values for Unevenness and Alignment:
Sl. Speed upto Speed above 100 Kmph; and
Parameter
No. 100 Kmph upto 160 Kmph
1. UN-1 6.0 mm 4.0 mm
2. UN-2 - 6.0 mm
3. AL-1 4.0 mm 3.0 mm
4. AL-2 - 4.0 mm
(3) For measurements recorded in floating conditions: (Back to Para 429, 715, 716)
(a) Gauge:
For new track and through renewal of track, following tolerances would be applicable-
(i) For straight including curves of radius up to 350 m and more -5 mm to +3 mm
(ii) For curves of radius less than 350 m Up to +10 mm
(b) Other parameters:
S.
Parameter Description of Measurement Value
No
1 Gauge Sleeper to sleeper variation 2 mm
Expansion Over average gap worked out by recording 20
2 ± 2 mm
gap successive gaps
Low joints not permitted High joints not more than + 2 mm
3 Joints
Squareness of joints on straight ±10 mm
Spacing of
4 With respect to theoretical spacing ± 20 mm
sleepers
5 Cross level To be recorded on every 4th sleeper ± 3 mm
6 On straight on 10 m Chord ± 2 mm
Variation over theoretical versines: (On 20 m Chord).
7
Alignment On curves of Radius more than 600 m 5 mm
Variation over theoretical versines: (On 20 m Chord).
8
On curves of Radius less than 600 m 10 mm
Longitudinal Variation with reference to approved longitudinal
9 50 mm
level sections.
Page 207 of 417

521 Planning of Maintenance – (Back to Para 510) For planning/taking up
maintenance of track in respect of Alignment, Unevenness, Gauge and Twist
Parameters based on TRC results, track shall be categorized under following three
categories:
(1) Track requiring planned maintenance
(2) Track requiring need based maintenance
(3) Track requiring urgent maintenance
(a) Planned Maintenance Limit (PML) –
(i) These tolerances provide a guidance to plan through maintenance of track in a
complete block section. These Limits, if exceeded, require that track geometry
condition be analysed and considered for planned maintenance operations.
(ii) The Planned Maintenance Limits (PML) for Unevenness and Alignment are
based on Standard Deviation (SD) values, as these Parameters affect Ride
quality.
(iii) Peak based limits are not stipulated for unevenness and alignment for planned
maintenance as the planned maintenance is to be carried out by track machines
for which the planning will be based on standard deviation values only.
(b) Need Based Maintenance Limit (NBML) –
(i) These limits are defined for applying timely correction before the defects size
grows to the level of Urgent Maintenance Limit (UML); requiring traffic slow
down. Allowable time for attention to defects exceeding the NBML would
depend upon the magnitude of the defects and various factors affecting track
geometry deterioration such as sectional speed, axle load, traffic volume etc.
(ii) The Need Based Maintenance Limits (NBML) are based on Standard Deviation
and peak values for Unevenness and Alignment. For Gauge and Twist, these
limits are based on peak values.
(c) Urgent Maintenance Limits (UML) –
(i) These limits are so specified that upon their exceedances, the permitted speed
should be reduced; which can be restored only after attending the track.
(ii) These are laid in terms of acceleration limits on comfort consideration and peak
values for Gauge and Twist.
522 Maintenance Limits for Different Speed Bands: Based on TRC and OMS
results, various limits of PML NBML and UML for Unevenness, Alignment, Gauge and
Twist Parameters for different speed bands are stipulated as under:
(1) For Speeds up to 100 Kmph:
Planned Need Based Urgent
SN Parameter Maintenance Maintenance Limit Maintenance
Limit (PML) (NBML) Limit (UML)
1 Unevenness
SD-6.8 mm
1.1 UN-1 SD-5.0 mm
Peak-20 mm Vertical and
1.2 UN-2 - - lateral
2 Alignment acceleration
SD-4.9 mm peak of 0.30 g
2.1 AL-1 SD-3.3 mm
Peak -15 mm
2.2 AL-2 - -
3 Gauge
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3.1 Mean gauge over 200 m section over nominal gauge
-10 mm to + 12
(a) Straight - -8 mm to +10 mm
mm
-7 mm to +17
(b) Curve with radius 440 m or more - -5 mm to +14 mm
mm
Curve with radius less than 440 m
-7 mm to +20
(c) (Permissible speed as per relevant - -5 mm to +18 mm
mm
Para of IRPWM)
3.2 Isolated defects – Nominal track gauge to peak value
-12 mm to + 15
(a) Straight - -10 mm to +12 mm
mm
-11 mm to +20
(b) Curve with radius 440 m or more - -7 mm to +17 mm
mm
Curve with radius less than 440 m
-8 mm to +25
(c) (Permissible speed as per relevant - -6 mm to +22 mm
mm
Para of IRPWM)
4 Twist (TW-1) 5 mm/m 7 mm/m
Note: In case of curve, the limits for alignment prescribed are above average versine.
(2) For Speeds above 100 Kmph and up to 110 Kmph:
Planned Need Based
Urgent Maintenance
SN Parameter Maintenance Maintenance Limit
Limit (UML)
Limit (PML) (NBML)
1 Unevenness
SD-5.5 mm
1.1 UN-1 SD-3.8 mm
Peak-17 mm
SD-7.5 mm
1.2 UN-2 SD-5.4 mm Vertical and lateral
Peak-23 mm
acceleration peak of 0.30
2 Alignment
g
SD-3.9 mm
2.1 AL-1 SD-2.5 mm
Peak -12 mm
SD-6.7 mm
2.2 AL-2 SD-4.1 mm
Peak-20 mm
3 Gauge
(a) Straight - -8 mm to +10 mm -10 mm to + 12 mm
Curve with radius 440
(b) - -5 mm to +14 mm -7 mm to +17 mm
m or more
Curve with radius
less than 440 m
(c) (Permissible speed - -5 mm to +18 mm -7 mm to +20 mm
as per relevant Para
of IRPWM)
Curve with radius 440
(b) - -7 mm to +17 mm -11 mm to +20 mm
m or more
Curve with radius
less than 440 m
(c) (Permissible speed - -6 mm to +22 mm -8 mm to +25 mm
as per relevant Para
of IRPWM)
Page 209 of 417

Planned Need Based Urgent
SN Parameter Maintenance Maintenance Limit Maintenance Limit
Limit (PML) (NBML) (UML)
1 Unevenness
SD-4.9 mm
1.1 UN-1 SD-3.3 mm
Peak-15 mm
SD-7.4 mm
1.2 UN-2 SD-5.1 mm Vertical and lateral
Peak-22 mm
acceleration peak of
2 Alignment
0.25 g
SD-3.6 mm
2.1 AL-1 SD-2.5 mm
Peak -11 mm
SD-5.3 mm
2.2 AL-2 SD-3.5 mm
Peak-16 mm
3 Gauge
Curve with radius 440 m or
(b) - -5 mm to +14 mm -7 mm to +17 mm
more
Curve with radius less than
440 m (Permissible speed
(c) - -5 mm to +18 mm -7 mm to +20 mm
as per relevant Para of
IRPWM)
Curve with radius 440 m or
(b) - -7 mm to +17 mm -11 mm to +20 mm
more
Curve with radius less than
440 m (Permissible speed
(c) - -6 mm to +22 mm -8 mm to +25 mm
as per relevant Para of
IRPWM)

Planned Need Based
Urgent Maintenance Limit
SN Parameter Maintenance Maintenance
(UML)
Limit (PML) Limit (NBML)
Vertical and lateral
1 Unevenness
acceleration peak of 0.20 g
SD-4.4 mm
1.1 UN-1 SD-2.9 mm
Peak-13 mm
SD-6.6 mm
1.2 UN-2 SD-4.4 mm
Peak-20 mm
2 Alignment
SD-3.6 mm
2.1 AL-1 SD-1.9 mm
Peak -11 mm
SD-4.9 mm
2.2 AL-2 SD-2.5 mm
Peak-15 mm
3 Gauge
-6 mm to +10
(a) Straight - -8 mm to + 12 mm
mm
Curve with radius 440 m or -5 mm to +13
(b) - -7 mm to +15 mm
more mm
Curve with radius less than 440
-5 mm to +18
(c) m (Permissible speed as per - -7 mm to +20 mm
mm
relevant Para of IRPWM)
Page 210 of 417

-8 mm to +12
(a) Straight - -10 mm to + 15 mm
mm
Curve with radius 440 m or -6 mm to +16
(b) - -9 mm to +20 mm
more mm
Curve with radius less than 440
-6 mm to +22
(c) m (Permissible speed as per - -8 mm to +25 mm
mm
relevant Para of IRPWM)
4 Twist (TW-1) 3.5 mm/m 5 mm/m
523 Action to be Taken Based on TRC Results: (Back to Para 510, 602, 604)
(1) Action to be taken on exceedance of UML:
Spots/blocks exceeding track Parameter limits, and acceleration peak limits set as
UML should be noted by the ADEN and SSE accompanying the TRC and suitable
speed restrictions have to be immediately imposed, which shall be relaxed only after
suitable attention/maintenance of track at concerned location. Similar action should
be taken on exceedance of UML during OMS run also.
(2) Action to be taken on exceedance of NBML:
(i) The blocks requiring Need Based Maintenance on the basis of laid down SD based
NBML and isolated spots on the basis of laid down Peak based NBML shall be
identified using offline software or through TMS. All such blocks and isolated spots
should be attended within a reasonable time of TRC run so that good ride quality
is maintained and the track geometry does not exceed the UML. The reasonable
time would be different for different sections depending upon the magnitude of
defects, cause of the defect, traffic density of the section, maximum permissible
speed of the section etc. The officials responsible for maintenance at various levels
have to plan the deployment of maintenance resources keeping in view the relative
priority and availability of maintenance resources.
(ii) Gap between two successive NBML locations in block sections/yards should also
be tamped while attending these NBML locations if this gap is less than/equal to
200 m. (1 TRC block).
(iii) While attending an NBML block in the yard in which any portion of the turnout falls,
the entire turnout should be tamped.
(3) Planning of through tamping based on PML:
(i) The blocks requiring planned maintenance on the basis of laid down SD based
PML shall be identified for block sections and for yards separately using off line
software or through TMS.
The block section for any main line should be treated from block (TRC block of 200
m) of last SEJ of preceding station to block of first SEJ of current station. Both the
blocks containing above SEJ would be excluded from the block section on any
particular line (UP & DOWN separately).
Similarly, the yard would be treated from a block of 200 m containing 1st SEJ to
block of last SEJ on any particular line (UP & DOWN separately) of the concerned
station/yard.
In case of CWR through yards, the yard should be taken as 50 metres beyond
farthest SRJ/ Back of crossing of turnout from centre of station yard on either side
on any particular line (UP and DN separately).
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(ii) The block section should be planned for through tamping if the percentage of
blocks exceeding PML is more than 40%.
(iii) Yards should be planned for through tamping if the percentage of blocks exceeding
PML is more than 50%.
Tamping of turnouts and straight of all other passenger loop lines should be
planned on condition basis by ADEN while machines are deployed in yard for need
based or planned attention of main line of yards.
(4) Maintenance action when track recording is not done
(i) For sections in which TRC has not run for more than one year and the last tamping
has been done more than two years before, the need based maintenance and
urgent maintenance should continue to be carried out based on OMS recording
and other inspections.
(ii) Sectional Sr.DEN/DEN should periodically (at suitable intervals not greater than
six months) review the need for maintenance of track of each such block sections
/ yards based on OMS recording , other inspections and other maintenance
considerations.
(iii) Through tamping of such block sections / yards, if considered necessary based on
OMS recording and other considerations, should be proposed for inclusion in
planning of Through Tamping by Sr.DEN / DEN of section through Sr.DEN /
Coordination of Division for approval of CTE.
524 Realignment Criteria for Curves:- (Back to Para 418)
The running over a curve depends not only on the difference between the actual
versine and the designed versine but also on the station to station variation of the
actual versine values, which determine the rate of change of lateral acceleration, on
which depends the riding comfort.
Sl. No. Speed on curve Limits of Station to Station Variation of Versine (mm)
10 mm
160 Kmph and up
1 (15 mm for speed of 110 Kmph); or
to 110 Kmph
20% of average Versine on circular portion, whichever is more.
Below 110 Kmph 20 mm; or
2
and up to 50 Kmph 20% of average Versine on circular portion, whichever is more.
40 mm; or
3 Below 50 Kmph
20% of average Versine on circular portion, whichever is more.
In case exceedances of the above Limit is observed during inspection, local
adjustment may be resorted to in cases where the variation of versine between
adjacent stations is only at a few locations, at the earliest possible. If more than 20%
stations are having versine variations above the limits prescribed, complete
realignment of curve should be planned within a month.
525 Track Parameters in Floating Conditions:- (Back to Para 429, Ann. 6/9)
The Gauge and Twist values for manual measurement in floating conditions are as under:
(1) Gauge:
While it is desirable to maintain correct gauge, variation in gauge may be there due
to age and condition of the rail, sleepers, and fastenings. The limits of gauge as per
measurement in floating condition, for the guidance of the engineering officials
regarding condition of track from passenger comfort perspective shall be as given
below, provided that generally a uniform gauge can be maintained over long lengths.
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a) On straight Track -6 mm to +6 mm
b) On curves with radius 440 m or more -6 mm to +15 mm
c) On curves with radius less than 440 m Up to + 20 mm
In case of exceedances of these limits, the results of last TRC/OMS shall be analyzed
for planning suitable maintenance action.
(2) Twist:
It is desirable to maintain the track geometry for a comfortable ride at sectional speed.
The limits of twists as per measurement in floating condition, for guidance of the
engineering officials regarding condition of track from passenger comfort perspective
shall be as under; (to be calculated on a base of 3.0 m)
(i) On straight and curve track, other than transition - 3.5 mm/m
(ii) On transition of curve- 2.1 mm/m (Local defects above Designed value)
In case of exceedances of above limits, the results of last TRC/OMS shall be analyzed
for planning suitable maintenance action.
526 Track Parameters for Low Speeds:-
For guidance of field officials, following track Parameters are stipulated in floating
conditions, for maintenance of tracks where speeds are low such as worksite, yard
line, etc.
Peak value of UN Peak value of twist
Speed Permissible gauge
(on 3.6 m chord) (on 3.0 m chord)
(in Kmph) range
in mm in mm
Up to 45 22 18 -10 to +27 mm
Up to 30 24 21 -10 to +27 mm
Up to 15 33 25 -12 to +27 mm
527 Stability of Trains Against Derailment: The stability of trains against derailment
depends upon several factors such as track geometry, vehicle characteristics and
state of their maintenance and speed of the particular vehicle at relevant point of time
etc. Rail wheel interaction is, thus, a complex phenomenon and, therefore, safety
tolerance for track alone cannot be prescribed in Isolation. Accordingly, safety
tolerances for maintenance of track have not been prescribed on Indian Railways.
Each derailment case, therefore, needs careful examination of all available evidence,
in respect of track, rolling stock, speed and other factors considered relevant, to arrive
at the cause. The provisions and tolerances mentioned herein before and elsewhere
in this Manual are with a view to maintain track geometry for good riding comfort
considered and deviation from these maintenance Parameters should not be
considered alone for cause of accident without examining all evidences mentioned
above.
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Typical Statement prepared in connection with an Oscillograph car run are given below
(Statement 'A' to 'C')
STATEMENT 'A'
Total length of Section: 232 kms Section: BBQ—KZJ
Length recorded: 185 kms Loco No ....................
Date of recording: 22nd March 2019 Type of Loco .............
Oscillograph Results Station Yards (Peaks above Threshold values)
SN Name of Yard Speed in Vertical Lateral remarks
and Location Kmph acceleration g acceleration g
1 SRUR 100 .. 0.26
FP-2 100
2 MCI 100 0.22
TP-1 100 0.22
TP-2
3 PPZ 105 0.20
FP-1 0.20
FP-2
4 BGSF 110 0.22
324/10-11
5 OPL 100 0.26
343/5-
6 HSP 100 0.20
TP-1
STATEMENT 'B'
Date of recording 22nd March 2018 Section: BPQ—KZJ (km 367- km 135
Loco No.: ................................ Length recorded: 185 km
Type of Loco: ............... Total length: 232 km
Oscillograph Results in Places other than Station Yards
Isolated Locations (Peaks above Threshold value)
SN Location Speed in Kmph Vertical Lateral Remark
acceleration g acceleration g
1 146/1-2 100 0.28 Curve
2 148/15-16 110 0.28 Br
3 149/7-8 110 0.28
4 149/7-8 110 0.35 Br
5 151/8-9 110 0.24
6 151/8-9 110 0.32
7 151/11-12 105 0.24
8 160/7-8 110 0.22 Curve
9 164/9-10 110 0.24
10 168/1-2 100 And so on 0.30
STATEMENT 'C'
Date of recording 22nd March 2018 Section: BPQ—KZJ (km 367- km 135
Loco No.: ................................ Length recorded: 185 km
Type of Loco: ............... Total length: 232 km
Oscillograph Results Active Continuous Stretches
S Km Distan Speed Active Total Maxim No. of No. of Rema
N From To ce in in in No of um peaks peaks rks
km Kmph mode peaks value between above
above 0.20 g. 0.30 g
0.20 g 0.30 g
Nil
Note – If there are on an average more than 10 peaks above the threshold value per km, the length
may be included in this statement.
Page 214 of 417

CHAPTER – 6
MAINTENANCE OF PERMANENT WAY
*********************
PART – ‘A’ - REGULAR TRACK MAINTENANCE
601 Track Maintenance:-The track should be maintained with the objective of restoring
it to best possible condition consistent with its maintainability by Mechanized system
of maintenance as per Para 604. However, till complete mechanization, few activities
like picking up of slacks may be done manually.
602 Annual Programme of Track Maintenance: -The annual machine deployment
programme shall be issued by CTE for track renewal, rail grinding, deep screening
and shoulder screening machines based on yearly requirement of track maintenance.
For other machines, the deployment programme shall be decided by Sr. DEN / Co
which will be periodically reviewed based on TRC results and Para 523. Field
engineers will also make annual (two half-yearly, first: April to September and second:
October to March) programme of regular track maintenance and works incidental
thereto which shall be consistent with annual machine deployment programme. The
annual programme of regular track maintenance and works incidental thereto may be
followed for guidance as below:
Annual Programme for Regular Track Maintenance
(a) Post monsoon Immediately after cessation of monsoon, attention to run down lengths, need
attention based maintenance or works incidental to requirement of urgent
maintenance as projected by OMS/TRC recording or identified during
footplate inspections should be taken up in the entire gang beat to restore
section to good shape.
Thereafter, the following schedule of work may be followed:
(i) Picking of slack: 1-2 days in a week
(ii) On remaining days Systematic planned/Need Based maintenance,
from one end of the section to the other as necessitated by TRC
results, including through gauging, Sleeper spacing/squaring, casual
renewals of rails/sleepers, attention to bridge approaches, level
crossings and points & crossings, SEJs, Glued Joints, lubrication of
rail joints, weld collar painting, Destressing of track, Cold weather
patrolling, etc.
(b) Pre-monsoon Normally 2 to 3 days in a week should be devoted to clearing of side and
attention catch water drains, earthwork repairs to cess, clearing waterways and picking
up slacks.
In the rest of the days normal systematic planned/Need Based maintenance
as necessitated by results of TRC/OMS etc., will be carried out, which
include through gauging, Sleeper spacing/squaring, casual renewals of rails
and sleepers, Shallow screening of specified lengths, Destressing of
track, Hot weather patrolling etc.
(c) Attention during Attention to track as required, consisting primarily of picking up slacks or
monsoon need based maintenance and attention to side and catch water drains and
waterways.
During abnormally heavy rains, patrolling of the line by gangs should be
carried out in addition to regular monsoon patrolling.
603 Maintenance Planning:-

Every SSE/P.Way (In-charge) should prepare a perspective maintenance plan of his
section in advance based on various track recording results and exception reports
from TMS. This should also take account of trolley and footplate inspections and
inspection of higher officials so that optimum utilization of various resources, track
machines, traffic blocks, and labour etc. is possible. Every SSE/P.Way (In-charge)
should also ensure that arrangements are made for adequate Materials, tools, labour,
man power and necessary caution orders/blocks, as may be necessary. The monthly
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and weekly maintenance planning shall be based broadly on annual plan to include:
(a) Plain track maintenance,
(b) Maintenance of yards including point and crossings,
(c) Maintenance and realignment of curves,
(d) Level crossings,
(e) Adjustment of creep, (SWR, Fish Plated track)
(f) Deep screening,
(g) Casual renewal,
(h) Renewal of over-aged assets such as points and crossings, SEJs, Glued Joints,
welds etc.
(i) Welding of joints,
(j) Destressing of long welded rails etc.
604 Mechanised Track Maintenance System:- (Back to Para 601)
The 3 tier system of track maintenance shall be adopted on sections nominated for
Mechanized track maintenance. This shall consist of the following 3 tiers of track
maintenance –
• On-track Machines Unit (OMU)
• Mobile Maintenance Gang (MMG)
• Sectional Gangs.
1) On-track Machines Unit (OMU): On track machines for track maintenance include Tie
– tamping machines for plain track and points and crossings, shoulder ballast cleaning
machines, ballast cleaning machines, ballast regulating machines, dynamic track
stabilizers and UTV.
These machines shall be used as per the various instructions contained in Indian
Railways Track Machines Manual and Para 523. These machines shall be deployed
to carry out the following jobs:
a) Systematic tamping of plain track as well as Points & Crossings;
b) Intermediate tamping of plain track as well as Points & crossings;
c) Shoulder ballast cleaning;
d) Ballast profiling/redistribution;
e) Track stabilization;
f) Periodical deep screening;
g) Picking up and transportation of Material.
2) Mobile Maintenance Gang:
a) There will be one Mobile Maintenance Gang (MMG) under each SSE/P.Way (In
overall charge) with a jurisdiction of about 70-80 km in single line section and 30
to 50 km in double or multi line section. lt will be headed by a sectional JE/SSE
P.Way/ (MMG) and shall be based on a Rail Borne Maintenance Vehicle (RBMV)
for mobility. Till RBMV are arranged for all In-charge SSE/P.Way. The activities
listed hereunder except (b) (viii) shall be done by sectional gangs.
b) The functions of MMG shall be as under:
(i) Repair to rail/weld fracture including in-situ AT welding.
(ii) Attention to SEJs.
(iii) Scattered replacement of switches and crossing components, glued joints,
SEJs, etc.
(iv) Rail cutting/drilling and chamfering.
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(v) Spot renewals of rails and sleepers.
(vi) Spot attention by Tamping of few sleepers with off-track tampers or any other
approved equipment.
(vii) Loading and unloading of Material required for spot attention.
(viii) Driving of RBMV.
(ix) Any other functions assigned.
c) The MMG shall possess the equipment and other accessories as given in
Annexure - 6/1, which shall be used according to the working instructions and
manufacturer's operating instructions.
3) Sectional Gangs: The sectional gangs shall perform the following functions:
a) Systematic through packing of track where tamping machines have not been
deployed or small stretches of track needing spot attention for which machines
cannot be deployed due to whatever reasons.
b) Overhauling of track.
c) In addition to above following works are /may also be assigned:
(i) Patrolling of track:
• Keyman’s daily patrol
• Hot/cold weather patrolling
• Monsoon Patrolling
(ii) Watching vulnerable locations
(iii) Need-based attention to bridges, turnouts, SEJs and level crossings and their
approaches.
(iv) Greasing of ERCs, lubrication of joints, casual changing of rubber pads and
other fittings
(v) Minor cess repairs
(vi) Cleaning of drains
(vii) Attention to loops
(viii) Creep and gap adjustment not involving use of machines
(ix) Pre & post tamping attention
(x) Examination of rails, sleepers and fastenings including measurement of toe load
of ERCs.
(xi) Inspection of and attention to insulated joints, switch expansion joints etc.
(xii) Weld collar painting, cess cleaning, cutting of tree branches/shrubs for
improving visibility.
(xiii) Any other functions assigned.
605 Systematic tamping of plain track and Points & Crossings:-
(1) General: Systematic tamping of plain track as well as Points & Crossings should be
planned on long continuous lengths, based on results of TRC/OMS etc.
(2) Deployment of Tamping Machines:
Deployment of tamping machines for plain track and Points & crossing shall be based
on results of TRC/OMS, the past history of deterioration of track, traffic GMT, type of
formation, condition of track and its components
(3) Pre-requisites to introduction of mechanical maintenance –
(a) A minimum depth of 150 mm of clean ballast cushion below the bottom of the
sleepers is recommended for the proper functioning of the tie tampers. Adequate
ballast should be available in the shoulders and cribs.
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(b) For this purpose, planning and execution of deep screening of ballast, where
required, as well as running out of ballast should be done well in advance.
(c) Time allowance for working the machines should be provided in the working
timetable. The block time should be interpolated in the master chart for passenger
and goods trains that is prepared with every change in timetable.
(d) It is as much the responsibility of the Operating Department as that of the
Engineering Department to ensure provision of adequate time for economical
working of machines.
(4) Pre-tamping attention – To achieve good results the JE/SSE/P.Way should carry out
the following preparatory work before taking up the tamping:
(a) Ballasting where there is shortage of ballast.
(b) Heaping up of ballast in the tamping zone, to ensure effective packing.
(c) Making up of low cess.
(d) Cleaning of pumping joints and providing additional clean ballast, where
necessary.
(e) Attention to hogged joints before tamping.
(f) Tightening of all fittings and fastenings like fish bolts and elastic fastenings and
replacement of worn out fittings.
(g) Renewing broken and damaged sleepers.
(h) Squaring of sleepers and spacing adjustment; re-gauging to be done as necessary.
(i) Adjusting creep and expansion gap in rails.
(j) Examination of rails for cracks, sleepers and fastenings etc.
(k) Survey for Realignment of curves, which are badly out of alignment.
(l) Clearing of ballast on sleepers to make them visible to the operator.
(m) All obstructions such as signal rods, cables, pipes, level crossing check rails,
joggled fish plates etc., likely to be damaged by the tampers should be preferably
removed. In unavoidable case, these should be clearly marked and made known
to the tamping operator before he starts work. Tight overhead clearance should
also be brought to his notice; the beginning and end of transitions should be
marked. Slew, Super elevation and lift value, if any should be marked on every
second/third sleeper so that it can guide the operator for levelling up correctly.
(5) Attention during Tamping – The following points should be observed by the machine
operator and JE/SSE/P.Way:
(a) The tamping depth i.e. gap between the top edge of the tamping blade and the
bottom edge of the sleeper in closed position of the tamping tool should be adjusted
to 15 mm to 20 mm. Care should be taken to ensure that tamping tools are inserted
centrally between the sleepers into the ballast to avoid any damage to the sleepers.
(b) The tamping (squeezing) Pressure (110 – 120 Kg/Sq. Cm for plain track and 125-
135 Kg/Sq.cm for P&C) and squeezing time (0.8 second to 1.2 second) should be
adjusted according to the track structure, as per the recommendations of the
manufacturer.
(c) Generally, one insertion is adequate. Two insertions may be necessary if the lift is
above 30 mm.
(d) The shoulders should be compacted along with tamping, where separate provision
for shoulder compaction is available.
(e) A run-off ramp of 1 in 1000 should be given before closing the day’s work.
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(6) Post Tamping Attention – The JE/SSE/P.Way shall pay attention to following points:
(a) Immediately after the tamping work, the track should be checked for quality of work
done, in respect of cross levels and alignment, and action taken as considered
necessary
(b) As some of the fastenings might become loose, tightening of fittings should be
done immediately after tamping.
(c) Any broken fitting/sleeper should be replaced.
(d) The ballast should be dressed neatly and proper filling and consolidation of ballast
between the sleepers should be done.
606 Picking Up Slacks:-
(1) Slacks usually occur on stretches of yielding formation, on high banks and cuttings,
on approaches of bridges, LC approaches, SEJs, P&C zones, Glued Joints, on badly
aligned curves, axle counter locations and other electrical and S&T installations where
ballast is poor in quality or quantity or where drainage is defective. Need for attention
to slacks is determined by inspections and results of track recording car and
OMS/Oscillograph car. The locations needing urgent maintenance as detected by
TRC/OMS shall be targeted first for restoring normal condition quickly and thereafter
the locations identified for Need Based Maintenance as determined by Track
recording Car or other inspections shall be attended. For spot attention/slack picking,
multipurpose Tampers and Off-track hand held tampers/ any other approved
equipment shall be used as a regular measure.
(2) For Off-track tampers, the working instructions, issued by Railway Board/RDSO
should be followed. As an interim measure, where Off-track tampers are not available,
packing may be done with the help of Crowbar/Beater, duly taking care that concrete
sleepers are not damaged.
(3) The quantum of work turned out by a gang during the day will depend on the extent
of slacks. In all cases, sighting is done, the defects assessed and marks made with
chalk on sleepers to be attended. The marked sleepers should then be dealt with as
in through packing as given in Para 607, care being taken to see that the packing of
adjacent sleepers does not get disturbed. In case a large percentage of sleepers
needs attention in a rail length, the entire rail length should be attended to. The
marking of defects shall be as indicated below –
Sl. No. Defects Symbol Place of indication
1 Cross levels C-2 On the sleeper inside gauge face.
2 Loose packing H or P On the sleeper outside the gauge face
3 Gauge G± On the sleeper inside the gauge face
4 Unevenness → ← On the rail web on gauge face side
↓
5 Alignment On the foot of rail inside the gauge face
→
(4) In the case of a low joint, the fishplates should be slightly loosened and the joint
tapped, so that the rail ends are, rendered free and are capable of being lifted. After
the joint is thoroughly packed the fishplates should be tightened again. When joints
are picked up, at least three sleepers on either side of the joints should be packed.
(5) If the length of track marked for need based maintenance is more in a Kilometer then
this should be attended by on track Machine
607 Through Packing by Conventional Manual Method:- (Back to Para 345, 609)
Normally manual through packing is not to be done in concrete sleeper track.
However, in locations of slacks where multipurpose tampers are not available,
following steps in sequence shall be followed. The length of track opened out on any
one day shall not be more than that can be efficiently tackled before the end of the
day –
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(a) Opening of the road.
(b) Examination of rails, sleepers and fastenings.
(c) Squaring of sleepers.
(d) Slewing of track to correct alignment.
(e) Gauging.
(f) Packing of sleepers.
(g) Repacking of joint sleepers.
(h) Boxing of ballast section and tidying.
The details of various steps listed above is given in Annexure - 6/9. The provisions
of Part D of Chapter 3 should be followed, wherever through packing is being done in
LWR/CWR track. Appropriate small track machines should be deployed instead of
conventional tools for carrying out various operations, wherever feasible.
608 Observance of Sleepers under Passage of Traffic:- During the passage of the
trains within working hours, the Gang Mate and Track Maintainers at the work site
should stand on the cess each about one rail-length apart on either side of the portion
of track they are attending to, and observe the movement of sleepers under load.
Immediately after the passing of train, loose sleepers should be marked, packed
uniformly and the packing tested. In respect of other trains, the Gang Mate and the
trackmen should observe the sleepers near where they are working and take similar
action. Firm and uniform packing is the primary need for good track maintenance.
609 Systematic Overhauling:-
The length of the section to be overhauled shall be such that complete overhauling of
track will be accomplished within a specific period (normally 3 to 5 years). The
overhauling should be done using SBCM for cleaning of shoulder ballast. The crib
ballast should also be shifted to shoulders for screening by the machine, which should
again be put back in crib portion. In case it is not feasible to screen the crib ballast by
machine, the same should be screened manually. Adequate care should be taken in
removing the crib ballast in LWR/CWR track.
All the loop lines should be shallow screened/overhauled once in 7 years or more
frequently as required, along with systematic tamping/packing.
(1) Sequence of operations – Overhauling consists of the following operations in
sequence –
(a) Shallow screening and making up of ballast.
(b) All items attended to, while doing through packing as detailed in Para 607.
(c) Making up the cess.
(2) Shallow Screening and making up of Ballast –
(a) For good drainage periodical screening of ballast is essential.
(b) In case of manual overhauling, the crib ballast in the shoulders should be opened
out to a depth of 75 to 100 mm below the bottom of sleepers, sloping from the
centre towards sleeper end. The ballast in the shoulders opposite to the crib as
well as between the sleepers is removed to the full depth. A slope is given at the
bottom sloping away from the sleeper end. The ballast is then screened and put
back. Care should be taken to see that the packing under the sleepers is not
disturbed and the muck removed is not allowed to raise the cess above the correct
level.
(c) Two contiguous spaces between sleepers should not be worked at the same time.
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(d) Screening should be progressed in alternate panels of one rail length. In no
circumstances should several rail lengths of track be stripped of ballast
simultaneously.
(e) Where drains across the track exist, they should be cleaned and filled with boulders
or ballast to prevent packing from working out and forming slacks.
(f) After screening, full ballast section should be provided, extra ballast being run out
in advance for the purpose. Work should be commenced after making sure that
the ballast will not be seriously deficient. Deficiency, if any, should be shown in the
central portion of sleeper and this also should be made up soon.
(3) Through packing of track – The detailed operations are described in Para 607.
Through packing may be done preferably by using machines and in unavoidable
situations by conventional beater packing.
(4) Making up of Cess – Cess when high should be cut along with overhauling and when
low should be made up. A template should be used for this purpose.
(5) Overhauling should be completed before the end of March.
(6) Overhauling of SWR/LWR/CWR track –
In such cases the relevant provisions detailed in Para 324 & 345 should be followed.
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PART – ‘B’
HANDLING AND MAINTENANCE OF RAILS, SLEEPERS,
FASTENINGS & OTHER MISC. ITEMS
610 Handling and Stacking of Rails:
(1) Any carelessness in loading, unloading, handling and laying of rails is liable to cause
damage, which will not only contribute towards bad running but also result in
irreparable damage to, or incipient failures of rails.
(a) During loading and unloading, ramps of un-serviceable rails should be made and
the rails slid over them, intermediate supports being given to prevent excessive
sagging. Preferably, crane may be used for loading/unloading of single rails.
(b) For handling rails, slings or tongs should be used.
(c) When hauled into position, prior to linking or otherwise, rails should be so spread
as to rest evenly along their entire length or on supports closely spaced and should
lie on the foot.
(2) During any operation requiring marking of rails such as yard surveys, curve
adjustments, and realigning operations etc., the marking on rail shall be done by paint
mark only and chisel or punch marking is not permitted.
(3) The gas cutting of rails; and making of holes using gas is prohibited.
(4) While stacking rails, care shall be taken that –
(a) The ground is level and well drained.
(b) Free rails are supported at least at four points, evenly along their length; Welded
rail panels shall be so spread on cess as to rest evenly along their entire length on
supports spaced at 4 metre centre to centre to prevent formation of kinks.
(c) Each stack of the rail should be of the same section and class.
(5) Detailed guidelines on stacking of rails as contained in RDSO's Guidelines for
Handling and Stacking of Rails (No. CT-35) may be referred to.
611 Inspection of Rails in Service:-
(1) General- The detection of rail flaws is done by visual examination of the rail and by
Ultra Sonic Flaw Detection (USFD) of rails.
(2) Visual examination of Rails –
Rail ends should be examined for cracks during the lubrication of rail joints by cleaning
the surface of the rail by wire brush and using a magnifying glass. A small mirror is of
assistance in examining the underside of rails. Such examination on important girder
bridges and their approaches should be done twice a year under the supervision of
JE/SSE/P.Way.
(3) USFD Testing of Service Rails: No rail, untested by USFD, shall be laid in the track
whether for new lines or layouts or renewals or for repair works or even temporarily
such as service rails for PQRS work.
(4) The JE/SSE/P.Way carrying out the ultrasonic testing of rails shall be trained by
RDSO. Detailed instructions for ultrasonic testing of rails and welds are contained in
the “Manual for Ultrasonic Testing of Rails and Welds”.
612 Causes of Rail Deterioration:-The principal factors causing rail deterioration are
detailed below: (Back to Para 310 (2) (b))
(1) Corrosion and rusting – Corrosion is caused not so much by the dampness as by acid
gases dissolved in the film of moisture, which frequently coats the rails. Corrosion is
generally noticed on the web and foot of the rail. Corrosion is generally heavy in the
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following locations:
(a) Platform lines where trains make prolonged halts.
(b) Sidings where saline or corrosive goods are dealt with.
(c) Near water hydrants due to insufficient drainage.
(d) Tunnels and deep cuttings.
(e) Areas near the seacoast.
(f) Industrial belts.
(2) Wear on Rail Table – The wear of top table increases with higher traffic density as in
suburban section, though not proportionately.
(3) Flattening of rail table —This mostly occurs on the inner rail of a curve because of
higher contact stresses due to heavy axle loads, large un-sprung mass or under
equilibrium speed on canted track, which causes slipping of wheel sets. Flattening of
rail table is an indication of overloading on inner rail; and this tendency can be
reduced, if appropriate cant is provided.
(4) Wear on Gauge Face – The outer rail of a curve has to withstand heavy pressure from
the wheels, which results in the running edge becoming worn or ‘side-cut’. Wear on
gauge face is especially pronounced in case of suburban sections where rolling stock
are provided with laterally un-sprung traction motors.
(5) Hogging of rail end – A hogged rail is one with its end or ends bent in vertical direction.
A hogged rail end in the track is ascertained by un-fishing the joints, removing the
fastenings and then measuring the extent of hog at the rail end by placing a 1 metre
long straight edge over the rail table, centrally over the joint as shown in the sketch
below –
HOGGING OF RAIL – METHOD OF MEASUREMENT

(6) Battering of rail ends – Rail end batter occurs where the joint gaps are excessive. It
is caused by the impact of wheels on end of a rail particularly if the fishplates do not
fit snugly. Rail end batter is measured as the difference in heights of the rail at its end
and at a point 30 cm away from the rail end as shown in the sketch below:
RAIL END BATTER – METHOD OF MEASUREMENT
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(7) Wheel burns – Wheel slipping occurs usually on adverse gradients or while starting
on rising grades when considerable heat is generated and top of the rail is torn off in
patches, causing depressions known as wheel burns, from which cracks may develop.
This also occurs when train brakes are applied suddenly and wheels lock and slide,
or due to under-powering of trains. Wheel burns cause the wheels to hammer the rails
and lead to difficulties in keeping the sleepers packed firmly and fastenings tight. Such
rail should be kept under observation and changed, in case repair by welding is not
feasible.
(8) Corrugation – In certain locations, rail table develops ridges and hollows called
corrugation and when vehicles pass over these rails, a roaring sound ensues. Such
rails are called “roaring rails”. In such locations, excessive vibrations are caused, due
to which fastenings and packing tend to get loose and track needs frequent attention.
613 Rail Maintenance to reduce Rail Deterioration:-
(1) Efficient maintenance of rails results in increased service life of rails. The following
precautions/maintenance practices, if observed, will effectively reduce rail
deterioration.
(2) Prevention of corrosion:
(a) Identification and measurement –
(i) Areas prone to corrosion of rails shall be identified by the Principal Chief
Engineer of the Railway on the basis of reports sent by Divisional Engineers.
(ii) In corrosion prone areas identified in accordance with above Para,
measurement of depth of corrosion both vertically and laterally (reduction in
bottom flange width of rail), shall be done using straight edge and feeler gauge
or any other suitable device at a fixed periodicity of once in a year on every 100
sleepers by removing Elastic Rail Clips and liners and such measurements shall
be recorded in TMS by JE/SSE/P.Way as per Annexure - 6/5.
(iii) For new line/gauge conversion projects, corrosion prone areas shall be
identified by CAO(C) in consultation with Principal Chief Engineer.
(b) Anti-corrosive painting –
(i) In case of the new rails to be laid during track renewal/doublings/other
construction projects in identified corrosion prone areas, anti-corrosive
bituminous coating as per procedure mentioned in (iii) below should be provided
before laying in track. This should preferably be done in Flash Butt Welding
Plants.
For severe corrosion prone areas, wherever possible, Zinc metallisation in lieu
of bituminous painting in centralized plant/ Flash Butt Welding plant can also be
done. The Zinc metallisation shall be done as per procedure laid down in
Technical Specification for Zinc Aluminium metallisation of Rails (IRS: T-51).
(ii) In case of rails that are already laid in track in identified corrosion prone areas,
anticorrosive bituminous coating to rails should be given in the track itself as per
procedure mentioned in (iii) below.
(iii) Surface preparation of rails shall be done, with the help of hand operated or
power operated tools i.e. scrappers, wire brushes, sand paper, pumice stones
etc. Wire brushing shall invariably be done at the end so as to obtain uniform
rubbed surface.
The surface prepared shall be checked visually for uniformity of surface. Special
care should be taken in surface preparation at weld collars and liner contact
areas. Surface preparation should not be done when ambient temperature is
below 10° C or above 50° C, in rainy season, during night, in winter before 8AM,
in summer between 11AM to 3PM and in extremely windy/misty/dusty
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conditions. Chemical should not be used for surface preparation. Painting
should be done in two coats of thickness of 100 microns each by anti-corrosive
bituminous black paint conforming to IS: 9862 after an interval of 8 hours
between two coats. All the liners and Elastic Rail Clips shall also be painted with
anti-corrosive black bituminous paint after duly cleaning the surface.
(iv) In identified corrosion prone areas, bituminous painting of rails shall be done
once in a year on inside of gauge face including web and flange and once in
three years on non-gauge face side of rail including web and flange. In other
areas, wherever signs of corrosion are seen in isolated patches, prompt action
for anti-corrosive painting shall be taken.
(c) Greasing and sealing of liner contact area – In identified corrosion prone areas,
the rail liner seat should be greased using graphite grease IS-408-1981 Gr. O
specification after proper cleaning. The grease is also applied all around the liner
on the rail foot on gauge face side to prevent the ingress of toilet droppings in the
gap between the liner and the rail foot. Greasing and sealing of liners contact area
shall be done once in year for gauge face side and once in two years on non-gauge
face side of rail.
(d) Shifting of liner locations – Shifting of liner location on rail foot at regular intervals
is desirable to ensure that the effect of corrosion is not allowed to build up at liner
locations and render rails vulnerable to fractures due to increased depth of liner
bite pits.Longitudinal shifting of liner location from the sleeper seat can be done
when corrosion is less than 1.5mm. The extent to which shifting of liner bite location
will be done during de-stressing shall be decided by the SSE/P.Way (In-charge).
After new rails are laid in an identified corrosion prone area, regular watch on the
effect of corrosion shall be kept by taking measurement of depth of pits. Corrective
measure should be taken by shifting of the liner biting locations/interchanging of
rails at the time of de-stressing of rails in LWR/CWR track and pulling back rails in
SWR/fish-plated track as per frequency and guidelines approved by the Chief
Track Engineer based on local conditions.
(e) Rail flange/web should be kept free of the muck.
(f) Periodical cleaning of rubbish should be done in goods shed siding lines.
(g) Train watering arrangements should be avoided on the run through main lines as
far as possible. Proper drainage should be ensured in yard/station lines including
washing lines, washable aprons, train watering lines etc.
(3) Reducing side wear on rails-(Gauge face of outer rails) –
(a) On sharp curves where the tendency of wear on the outer rail is noticeable,
lubricators should be installed as per Para 424 or hand lubrication of gauge face
should be done, care being taken not to apply the lubricant on the top of the table.
In case of hand lubrication, the Divisional Engineer may decide frequency of
lubrication duly considering local conditions and traffic on the line.
(b) Increased life can be obtained by turning the rails when side wear reaches the
permissible limit. At the time of turning, matching of rail ends on the gauge face
should be ensured. Spot renewals should not be carried out with new rails
particularly, if the heads of the existing rails are worn badly. These should be spot
renewed with matching sections of serviceable rails.
(4) Repairs to wheel burns – This could be carried out at site by replacing the affected
length.
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614 Rail Closures on other than LWR Track:-
(1) Permanent rail closure in running lines should not be less than 11 metre in length.
However, on sections having maximum speed upto 100 Kmph, minimum length of
permanent rail closure can be 5.5 metre.
Temporary closure, not less than 4 m, can be used with speed restriction of 30 Kmph.
(2) For locations such as;
(a) tunnel
(b) major and important bridges
(c) deep cuttings
(d) high embankments
(e) junctions of different types of rails and/or sleepers
(f) points and crossings
(g) including 500 metre length on both side approaches of all the above,
Permanent closure in running lines should not be less than 11 metre in length. Closure
rails existing in track, which are less than 11 metre, should be welded at least at one
joint on either side to make the minimum rail length of 11 metre between two adjoining
fish plated joints. Until such time this welding is done and the length of at least 11
metre is achieved, speed restriction of 30 Kmph shall be imposed.
(3) Closures should not be located near each other, or opposite to each other. They
should be separated by at least 39 m on the same rail (left or right rail) and 11m on
opposite rails.
(4) Use of closures should be limited and reduced to the minimum possible.
615 Attention to Defective Rails and welds detected by USFD:-On getting
information about a defective rail or weld JE/SSE/P.Way shall take action in
accordance with the Para 6.4 and 8.14 of “Manual for Ultrasonic Testing of Rails
and Welds” for provision of joggle fish plate and/or removal of defective rails or welds.
616 Casual Renewal of Rails:-
Casual rail renewal shall be done for replacement of defective rail, fractured rail, wheel
burnt rail or old worn out rail. On detection of such defective rail, the affected rail length
should be cut during block and the same should be replaced with serviceable rail duly
observing all the precautions for SWR/LWR/CWR as the case may be.
For repairs and casual renewals, location-wise Imprest of tested rails of various
lengths (13 m, 9 m, 6 m etc.) shall be prescribed for each JE/SSE/P.Way by
Sr.DEN/DEN.
617 Rail Failures:-
(1) Action to be taken in case of Rail failures – When a rail fails in track, action as detailed
below is to be taken:
a) Entry in the SSE/P.Way section register as detailed in Sub Para (2) below.
b) Preparation of a detailed report of the failure in cases where applicable as laid
down in Sub-Para (3) below.
c) Detailed metallurgical investigation in cases, where applicable, as per Sub-Para
(3) & (4) below
(2) Record of Rail failures – All the cases of rail failures have to be entered in TMS by the
JE/SSE/P.Way as laid down in Annexure - 6/6. For this purpose, all failures whether
in running lines, points and crossing rails etc. and irrespective of type and age of the
rails, have to be entered in the section register. This record is intended to serve as a
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basic record, which should be available in the office of the JE/SSE/P.Way and will
serve to furnish data, if required subsequently for any statistical analysis or for framing
out proposals for track renewal works. Care should therefore be taken by the
JE/SSE/P.Way for filling up all the details. The Divisional Engineer and Assistant
Divisional Engineer concerned shall frequently peruse the TMS records of rail/weld
failures.
(3) Reports of Rail failures – In addition to the records maintained, as detailed in Sub
Para (2) above, a report has to be prepared as per Annexure - 6/6 in all cases of rail
failures occurring in track with the exception of the cases noted below:
• Rail failures occurring in non-running lines.
• Non-standard and obsolete rails.
• Accidental damages to the rails such as wheel burn and scabbing, buckling,
kinks, derailments, abnormal slipping of loco wheels, excessive wear, loss of
section by corrosion, battering, elongation of holes etc.
a) JE/SSE/P.Way will prepare a ‘Rail failure’ Report as per proforma (Annexure -
6/6), enter into TMS and forward to the Assistant Divisional Engineer, who will
transmit with his remarks to the Divisional Engineer, for onward transmission to the
Chief Track Engineer and Executive Director (M&C)/RDSO/Lucknow.
b) In case of failures requiring metallurgical investigation, a copy of report should be
sent to the Chemist and Metallurgist of the Zonal Railway along with the samples
as detailed in the Sub-Para (4 to 6) below.
c) Sketches and photographs illustrating the fractures should also be submitted with
the failure reports on each case duly indicating the running/gauge face of the rail.
d) It is particularly essential to record the type of failure in the failure reports against
item No. 5.3 as per RDSO monograph “Rail Failures - Description, Classification
and Reporting”. The Executive Director (M&C) will arrange to carry out analysis of
rail failures from the reports received from the JE/SSE/P.Way and the Chemist and
metallurgical investigation, and publish reports with suggestions for reducing
failures.
e) In most cases, it is possible to determine the cause of the failure by visual
examination/ultrasonic detection report without the need for metallurgical
investigation however, in cases mentioned in Sub-Para (4) below, it is obligatory
to take up full metallurgical examination by the Chemist and Metallurgist of the
Railway concerned with a view to ascertain the exact cause of failure.
f) In such cases the rail failure report should be made out in the prescribed proforma
inserting the most probable code of failure against item No. 5.3 of rail fracture
report proforma as given in Annexure - 6/7, and indicating whether the sample has
been sent to the Chemist and Metallurgist for metallurgical investigation.
g) In cases, detected visually or by ultrasonic flaw detectors, the rail pieces of 1m
length (500mm + 500mm) containing the flaw shall be sent for metallurgical test
only from those rails which are removed from track based on the criteria for removal
of rails and falling in the category listed in Sub-Para (4) below.
h) The test pieces for metallurgical examination are to be sent only for rail failures
which occur within first 25% of service life subject to maximum of 10 years of rolling
and for which detailed reports are to be prepared.
i) In case of repetitive failures of rails of same rolling mark, irrespective of the type of
fracture/flaw, short rail piece of approximately 1m long (500mm + 500mm)
containing the fracture/flaw detected visually or by ultrasonic flaw detector should
be sent to the Chemist and Metallurgist together with a rail failure report for
metallurgical investigation.
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j) Chief Track Engineer of zonal railway shall forward the cases of repetitive failure
of rails of same rolling mark on account of chemical & metallurgical reasons to
Executive Director/M&C/RDSO along with investigation reports from Chemist and
Metallurgist. The rail pieces of approximately 1m long (500mm + 500mm)
containing the fracture should be sent to Executive Director/M&C/RDSO together
with a rail failure report for metallurgical investigation where rail/weld failure is
prima facie cause of train accident.
k) To sum up, test pieces to the Chemist and Metallurgist or RDSO, would be sent in
either of the following condition
i. The rail failure is within first 25% of service life subject to maximum of 10
years of rolling of rail, irrespective of the type of fracture/flaw.
ii. The rails have been removed from track as a result of visual or ultrasonic
detection and rail failure falls in categories listed in Sub Para (4) below.
iii. The rail where rail/ weld failure is prima facie cause of train accident
should be sent to RDSO.
iv. The rails with repetitive failure of same rolling mark irrespective of type of
failure.
l) In cases of failures of imported rails occurring within guarantee period, stipulation of
Sub Para (5) shall be followed.
(4) Type of rail failures for which metallurgical investigation is required -
100/200 - Transverse breakage with apparent origin (sudden breakage)
1212/2212 - Head, surface, shallow surface defect (line).
1321/2321 - Web horizontal crack at top fillet radius.
1322/2322 - Web horizontal crack at bottom fillet radius.
1323/2323 - Web horizontal crack not at fillet radius.
238 - Web diagonal cracks not at a hole.
253 - Foot, vertical, longitudinal crack in foot half-moon break
1511/2511 - Foot transverse break at rail seat.
1512/2512 - Foot transverse break not at rail seat.
111/211 - Internal flaw in head, transverse breakage.
112/212 - Internal flaw in head, horizontal crack.
113/213 - Internal flaw in head, vertical longitudinal split
133/23 - Web, vertical longitudinal splitting
139/239 - Web, lap.
153/253 - Foot, vertical longitudinal split.
(5) Failure of imported rails within the Guarantee period - In all cases of failure of imported
rail occurring within the guarantee period, irrespective of the type of fracture/flaw rail
piece approximately 1m long (500mm + 500mm) containing the fracture/ flaw detected
visually or by ultrasonic flaw detector should be sent to the Chemist and Metallurgist
together with a rail failure report for metallurgical investigation.
(6) Procedure for sending samples for metallurgical investigation - In case of fractured
rail, both the pieces of approximately 500 mm long each i.e. total 1m long containing
fractured faces/flaw should be sent to the Chemist and Metallurgist for investigation.
To avoid damage in transit, the fractured faces shall be protected with mineral jelly
and suitably covered with hessian cloth. Cracked rails may also be suitably protected
at the crack location to avoid damage in transit. Pieces having internal defects may
be dispatched as such.
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The Chemist and Metallurgist of the Railway will carry out metallurgical investigation,
as required, and forward one copy of the report each to the Chief Track Engineer of
the Railway and the Executive Director (M&C)/RDSO and the report shall be, attached
to rail/weld fracture report previously uploaded, in the TMS by DEN/Sr. DEN.
In case of failures of imported rails within the guarantee period, attributable to
manufacturing defects as revealed by metallurgical investigation, the Chief Track
Engineer should immediately lodge a provisional claim with the manufacturer pending
Executive Director (M&C)’s confirmation of the findings submitted by the Chemist and
Metallurgist of the Railway.
The Executive Director (M&C)/RDSO will scrutinize the report submitted by the
Chemist and Metallurgist and if he agrees with the findings as submitted, inform the
Chief Track Engineer accordingly.
Where the Executive Director (M&C)/RDSO feels the need for carrying out further
investigation before giving his verdict, he will call for the sample from the Chemist and
Metallurgist of the Railway and carry out confirmatory tests, as necessary and intimate
the findings to the Chief Track Engineer. On the basis of Executive Director (M&C)’s
advice, the Chief Track Engineer will then finalize the claim with the manufacturer.
In case of failures of rails other than imported, the Executive Director (M&C)/RDSO
will call for samples from the Chemist and Metallurgist, for confirmatory test, where
necessary. Based on the trend indicated by the numerical analysis of the rail failures
for the period under review, the Executive Director (M&C) will bring to the notice of
the indigenous manufacturers and Inspecting Agency, any predominance of failures
attributable to manufacturing defects, to enable corrective action being taken.
618 Action to be taken in case of Rail fractures/Weld failures:-
It is of Paramount importance that whenever a fracture of a rail/welded joint is noticed,
immediate action is taken to restore the track, if necessary with restricted speed, with the
least possible delay.
(1) The Gang Mate/Keyman/Trackman, as soon as he notices the rail fracture/weld failure
should first protect the track. He should also send information to the JE/SSE/P.Way
and the Station Master of the nearest station.
(2) If the fracture is with a gap of less than 30 mm, the fractured rail ends should be joined
with fish plates and clamps.
(3) When the fracture gap is more than 30 mm, a closure of appropriate length should be
used, and fish plated with clamps.
(4) In cases where a small portion or piece of rail has come off or in the case of multiple
fractures, the rail has to be changed before allowing traffic.
(5) In the case of weld failure, joggled fishplates and clamps should be used.
(6) After carrying out the emergency repairs the trains may be passed by a Gang
Mate/Keyman at speed prescribed in Annexure - 3/8, until the Permanent Way
Official replaces the rail. Trackman deputed as patrolman (Railway Employee) may
also pass only the first train which is stopped by him in the course of protection of
track after detecting rail/weld failure and after carrying out the emergency repairs, if
he feels confident of passing the train.
619 Lubrication of Rail Joints:-
(1) The purpose of lubricating rail joints is not only to facilitate expansion of rails but also
to retard wear on the fishing planes of the rail and the fishplate. Reduced wear on
the fishing planes is one of the preventives of the low joints.
(2) A stiff paste of plumbago (Graphite) and kerosene oil, made in the proportion of 3 kg
of plumbago to 2 kg of kerosene oil may be used as lubricant. Black oil or reclaimed
oil may be used for fish bolts and nuts. Alternatives to the above may be used, with
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the specific approval of Chief Engineer.
(3) All rail joints should normally be lubricated once a year on a programmed basis
during the cold weather months after the monsoon, from October to February.
Lubrication should not be carried out in extremes of weather both hot and cold. On
non-running lines, this period may be extended to 2 years with the approval of the
Chief Engineer.
(4) Creep in excess of 150 mm should be adjusted before the work of lubrication of rail
joints is undertaken.
(5) The lubrication of rail joints should normally be carried out by gangs working under
the direct supervision of at least JE/P.Way. The work should be carried out under
caution orders arranged to be issued daily by the JE/SSE(P.Way) and under
protection of engineering signals or under traffic block, as per Para 806 The
procedure to be followed will be as below:
a) The nuts are unscrewed and the fish bolts and fishplates are removed.
b) The fishing surfaces of the fishplates and rail are then cleaned with a wire brush.
c) The rail ends are inspected for cracks and the fishing surfaces of rails and
fishplates are checked for wear. A magnifying glass and a mirror should be used
for detecting cracks in rail ends and fishplates.
d) The fishing surfaces of the rails and fishplates are then lubricated.
e) The fish bolts are then put back in reverse position and tightened using a standard
fish bolt spanner, the inner two bolts being tightened first.
f) While tightening overstraining of bolts shall be avoided.
g) Spare fishplates and bolts should be available for replacement of cracked ones.
(6) The Chief Engineer may issue subsidiary instructions as necessary.
(7) The lengths over which the rail joints are lubricated together with dates shall be
recorded in the TMS. In the month of April, SSE/P.Way (In-charge) should submit
the certificate of lubrication of rail joints giving reasons for any exception to the
Assistant Divisional Engineer. Copies of these certificates should be forwarded with
the Assistant Divisional Engineer’s comments to the Divisional Engineer for scrutiny
and record.
(8) During all works such as relaying, rail renewals and renewals of turnouts, etc. rail
joints should be lubricated. All such joints those have been lubricated by the gang
should be checked and retightened by Keyman during his routine patrolling.
(9) Insulated joint fishplates should not be greased.
620 Maintenance of Rail Joints:
(1) Special care is needed for maintenance of fish-plated joints to get better rail life as
well as improved running.
(2) The hammering of the fishplates is forbidden. For removing a fishplate, which has
seized to the rails, the fishplate may be tamped gently by a hammer, by interposing a
wooden piece.
(3) Over tightening of fish bolts shall be avoided. Mechanical/light weight battery operated
torque wrenches with predetermined torque should be used. Alternatively, Fish bolt
spanner of standard length shall be used. When tightening bolts, the two central bolts
should be tightened first.
(4) The efficient maintenance of joint depends on –
(a) Efficiency of elastic fastenings.
(b) The efficiency of packing and correct spacing of sleepers.
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(c) The provision and maintenance of correct expansion gaps.
(d) The proper lubrication and fishing of the joints.
(e) The correct maintenance of gauge and cross level.
(f) Efficient drainage.
(5) Defects in rail joints – Some of the major defects, noticed at the rail joints and the
preventive measures suggested to rectify or minimise the deficiencies /defects
noticed are detailed below –
(a) Slack sleepers – During packing ballast below sleepers, it should be ensured that
the sleepers do not get tilted.
(b) Loose Fish-Plates – Fish bolts must be kept tight but not so tight as to prevent
expansion or contraction of rails.
(c) Wear of Fish-Plates and Rails at fishing surfaces – When wear takes place on the
fishing planes of rails and fish-plates, the joint dips down. The wear is generally
more at the centre of the top of the fishplates and less at the ends. Corrective
action should be taken by providing tapered shims or by replacing the rail end.
(d) Battering of Rail ends – Battering can be avoided by packing the joint sleepers
firmly and by maintaining correct expansion gaps. Battering of rail ends can be
repaired by end cropping.
(e) Hogged Rail Joints – Cropping of rail ends can eliminate hogging. The use of
repressed fishplates also helps in improving the hogged joints. De-hogging
machines can be used for this purpose.
(f) Broken Fish-plates – Broken or cracked fishplates must be replaced.
(g) Cracked or Broken Rail ends – The fish bolt and bond holes at rail ends weaken
the rails, which might result in rail end fractures. Chamfering of boltholes and bond
holes should be done.
The fracture normally starts as a fine crack from the fish bolt or bond holes. During
lubrication of rail joints, opportunity should be taken to observe the rail ends
carefully for presence of fine cracks.
If cracks are noticed, rails should be replaced. Ultrasonic testing of rails helps in
detecting the cracks, which are difficult to detect by visual examination.
(h) Pumping of Joints – Immediately after the monsoon, the ballast at such joints
should be removed and replaced. Cross drains should be provided between first
and second shoulder sleepers.
(6) Other important points regarding joint maintenance –
(a) Gap survey should be undertaken periodically and gap adjusted, as detailed in
Para 320.
(b) Ordinary fish-plated track could be converted into three-rail panel, wherever all
other conditions for SWR are satisfied, to minimize number of fish-plated joints.
(7) Chamfering of bolt holes in rails –
(a) General –
(i) Chamfering of boltholes work hardens the periphery of holes and thereby delays
the formation of star cracks. Each drilled hole, including holes done for providing
structural/continuity bonds by Electrical/S&T departments, shall be chamfered.
(ii) Existing boltholes, if elongated, should be removed; new holes drilled and
chamfered.
(iii) Chamfering of bolt holes should be done with approved chamfering kit.
Procedure for chamfering of boltholes shall be as per the manufacturer's manual
accompanying the equipment.
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(b) Bolt holes in new rails received directly from steel plant should be chamfered
before rails are laid in track.
(c) Chamfering of boltholes in the welded rail panels should be done before despatch
in the Flash Butt Welding Plants.
(d) When rails in track are end-cropped, new boltholes should be chamfered at site.
621 Fish-plate failures:-
(1) A fish-plate is said to have failed if it fractures or cracks for reasons other than service
wear and tear, accidents, or excessive wheel grazing noticed on it, and it becomes
necessary to remove it from track.
(2) Renewal of worn fishplates should be considered when condition so warrants.
622 Inspection and Maintenance of Insulated Rail joints/Glued Joints:- (Back to Para
223)
(1) General- There are two types of insulated rail joints provided for track circuiting.
(a) Fish-plated insulated joints: Insulating components of this type are provided and
maintained by S&T department. Rail ends shall be provided as square and smooth,
battered ends should be rectified and gap between rails, if large, should be
adjusted. The fish plated joint shall be kept tight and ballast well packed in the
vicinity of joints to prevent undue movement of rail ends. JE/SSE/P.Way and
JE/SSE (Sig) should carry out the joint inspection of such insulated joints once in
year and observations recorded in TMS.
(b) Glued Insulated Joint - The G3L type glued joint should be provided on all run
through lines. The glued joints should be tested for insulation resistance as per
Para 3.3 &3.5 of “Manual for Glued Insulated Rail Joints” both in dry and wet
condition before laying on track and in service.
(2) Laying and Maintenance of Insulated joints –
(a) Insulated joints, wherever provided, shall be maintained as square joints.
(b) Rail ends of the insulated joints shall be square and the gap between the rails
should be equal to the thickness of the end post.
(c) The metal burrs at the end, if any should be removed well in time to avoid short-
circuiting.
(d) Fish bolts at the insulated joints must be kept tight and the sleepers well packed in
the vicinity of the joints.
(e) Rail ends shall be kept free from brake dust, dirt, sand, rust, other foreign Materials
etc.
(3) Maintenance of Glued Insulated Joints –
(a) The ballast used in track in the vicinity of glued insulated joints shall be clean to
ensure efficient packing and drainage.
(b) Care should be taken to see that the ballast is clear of rails and rail fastenings.
(c) In glued joints, normally no relative movement occurs between rails and fishplates.
In case, failure of joints occurs by separation of rail, fishplate surfaces with
consequent relative movement, fishplates crack/breakages etc., the damaged
glued joint shall be refurbished/replaced. Refurbishing shall be done as per
“Technical Specification for Re-Furbishing of Existing Glued Insulated Rail Joints
and In-Situ Fabrication of Glued Insulated Rail Joints (PROVISIONAL)”.
(d) The track at glued joint and its vicinity shall be kept clean with efficient drainage.
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623 Laying of PSC Plain track Sleepers:- (Back to Para 625)
(1) General – PSC Sleepers shall be laid and maintained square to the rails on straights
and radially on curves. The rail joints should be suspended.
(2) Relaying with Mechanical Equipment should be adopted while carrying out track
renewals with concrete sleepers, as the manual handling of concrete sleepers is
difficult and may cause damage to the sleepers.
(3) The preliminary (preparatory) work prior to relaying at site, the actual relaying process
at site and the post relaying operations are described in detail in “IRTMM”.
(4) Operations Connected with Manual Relaying –
(a) Manual Laying will not normally be adopted except under exceptional
circumstances
(b) Loading and Unloading – Concrete sleepers shall be placed perpendicular to the
length of the BFR. Manual unloading, if unavoidable, shall be done sleeper by
sleeper. Wooden or steel sleepers provided with hooks at the top ends for gripping
the side of the BFR shall be used as ramps for sliding the sleepers down to the
cess level.
Damage by over-running shall be prevented by placing the lower ends of the ramps
either inside an old motor truck tyre or between gunny bags filled with wood shavings
and the sleeper allowed to move down the ramp. Two men shall stand on the cess
with crowbars planted into the cess and control the downward sliding of the concrete
sleepers
After unloading, the sleepers shall be placed on the cess approximately alongside the
final position.
(c) Laying Procedure – The following procedure shall be adopted for manual laying of
concrete sleepers under block protection:
(i) Just prior to the line block, a speed restriction of 20 Kmph shall be imposed on
the portion to be re-laid during the block and rail sleeper fastenings shall be
removed from the alternate sleepers. Ballast cribs between sleepers shall be
exposed upto bottom level of sleepers. It shall be ensured that the number of
sleepers taken up for replacement during the line block period shall not be more
than that which can be given at least one mechanical tamping with ‘on track’
tamper before the first train is allowed after the replacement of the sleepers.
(ii) After taking the line block, the rails over the length to be dealt with during the
line block period shall be disconnected and removed. The sleepers shall then
be taken out, taking care to disturb the ballast bed only to the minimum extent.
(iii) The new concrete sleepers shall then be laid in position by means of sleeper
slings taking care to ensure the correct longitudinal and lateral alignment. When
the sleepers are being placed in position, the prepared ballast bed should be
disturbed only as little as possible. Care should be taken not to damage the
edges of the sleepers or to chip the concrete. After the sleepers are placed,
rubber pads shall be placed at the rail seats. Elastic clips shall be loosely
fastened at this stage. If the original rails are to be continued after relaying, the
track rails shall be laid and connected on either side.
(iv) After the sleepers are packed, the rails shall be secured in position by inserting
liners and elastic rail clips and firmly fastened.
(d) Renewal of concrete sleepers without block protection can be carried out along with
manual deep screening as given in Para 637.
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624 Laying of Fan Shaped Turnout Sleeper:-
(1) Loading of PSC turnout sleepers in BFRs –
Sleeper of the approach and sleepers meant for lock bar crank are loaded at right angles
to the track. The remaining sleepers are loaded Parallel to the track on the BFRs. Suitable
nos. of wooden battens to support the sleepers in between layers of turnout sleepers will
be used as in case of main line sleepers to prevent damage.
(2) Unloading –
Depending upon the process of laying of the turnout adopted, the sleepers shall be
unloaded either near the proposed location on firm & level ground or adjacent to a nearby
siding or on a goods platform by means of a crane. While unloading, due care shall be taken
that the sleepers or the inserts are not damaged.
(3) Site preparation for laying –
Ensure that a clean ballast cushion of 30 cm below the bottom of sleeper is available. The
ballast bed has to be perfectly level. Enough ballast shall be stacked along the cess to
enable the filling of ballast in the cribs on the same day. Longitudinal and cross drains may
be provided in turnout area to avoid accumulation of water. The site preparation to be
completed well before laying turnout ensuring deep screening of ballast in turnout length
and 30 m on either side along the track.
(4) Assembling –
Ensure the availability of all fittings at site strictly as per requirement of latest drawings for
switch portion, lead and crossing portion. The complete turnout will be assembled on a level
ground adjacent to the site of laying or on the loop line connected to turnout. Red/blue
rounded marking on the sleepers should invariably be kept on the right hand side
irrespective of left hand or right hand turnout.
Spacing of sleepers should be strictly as per layout drawing. The sleepers shall be
perpendicular to the straight track in switch portion only. In lead portion, the sleepers will be
inclined at half the angle between the normal to straight and curved track at that point.
To ensure correct layout, laying of sleeper falling at transition from switch to lead and lead
to crossing portion should be paid special attention. Sleepers in the switch portion, lead
portion and crossing portion are as under –
Turnout Switch Lead Crossing
1 in 8½ 1 to 13 14 to 41 42 to 54
1 in 12 1 to 20 21 to 64 65 to 83
1 in 16 1 to 20 21 to 75 76 to 101
The spacing of the sleepers in the switch, lead and crossing portion should be as per
standard RDSO layout drawing to make a radial or fan shaped layout. The spacing has
been worked out separately for both the rails. The sleepers in the crossing portion shall be
perpendicular to bisector line of crossing angle. Long Sleepers in switch portion meant for
providing motor may be placed for housing motor with the extended portion of sleeper in
reverse direction only in circumstances where it cannot be avoided.
The approach sleeper in advance of switch portion should be provided without fail, they are
for gradual elimination of slope of rail top (1 in 20). The exit sleepers behind the crossing
portion should also be provided for gradual introduction of rail slope (1 in 20).
(5) Insertion of pre-assembled turnout – The complete assembled turnout shall be
inserted in position by using T-28 machine as one unit or after breaking it into three
panels viz. Switch, lead and crossing portions by means of T-28 machine or cranes
or rollers.
(6) Manual insertion – In case the PSC turnout sleepers are to be manually inserted, then
the same must be done sleeper by sleeper ensuring that at no time the alignment and
level is beyond permissible limits. This work may be done under a suitable speed
restriction if necessary and adequate mechanical means for packing the sleepers
must also be available.
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625 Casual Renewal of Concrete Sleepers: - While carrying out casual renewal of
Concrete sleepers, manual handling becomes necessary and precautions indicated
in Para 623 (4) should be observed. In addition, the provisions relating to LWR/CWR
regarding the precautions to be taken for casual renewal of sleepers shall be followed.
Special care shall be taken to consolidate the shoulders of the ballast section after
renewal of the sleepers.
626 Corrosion of Steel in Concrete Sleepers:-Both the ends of concrete sleepers
should be painted with an approved type of anti-corrosive paint at the concrete sleeper
manufacturing plant to prevent corrosion of the exposed ends of pre-stressing wires.
627 Maintenance of Concrete Sleeper Fastenings:-
(1) Elastic Rail clips – The essential feature of the Elastic rail clip is the correct driving of
the clip, which should be checked by the Keyman during his daily petrol. The clip
should be driven so that the leg of the clip is flush with the end face of the insert. Over
driving and under driving shall be guarded against by observations of the clips in
position. The clips should be driven/taken out with clip applicator/extractor.
Over driving/under driving of the clip causes eccentric load on the liners and results
in their displacement and variation of toe load. A vigilant watch should be kept to
ascertain that no creep is taking place in any of the portion of the track or excessive
movement near SEJs. The elastic fastenings should be checked for corrosion and
corroded fastenings should be replaced.
(2) Rubber Pads – It must be ensured that the rubber pads are in correct position.
Whenever it is found that the rubber pads have developed a permanent set, these
shall be renewed. The loss of toe load can also be due to ineffective pads. The toe
load should be checked regularly, as prescribed, and also if any creep is noticed
resulting in excessive movements of the SEJs. In case of Composite GRSP, it shall
be ensured that the manufacturer’s initials embossed on CGRSP are in contact with
the rail bottom.
(3) Metal Liners- The liners should be inspected and fitted in proper position.
Corroded/dent marked liners adversely affect the toe load and should be planned for
replacement.
(4) Insulating liners – Nylon/composite insulating liners used with clip shall be examined
periodically for sign of cracking and breakage. Adequate care should be exercised
while driving the clip at the time of installation to prevent damage.
On first laying, a small indentation on the nylon insulating liner will be formed due to
the toe-load of the clip. This is not objectionable so long as the insulating liner does
not crack. All cracked insulating liners should be replaced with fresh ones.
628 Renewal of fastenings: - Precaution during renewal of fastenings shall be taken
as per the provisions of LWR/CWR (refer Chapter 3, Part D).
Large scale replacement of fastenings must be done under the supervision of
JE/SSE/P.Way. The cause for large-scale development of defects must be
investigated by the Assistant Divisional Engineer.
(1) Periodicity of measurement of performance of Elastic Fastening Components –
Sample, Size and Testing Frequency –
(a) Sample Size –
Toe load of elastic rail clip should be measured on 1% of ERCs randomly on every
100 sleepers (all 4 ERCs to be measured on one sleeper).
(b) Testing Frequency –
The testing of ERCs is to be done after four years or passage of 200 GMT of traffic,
whichever is earlier. In corrosion prone area, the initial testing of ERC is to be done
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after two years or passage of 100 GMT, whichever is earlier
However, if 20% or more of sample size records toe load below 600 kg, both
frequency of inspection and sample size are to be doubled.
Replacement of ERC –
(i) If 20% or more of sample size records toe load below 400 kg, which is to be
confirmed by 5% sample size, proposal of through fastening renewal should be
initiated.
(ii) The provisions given above are only for guidance of Railways. The Railways on
the basis of the overall condition of track, pattern of traffic and the required level
of maintenance should undertake the large scale replacement of the fastening.
(iii) Further, as the loss of toe load is reflective of conditions of other elastic
fastening components like groove rubber sole plate, GFN/metal liners etc. as
well, the railways may also record condition of these components along with
measuring toe loads for elastic rail clips.
(2) Measures to prevent corrosion and seizure of ERCs with MCI inserts –
Initial treatment – At the base depot, all the elastic rail clips and MCI Inserts should
be thoroughly cleaned. Grease to IS: 408-1981(Specification for Grease Gr. ‘O’
Graphited) should then be applied on the central leg of the ERC and eye of the MCI
insert and then the clip should be driven at the time of assembly of the service panel.
Lubrication of ERCs – Grease Graphite to the specification IS-408-1981 Gr. O should
be used for this purpose. This work should not be carried out during extreme of
summer and heavy rainfall. At a time, ERCs should not be removed from more than
one sleeper. If for any reason mass lubrication of ERCs is taken up, at least 15
sleepers shall be kept intact between any two sleepers taken up for lubrication of
ERCs at the same time. The ERCs should be cleaned by wire brush and emery paper.
The eye of the insert shall also be cleaned by suitable brush. After cleaning, grease
graphite shall be applied to the inside surface of eye of insert and leg of ERC.
Inside/Outside ERCs should be interchanged and fixed again.
The lubrication of ERCs and insert at the time of initial laying should be done and
thereafter should be done once in a year in corrosion prone areas & platform lines
and once in two years in other areas or more frequently as decided by PCE.
629 Steel sleeper for Bridges:-
(1) Maintenance –
(a) After laying Steel sleepers, tightening of all fittings including hook bolts should be
done once in 15 days for initial one month. Thereafter it should be done once a
month for next six months and subsequently it should be on need basis as observed
by inspecting officials. Regarding hook bolts, Para 631 (3) should be followed.
(b) Guard rail fittings should be tightened once in three months for first six months and
thereafter on need basis.
(c) The above will be in addition to daily attention by Keyman.
(d) Replacement of grooved rubber pads & elastomeric pads shall be done on condition
basis.
(e) Suitable stock of spare fittings should always be maintained keeping different types
of girders in view.
(f) Suitable quantity of the Steel sleepers along with fittings should be kept as
emergency reserve. Emergency reserve stock of channel sleepers should be
maintained keeping different types of girders in view.
(g) In case Galvanized coating is damaged, it should be repaired.
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(2) Inspection of channel sleepers –
(a) During intensive inspection, the condition of Rivets, distortion or crack in sleepers
or any sign of crack in girder flange and tightness of fittings should be looked for.
All loose fittings should be tightened after inspection. If required, for few days in
the beginning, a watch may be kept depending upon the need.
(b) During joint inspection, the effectiveness of insulation in track-circuited areas
should also be checked.
630 Inspection and maintenance of Track on Approaches of Bridges:-
(1) For all Bridges –
(a) On the bridge approaches, sleepers with arrangement for fixing guard rails should
be provided for provision of guard rails as per Para 228.
(b) Full complement of track fittings at bridge approaches up to 100 metres should be
provided to maintain required track geometry and effort should be made to
immediately recoup deficiency noticed, if any.
(c) Rail level of track at approaches of bridges should be maintained as per designed
L-section and dips in rail level immediately after the abutments should be avoided.
The alignment and super elevation in case of curved track should also be
maintained as per provisions of Chapter 4.
(d) Rail joints should be avoided within three metres of a bridge abutment.
(e) In case of LWR/CWR track, full ballast section as specified should be provided up
to 100 metres from the abutment.
(f) Switch expansion joints should be provided at the bridge approaches in LWR/CWR
track as per provisions (Refer Chapter 3, Part D).
(g) Joggled fish plate with clamps or two far end bolts on good AT welds shall be
provided on bridges having length of water way as 100 m or more and on
approaches upto 100 m length.
(2) In addition, for important and major bridge approaches, for a length of about 100
metres, width of cess should be 90 cm clear of full ballast section to maintain ballast
profile.
(3) For maintaining ballast section, suitable ballast retaining arrangement should also be
provided.
631 Inspection and Maintenance of Track on Bridge proper:- (Back to Para 629)
(1) Condition of track – It should be ascertained whether track is central on the rail bearers
and main girders and in good line and level. Departure from good alignment is caused
by incorrect seating of girders, shifting of girders laterally or lengthwise, incorrect
seating of sleepers on girders or rails on sleepers, varying gauge or creep.
Departure from level is caused by errors in level of bed blocks or careless sleepering.
The adequacy of clearances of running rails over ballast walls or ballasted girders at
the abutments and condition of sleepers and fastening on the run off and skew spans
should be inspected.
(2) Sleepers – The condition of sleepers and fastenings should be checked. The spacing
of sleepers should not exceed the limits laid down in Para 227 (2). Squareness of
sleepers shall be ensured. Sleepers requiring renewals should be marked with paint,
and renewals carried out.
(3) Hook Bolts – Hook bolts shall, preferably be galvanised. These should be checked for
their firm grip. Position of arrows on top of the bolts should be at right angles to the
rails pointing towards the rail. Hook bolts, if not galvanised, should be oiled
periodically to prevent rusting.
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(4) Creep and joint gaps should be checked and rails pulled back wherever necessary.
Rail fastenings should be tight. Defective rails should be replaced. Where switch
expansion joints are provided on the girder bridge, it should be ensured that free
movement of the switch is not hindered.
(5) Guard rails – Adequacy of guardrail arrangements should be checked. Correct
distance between the running rail and guardrail should be maintained as per the
prescribed dimensions.
(6) On girder bridges adequacy of pathways for inspection should be checked.
632 Maintenance of yard lines:-Train movement takes place through yard lines
though at a slower speed. Normally track recording to these lines is not covered by
TRC/OMS; hence, track Parameters on these lines will have to be measured manually
or by other suitable methods.
The defects noticed during inspection of yard lines shall be attended by deploying the
gangs or machine.
Preferably, all passenger loop lines should be maintained by track machines and other
loops can be maintained by manual/mechanised methods.
633 Sand hump / Dead end: - Sand humps and dead ends are provided to give the
required signal overlap. These are safety works and brought in to use when trains
overshoot starter signals at danger. All sand humps shall be laid as per standard
RDSO drawing as given in figure below. A sand hump or snag dead end shall not be
obstructed for any purpose and when it has become obstructed, it shall cease to be a
substitute for the adequate distance for the purpose of taking ‘off’ signals.
Fig. 6.1 – Sand hump

634 Sample of Standard Section of Track: - At or near the commencement of each
gang length between stations a sample of three rail lengths of track should be maintained
in accordance with all standards laid down as given below –
(1) Formation of standard width and level below rail.
(2) Clean ballast of correct size, quantity and cross section.
(3) Correct alignment, level and gauge.
(4) Sleepers and fastenings in good condition.
The object of the sample track is to indicate the standard to which the track should be
maintained throughout the gang length.
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635 Checking work of Gangs by JE/SSE/P.Way:-
(1) Examination of Gang’s Work – The work done by a gang either on the previous day
or during the interval when the JE/SSE/P.Way is next with the gang should be
examined for alignment, surfacing and boxing throughout. The JE/SSE/P.Way should
inspect rails and sleepers and their fastenings and check cross levels, gauge,
squareness of sleepers, packing, joint maintenance, profile of ballast and depths of
cess below rail level. The Gang Mate’s Muster Sheet should be checked and initialled.
Instructions to the Gang Mates should be recorded in the gang diaries.
(2) Examination of tools and equipment –
(a) The JE/SSE/P.Way should examine every month and replace, when necessary,
worn out tools and equipment.
(b) The JE/SSE/P.Way should check the accuracy of the spirit level/gauge and straight
edge every month, the result of this examination being entered in the Gang Mate’s
diary book.
(c) Each gang should have the following minimum equipment –
(i) Level-cum-gauge.
(ii) Two set of hand signal flags, red and green (2 hand signal/LED lamps at night).
(iii) 10 detonators.
(iv) Steel scale 30 cm long.
(v) Straight edge 1 metre long.
(vi) Square.
(vii) Hemp cord.
(viii) Keying and spiking hammer.
(ix) Marking chalk.
(x) Rail thermometer.
(xi) Sufficient No. of shovels, Powrah, beaters, crow-bars, Ballast-forks or rakes,
mortar pans or baskets.
(xii) Wooden mallet or Canne-a-Boule.
(xiii) Feeler gauge.
(xiv) 2 no. whistle thunderers.
(3) Instructions and Counselling – JE/SSE/P.Way should ensure that every man in each
gang is aware of the following rules in which the men should be examined periodically
and on appointment, promotion or transfer –
(a) Protecting the lines in an emergency or during work affecting the running of trains
(b) Method of fixing and safety range of detonators.
(c) Showing of signals with or without hand signal flags during day and with hand
signal/LED lamps during night.
(d) Action to be taken when a train is noticed to have parted.
(e) ‘Safety First’ rules.
(f) Patrolling of the line during heavy rains / storms and hot weather on LWR lengths.
The JE/SSE/P.Way should instruct the men for the proper use of tools and upkeep
of the road. The instructions should not be of a casual nature; they should be
demonstrative.
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PART – ‘C’
WORKS INCIDENTAL TO REGULAR TRACK MAINTENANCE
636 Deep Screening of Ballast:-
(1) General –
(a) It is essential that track is well drained for which screening of ballast should be
carried out periodically as described in Sub Para (2) below. Due to presence of
bad formation, ballast attrition, excessive rainfall and dropping of fines and ore,
ballast gets choked up and track drainage is impaired. In such situations, it
becomes necessary to screen the entire ballast right up to the formation level /sub-
ballast level. Further, through screening restores the resilience and elasticity of the
ballast bed, resulting in improved running quality of track. Such screening is called
“Deep screening”, as distinguished from shallow screening, which is done, during
overhauling.
(b) The need for intermediate screening between track renewals may be decided by
the Chief Engineer depending on the local conditions.
(c) At the time of deep screening, standard ballast section should be provided
invariably.
(d) Side drains in cuttings, yards etc. should also be restored after deep screening.
(e) In case of the bad formation, formation treatment should be carried out along with
deep screening.
(f) The work of deep screening should be carried out continuously from one end of
the section to the other.
(2) Criteria for Deep Screening:
Deep screening should be carried out in the following situations by providing full ballast
cushion –
(a) Prior to complete track renewal.
(b) Prior to through sleeper renewal.
(c) Where the caking of ballast has resulted in unsatisfactory riding.
(d) Before converting existing track, fish plated or SWR into LWR or CWR, unless the
ballast was screened in recent past.
(e) Deep screening of Track shall be done after 500 GMT or 10 years, whichever is
earlier. However, deep screening shall also be carried out if the existing clean
ballast cushion is less than 150 mm to ensure proper machine tamping.
All the loop lines should be deep screened once in 15 years.
637 Procedure for systematic Deep screening:- (Back to Para 623)
(1) By manual method (not applicable to LWR Sections) –
(a) Survey – Before deep screening of a section is undertaken, it is necessary to survey
the section. This will consist of the following operations –
(i) A longitudinal section of the track should be taken indicating the rail levels at
every 30 metres, and also at changes of the grades, obligatory points like
culverts, bridges, overhead structures, tunnels, level crossings, signal gantries,
and points and crossings etc.
(ii) In station yards, on run through lines, cross sections at every 50 metres should
be taken and plotted including platform levels, rail levels and clearance to
underside of overhead structures.
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(iii) On the basis of longitudinal and cross sections, the final levels will be decided
by the Divisional Engineer, keeping in view the depth of ballast cushion to be
provided and the relative implications of lifting or lowering of track;
(iv) The possibility of eliminating humps, sags, and unevenness in the existing
longitudinal section to be explored. It is not necessarily the intention that the
original longitudinal section of the line should be restored.
(b) Preliminary works –
(i) Additional ballast required, should be unloaded/spread out opposite to the place
where it is required. When ballast is collected along the track, care should be
taken to see that the new ballast is not mixed with the unscreened ballast.
(ii) Cess should be brought up to correct level in relation to the final rail level.
(iii) Pegs should be provided at intervals of 30 metres to indicate the final rail levels.
(iv) Slewing of curves should be done in advance.
(v) Sleeper renewal as necessary should be carried out in advance.
(c) Screening operations – General –
(i) The work of deep screening would be done under the supervision of an official
not lower in rank than the JE/P.Way.
Note – For LWR/CWR track, provisions given in chapter 3 shall be followed.
(ii) The daily output should be predetermined, depending on the time allowance,
availability of labour, extent of ballasting/screening to be done etc.
(iii) Taking the length to be deep screened daily, planning of speed restriction
should be done and necessary notice should be issued to all concerned and
speed restriction boards put up.
(iv) It will be desirable to proceed with the work of deep screening in the direction
opposite to that of the traffic on double line.
(d) Detailed procedure – A day’s length will be deep screened as per the procedure
detailed below:
Stage I: The ballast should be removed from space ‘A’ and ‘B’ on either side of the
sleeper ‘1’ down to final formation level and wooden blocks provided to
support the rail for passing trains.
Stage II: The ballast is removed from under sleeper ‘1’ down to final formation
level/sub ballast level.
Stage III The ballast should then be screened and placed back under sleeper ‘1’
which should then be packed.
Stage IV The wooden blocks from space ‘A’ should then be removed.
Stage V The ballast from space ‘C’ down to formation level should be removed and
after screening, be placed in space ‘A’ upto bottom of sleeper. The balance
may be taken outside the track and screened. The rail in space ‘C’ should
be supported with wooden blocks.
Stage VI The ballast should be removed from under sleeper ‘2’ down to formation
level.
Stage VII Screened ballast should be provided under sleeper ‘2’ and sleeper well
packed.
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Fig. 6.2
Stage VIII The ballast from space ‘D’ down to formation level should be removed and
after screening, be placed in space ‘B’ upto bottom of sleeper; the balance
may be taken outside the track and screened. The wooden blocks should
be removed from space ‘B’ and placed to support the rail in space ‘D’.
Stage IX The ballast from under sleeper ‘3’ should be removed and so on till the
whole rail length is provided with screened ballast upto level of the bottom
of sleepers.
Final Stage: The track should be lifted to provide additional cushion where required.
The track should be packed in the final position and then boxed.
Sequence of the operations is shown in the Fig 6.2 above.
(e) The following points may be kept in view while doing the work –
(i) No unscreened length should be left between screened lengths of the track at
the same time.
(ii) It should be ensured, that when ballast is being removed from any sleeper,
invariably, there are at least four fully supported sleepers between it and the
next sleeper worked upon.
(iii) Lifting should be limited to 50 mm at a time.
(iv) It should be ensured that packing, cross-levels and grade run off are satisfactory
before closing the day’s work.
(v) The work should be done under a speed restriction of 20 Kmph.
(vi) The speed should be gradually raised as in Para (f) below, which will vary
depending on the type of maintenance in the section.
(f) Schedule for working and speed restriction to be observed, in deep screening
works:
(i) With Manual Packing – The details of the work to be carried out in stages on
various days, after the starting of the screening operation and the speed
restriction recommended to be imposed are shown in Table I. According to the
above schedule, normal Sectional speed can be resorted on the 21stday.
(ii) With Machine Packing – The details of work to be carried out in stages on
various days after the start of the screening operations and the speed restriction
recommended to be imposed are indicated in the schematic representation in
Table II. According to this schedule, normal sectional speed can be resumed
on the 10thday.
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(2) Deep Screening with BCM (Ballast Cleaning Machine) (Back to Para 346)- The
deep screening by BCM machine is to be carried out as detailed in IRTMM. The work
of deep screening shall be followed by Tamping and Stabilisation of Track with TTM
(Tie Tamping Machine) and DTS (Dynamic Track Stabiliser) respectively. The work
is to be carried out in stages on various days after the start of the screening operations
and the speed restriction recommended to be imposed are indicated in the schematic
representation in Table – III. According to the schedule, normal sectional speed can
be resumed on the 8th day.
TABLE – I
PROPOSED SCHEDULE FOR MANUAL DEEP SCREENING (MANUAL PACKING)
Day Sequence of events Speed in Kmph
1st Deep Screening and initial packing 20
nd st
2 1 through packing 20
3rd 2nd through packing 20
4th to 9th Picking up of slacks as required 45
th rd
10 3 through packing 45
11th to 19th Picking up of slacks as required 75
Speed raised to normal sectional speed, only after one round of tamping by machine in design mode
and stabilisation in controlled settlement mode
TABLE – II
PROPOSED SCHEDULE FOR MANUAL DEEP SCREENING (MACHINE PACKING)
Day Sequence of Events Speed in Kmph
1st Deep Screening with Initial Packing 20
2nd First Machine Packing 20
3rd to 5th Picking up of slacks as required 45
6th Second Machine packing 45
7th& 8th Picking up of slacks as required 75
9th Third Machine packing 75
10th Normal Sectional speed
TABLE— Ill
SCHEDULE OF SPEED RESTRICTION FOR DEEP SCREENING BY BCM FOLLOWED BY
TAMPING AND STABILISATION BY TTM AND DTS MACHINES
Details of Work Days of Work Speed Restriction
Deep screening of track by BCM, ballast equalisation
1st day 40 Kmph
followed by initial packing and initial stabilization by DTS.
nd
First round of tamping followed by stabilization of track by 2 day 40 Kmph
DTS. (1st Tamping)
Survey of track for design tamping mode as per Annexure
3rd day 40 Kmph
- 5.3 of IRTMM boxing or ballast section and tidying.
th
Second round of tamping followed by stabilization of track 4 day
40 Kmph
by DTS. (2nd Tamping)
Survey of track for design tamping mode as per Annexure
5th day 40 Kmph
- 5.3 of IRTMM, boxing of ballast section and tidying.
Third round of tamping in design mode followed by third 6th day
rd 75 Kmph
round of stabilization by DTS. (3 Tamping)
Normal speed of
Inspection of track, boxing of ballast section and tidying. 8th day
the section
NOTE: The period of the schedule shown above can be suitably increased to suit local conditions
of the track consolidation.
(3) Precautions to be taken during deep screening of track by BCM followed by TTM and
DTS machines -
(a) All precautions stipulated for LWR/CWR track (chapter 3) shall be strictly followed.
(b) The cutter bar shall be removed after completion of day's work, ballast filled and
packed & stabilized by TTM/DTS.
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(c) Ramp shall not be located in locations like level crossing, Girder Bridge, transition
portion of curve etc. It shall be kept minimum two rail length away.
(d) In case of malfunctioning of TTM and/or DTS, deep screening shall be stopped
and track which has not been tamped and stabilized shall be attended manually by
ballast ramming and correction of track geometry to ensure safety of running trains.
Speed restriction shall be imposed and relaxed in terms of Sub Para (1) (f) (i) or
(ii) above, whichever is the case.
(e) In case of non-availability of traffic block on subsequent days of deep screening by
BCM, speed restrictions shall be imposed and relaxed in terms of Sub Para (1) (f)
(i) or (ii) above, whichever is the case.
(f) When BRM is not deployed, adequate trackmen shall be deputed to recoup ballast,
particularly in shoulder and maintain ballast profile after machine working.
(g) Lifting of track shall be resorted to after ensuring adequate availability of ballast for
maintaining ballast profile for planned lifting.
(h) Adequate arrangements for supply and training out of ballast prior to deep
screening should be made. Special care shall be taken by deploying watchman on
stretches overdue for rail renewal.
638 Lifting of Track:-
(1) Lifting of track will become necessary during re-grading and for elimination of minor
sags, which develop through improper maintenance or yielding soil, to keep a good
top.
(2) Correct level pegs should be fixed at suitable intervals, before lifting is commenced.
(3) Heavy lifting should always be carried out under suitable speed restriction and under
the protection of corresponding engineering signals.
(4) The lifting should not exceed 50 mm at a time so as to allow proper consolidation.
The easement gradient for the passage of trains should not be steeper than 25 mm
in one rail length of 13 metres.
(5) The operation should be repeated until the required level is attained when the track
should be finally ballasted, through packed and boxed, the cess being made up to
proper level.
(6) Lifting should commence from the downhill end carried out in the direction of rising
grade in case of single line. It should proceed in the opposite direction to traffic, in
case of double line, care being taken not to exceed the easement grade.
(7) While lifting track under bridges and overhead structures and in tunnels, it should be
ensured that there is no infringement of standard dimensions.
(8) In case of curves, it is usual to set the inner rail to the correct level and grade and to
raise the outer rail to give the required super elevation, care being taken to see that
the cant gradient is within the permissible limit.
(9) For LWR/CWR track, provisions given in Chapter 3 shall be followed
639 Lowering of Track:-
(1) Lowering of the track should not be resorted to except where it cannot be avoided and
if resorted to, it should be done under suitable speed restriction and under the
protection of Engineering signals.
(2) When lowering is to be done, trenches should be made across the track at every 30
m to the final level in order to give a continuous indication, while the work is in
progress. The ballast should be removed sufficiently far away from the track to prevent
it getting mixed up with excavated Material.
(3) The procedure is to clear the spaces between the sleepers, then slightly lift the track,
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break the packing beneath and level it into the space between sleepers. This Material
is then removed and the operation repeated until the final level is reached. The road
should then be ballasted, through packed and boxed, the cess being cut down to
proper level.
(4) Lowering, should be restricted to a maximum of 75 mm at a time and the grade for
passage of trains should not exceed 25 mm in a rail length of 13 m.
(5) As opposed to lifting, lowering should be carried out in the direction of the falling
grade.
(6) Work of lifting or lowering of track shall be carried out under supervision of JE/P.Way.
(7) For LWR/CWR track, provisions given in Chapter 3 shall be followed.
640 Side and Catch Water Drains and Waterways:-
(1) For efficient drainage of cuttings, side and catch water drains of suitable type and size
should be provided. The bottom of side drains should be at least 30 cm below the
formation level.
(2) Adequate openings to take the full flow of side drains should be provided under level
crossings where they exist in or at the end of the cuttings.
(3) In cuttings, in black cotton or similar soils, catch water drain should be provided
sufficiently away from the top of the cutting to avoid any danger of a breach occurring
between the drain and the cutting itself. The excavated spoil should be used to form
a ‘bund’ between the drain and the top of the cutting.
(4) Ballast walls, where provided in cuttings, should be regularly inspected. The efficient
maintenance of ballast walls includes regular cleaning of weep holes, the provision of
weep holes where none exist and rebuilding where necessary.
(5) The cleaning of side and catch water drains, clearing of obstructions from outfalls and
cleaning water-ways of bridges and culverts shall be completed before the monsoon
sets in. The spoil from cleaning drains or cuttings should not be deposited at a place
from where it is likely to be washed back into the drains.
(6) In the Municipal areas, where the outfall of Railway drains is in the municipal drains,
close co-ordination should be maintained with the municipal authorities to ensure free
flow from Railway drains.
641 Drainage in Station Yards:-
The network of cross and longitudinal drains in yards, should be so planned that
storm water is led away in least possible time. The system of surface drains of
carriage-watering and carriage washing hydrants should be efficiently maintained.
Proper yard drainage plan should be prepared and maintained by SSE (Works).
642 Section Limit Boards:-
(1) Boards at jurisdictional limits should be provided thus:
(a) End of Divisions:
BB DIVN. BSL DIVN.
D.E.N./BB D.E.N./BSL
A.D.E.N./IGP A.D.E.N./MMR
SSE/P.Way/IGP SSE/P.Way/DVL
(b) End of Sub-Divisions:
A.D.E.N./TNA A.D.E.N./KYN
SSE/P.Way/KYN SSE/P.Way/VSD
(c) End of Sections:
SSE/P.Way/TNA SSE/P.Way/KYN
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(d) End of Gang lengths:
G-3 G-4
1+1+14 1+1+13
(2) If the gang beat ends in a curve the beat should be so adjusted that the entire curve
lies in one of the beats.
Similarly, in case of yards, Gang beats should be so adjusted that the yard is
maintained as far as possible by one gang, exception being in the case of big yards
where the yard may have to be maintained by more than one gang.
(3) Suitable boards should also be provided indicating the state and district boundaries.
(4) When a board has to be located at an exact kilometre, it should be fixed by the side
of the kilometre post.
(5) The boards, which may be of, scrap iron or RCC should throughout a division be fixed
on the cess on the same side of the line. The letters and figures should be painted
black on white background.
643 Kilometre and Gradient Posts:-These may preferably be of RCC of suitable
dimensions and fixed at right angles to the track on the cess so as to be distinctly
visible. The figures, arrows and letters should be painted in black on a white
background.
644 OHE Mast/Hectometre Post Numbers:-
(1) Kilometerage should be indicated on OHE Mast/Hectometer Post either by painting
or providing number plates thereon.
(2) Where single plates are provided, they should be fixed at 45 degrees to the track
and face alternatively in the up and down directions. Where one piece angle type
plates are provided, they should be fixed so that either face is at 45 degrees to the
track. Figures should be painted in black on white background.
(3) In deep-cuttings or tunnels, OHE Mast/Hectometer Post numbers should be
repeated at cess level.
(4) On double line section where one line is located away from the line along which the
OHE Mast/Hectometer Post numbers are provided and from where the figures on
the Mast/Hectometer cannot be easily read, additional rail posts should be provided
along the other line, which should indicate the corresponding OHE Mast/Hectometer
Post numbers.
(5) On electrified sections, the kilometerage is indicated on the structure posts. The
responsibility of providing number plates or painting kilometerage on the Electric
structure devolves on the Electrical Department.
645 Verification of Land Boundaries:-
(1) Every Railway Administration is responsible for the demarcation and periodical
verification of the boundaries and the maintenance of proper records in connection
therewith of all land in the possession of that Railway (Para 1048-E of Engineering
Code).
(2) The SSE/P.Way (In-charge) is responsible for maintaining the railway land
boundaries between stations and at unimportant stations. The unimportant stations
where the land boundaries are to be maintained by the SSE/P.Way (In-charge)
should be specified by the administration.
(3) The SSE/P.Way (in-charge) is responsible for reporting any encroachment that may
occur as soon as they are noticed, to the Assistant Divisional Engineer who will on
receipt of such report initiate measures to remove the encroachments.
(4) The SSE/P.Way (In-charge) shall submit, by the prescribed date every year, a
certificate to the Assistant Divisional Engineer, copy endorsed to the Divisional
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Engineer for information, in the following form:
I certify that I have inspected the railway land boundaries on my section during the year ending...
…… and that they are in accordance with the land plans. There have been no encroachments
except at the following kilometres that have been reported by me vide reference given against each.
I further certify that missing boundary stones at the kilometrages shown below have been replaced.
No Date:
SSE/P.Way (In-charge)
(5) During his inspection ADEN shall ensure that railway boundaries are demarcated
correctly and that there are no encroachments. In cases where he cannot prevail on
the parties to remove the encroachments, he must report the facts with particulars to
the DEN who will take up the matter with the Local Authorities.
646 Trolley Refuges:-
(1) Maximum distance apart of trolley refuges shall not exceed 1 km, subject to following:
(a) Cuttings – 200 m on straight and 100 m in curve.
(b) High banks – 200 m
However, Railways may provide trolley refuges at closer interval depending upon site
conditions such as speed of the trains in section, visibility, timings of the trains,
gradients etc.
(2) On double line these should be staggered, alternate trolley refuges being on up and
down sides respectively. The space between the track should be filled with ballast
and levelled up to the rail level for easy off-tracking of the trolleys opposite to the
trolley refuges.
(3) Maximum distance apart of trolley refuges on bridges will be as under:-
(a) On bridges with main spans of less than 100 metres – 100 metres.
(b) On bridges with main spans of 100 metres or more – A refuge over each
pier.
(4) In the case of tunnels, the maximum distance apart of trolley refuges shall not exceed
100 metres. For easy identification of the location of trolley refuges in tunnels and
deep cuttings a distinguishing mark such as a rail post, painted with luminous paint
with a mark ‘R’ may be erected by the side of the trolley refuge.
647 Standard Dimensions:-

(1) Infringement – The SSE/P.Way (In-charge) should refer any work resulting in
infringement of standard dimension to the ADEN for instructions. Work involving
permanent infringement should be referred to the Competent Authority for sanction
through the Commissioner of Railway Safety.
Permanent way staff shall be on the alert to prevent occurrence of –
(a) ‘Slacks’ in platform line causing the platform heights to exceed the standard
dimension.
(b) Errors in alignment causing the minimum distance to adjacent structures infringed,
for example, platform coping, over-bridges, O.H.E. structures.
(c) Excessive lifting of the track, causing minimum height to overhead structure to be
infringed, for example, underside of over-bridge, roofs of tunnels, overhead
contact wires.
(2) Verification and preparation of yearly statements of infringements – Once a year, the
standard dimensions over their sections shall be verified personally by the
SSE/P.Way (In-charge) according to the profiles shown in the schedule of
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dimensions and statements of infringements, if any, submitted to the ADEN by the
end of March. ADEN after scrutiny should forward these to DEN.
The statement shall briefly indicate against each infringement the reason for its
continuance together with reference to the sanction of Railway Board/ Commissioner
of Railway Safety. The DEN after scrutinising the yearly returns will issue necessary
instructions to the ADEN. Important items should be referred to the Chief Track
Engineer.
648 Felling of Trees Obstructing View:- (Back to Para 913) Trees and bushes that
interfere or tend to interfere with the view from a train or trolley, of signals or level
crossings or along the inside of curves, shall be cut. When cut, it should be ensured
that they do not foul the track.
When trees and bushes require to be cut in terms of Sub-Para above, on private
lands, action should be taken as laid down in Section 14 of the Railways Act 1989
(24 of 1989) reproduced below –
“14. (1) Where in the opinion of a railway administration –
(a) there is imminent danger that any tree, post or structure may fall on the railway
so as to obstruct the movement of rolling stock; or
(b) any tree, post, structure or light obstructs the view of any signal provided for
movement of rolling stock; or
(c) any tree, post or structure obstructs any telephone or telegraph line maintained
by it, it may take such steps as may be necessary to avert such danger or
remove such obstruction and submit a report thereof to the central government
in such manner and within such time as may be prescribed.”
649 Distance Pieces to Platform Lines:-Tracks adjacent to platforms should be
provided, with ‘distance pieces’ made of unserviceable timber or any suitable Material
fixed at intervals of about 30 m one end of each such piece butting against the near
rail and the other against the face of the platform wall or any other suitable
arrangement to obviate the possibility of infringement of the horizontal distance from
centre of track to face of platform coping.
650 Fouling Marks:-
(1) Fouling marks should be distinctly visible and difficult to remove.
(2) These should be fixed at the point at which the spacing between the tracks, begin to
reduce to less than the minimum as laid down in the schedule of dimensions, i.e. not
less than 4.265 m for existing yards and 5.3 m for new yard lines.
(3) The CSL (Clear Standing Length) of loop and number of wagons, which can be
accommodated in a siding or a loop, should be marked on each fouling mark.
(4) The fouling marks should consist of a stone/ cement concrete block about 1500 mm
in length, 250 mm wide and 125 mm thick, with the top edge rounded off and the top
surface white-washed or of unserviceable rail pieces embedded in concrete support
& painted white. These should be laid level with the top line of the ballast section.
651 Maintenance of P.Way Store: -SSE/P.Way (In-charge) shall maintain his store
duly maintaining all records in store module of TMS. He shall keep his store premises
neat and clean and all P.Way Material properly stacked in an identifiable manner. The
Material should be stacked in different category and in different locations duly marking
the boards for new, second hand and unserviceable or obsolete Material. He should
dispose of all the scrap and obsolete Material quickly as per the laid down procedure
in this regard.
SSE/P.Way (In-charge) should maintain minimum Imprest of the store as decided by
Chief Track Engineer depending on type and condition of track, traffic density, terrain
and other misc. features.
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652 Action in case of Derailments:-
(1) For other than LWR track:
(a) When the damage is extensive and track is distorted in such a way that it is not
possible to pass traffic even at a restricted speed, the distorted track should be
removed and replaced by track laid with available rails and sleepers. The traffic
should be restored at a restricted speed.
(b) When the damage is not extensive and it is possible to pass traffic at a restricted
speed, suitable speed restriction should be imposed after assessing the damage to
track. After all the damaged sleepers are replaced and necessary repairs are done
including welding of joints, normal speed should be restored after consolidation.
(2) For LWR Track:-
(a) When the damage is extensive and track is distorted in such a way that it is not
possible to pass traffic even at a restricted speed, the affected portion should be
isolated by introducing buffer rails/SEJ on either end of the affected portion. The
distorted track should be removed and replaced by track laid with available rails and
sleepers. The traffic should be restored at a restricted speed. The affected portion
should then be converted to long welded rails by taking usual precautions for LWR.
(b) When the damage is not extensive and it is possible to pass traffic at a restricted
speed, suitable speed restriction should be imposed after assessing the damage to
track, sleepers should be replaced as in the case of casual renewals taking
precautions as laid down for LWR/CWR. After all the damaged sleepers are
replaced, the affected portion and 100 metres on either side should be de-stressed
after consolidation, and normal speed should be restored thereafter.
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PART – ‘D’
RECORD KEEPING
653 Record of Gang Work:-Almost all the records (except few) have to be maintained
in TMS. Entries in TMS have to be made by concerned JE/SSE/P.Way, which shall
be periodically scrutinized by ADEN.
(1) Each Gang Mate should be supplied with a gang chart (Annexure - 6/2) and a gang
diary.
(a) In the gang chart, the work set to the gang for a fortnight should be indicated by
suitable notations and the details of track maintenance work done over the gang
length, on a day-to-day basis shall be recorded by the JE/SSE/P.Way, according to
extant instructions.
(b) In the gang diary supplied to each gang, fortnightly programme of work should be
entered by the JE/SSE/P.Way. Each diary should be adequate for recording the work
during the complete year
(2) At the end of the fortnight, the JE/SSE/P.Way should carry out a quantitative and
qualitative assessment of the work done after thorough inspection and make suitable
observations in the gang diary.
Temporary gangs employed in work allied to track maintenance, should also be
supplied with gang diary, wherein the details of the work set and the work carried out
will be entered by the JE/SSE/P.Way.
(3) Details of maintenance work carried out by these gangs should be entered in the
TMS for the respective permanent gang.
(4) Gang charts/diaries should be checked by ADEN and DEN during their inspections.
They should record their observation in the gang diary.
(5) On withdrawal of gang diary and supply of fresh ones, the SSE/P.Way (In-charge)
should carefully analyse the work done and take notes of kilometerages that
frequently gave trouble during the previous year, with a view to formulating such
special measures as may be necessary.
(6) Maintenance attention given to the signalled loop lines and turnouts should be
recorded in TMS and Gang Chart.
(7) Whenever the gang equipment are checked by JE/SSE/P.Way, the same should be
recorded in gang dairy against the date on which such inspection is done. Inspecting
officials should initial against the date and also make suitable entries in gang diary.
(8) Six months after the end of each year, the gang charts will be collected by the
SSE/P.Way (In-charge) and maintained as record. Thus, for the overlapping period
of six months, the gang will have two gang charts with them. A six months record
will, therefore, always be available with the gang for reference. Normally, this record
should be kept for at least five years. When a particular kilometre or section is under
special observation, the record may be maintained for a longer period at the
discretion of P.Way officials.
654 Record of Work of Artisans and Other Workmen Employed :-Each
artisan/workman will be supplied with a diary in which entries will be made by the
artisan/workman showing his movement by train and the details of daily work
performed by him. The JE/SSE/P.Way will scrutinise the work during his inspection
and make suitable observations in the artisan’s/workman’s diary. At the end of the
month, these diaries will be sent to the Office of the SSE/P.Way (In-charge).
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655 Half-yearly report on the condition of Permanent Way:-
(1) SSE/P.Way (In-charge) shall submit half- yearly Reports on the state of track in his
charge, to DEN through ADEN in the format placed at Annexure - 6/3.
(2) In this Report the SSE/P.Way (In-charge) shall make candid statement of the defects
in the track, reasons for defects and proposals for rectifying them.
(3) ADEN should check the track during his trolley inspections and verify the conditions
mentioned by the SSE/P.Way (In-charge), and also study the proposed remedial
actions. Remedial actions as necessary should be ordered within his power or
referred to the Divisional Engineer for further orders.
(4) DEN should scrutinize the half-yearly reports of the SSE/P.Way (In-charge) and the
comments forwarded by the ADEN, and give his orders thereon to the SSE/P.Way
(In-charge) through the ADEN. The ADEN and SSE/P.Way (In-charge) should
promptly attend to the orders issued by the DEN.
(5) Submission of half-year reports does not absolve the SSE/P.Way (In-charge) of this
basic responsibility of maintaining the track in fit condition for the load and speed
sanctioned for the section.
656 SSE/P.Way (In-charge)’s Section Register:-
(1) Each SSE/P.Way (In-charge) shall maintain a Section register containing all
important information including a brief history of the section. The details as under
shall be entered in the register:
(a) Administration –
(i) Change in JE/SSE/P.Way and Clerks.
(ii) Change in jurisdiction.
(b) Permanent Way –
(i) Formation – Sections giving frequent trouble with brief history and remedial
measures adopted, if any.
(ii) Track structure, method of maintenance, details of particular locations giving
frequent trouble and remedial measures adopted if any.
(iii) Details of kilometerages of track laid as short welded panels, long welded rails,
continuous welded rails, etc. incidence of buckling, maximum and minimum rail
temperatures observed.
(iv) Grades – Re-grading done, with brief details of lifting or lowering of track.
(v) Curves – Change in geometry or design Parameters of curve.
(vi) Particulars of deep screening carried out year wise.
(vii) Permanent Way renewals – Major renewal carried out as relaying, re-railing
and re-sleepering; large-scale renewal of track components at a section should
also be shown.
(viii) Station yards and sidings – Extension or alteration to yard layouts, sidings, and
platforms.
(ix) Material under trial – Brief particulars- Connect reference to notes in the
‘Materials-under-trial’ register.
(c) Bridges and Floods –
(i) Yearly record of rainfall showing month wise distribution.
(ii) Important repairs and renewal to bridges, details of extensive repairs to
bridges, dismantling and rebuilding bridges, strengthening of girders, renewal
of girders, extension of bridges and through renewal of sleepers, should be
shown. Ordinary repairs need not be recorded.
(iii) Damage due to floods – Extent of damage with particulars of rainfall,
arrangements made for labour and Material, time and labour spent for
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restoration and approximate cost. Cause of damage and notes of remedial
measures.
(iv) List of Railway affecting Works with brief history.
(v) List of vulnerable locations, where stationary watchmen are to be posted.
(d) Miscellaneous –
(i) Encroachment and steps taken to remove them.
(ii) Infringement particulars.
(iii) Accidents attributable to Permanent Way with details.
(iv) Any other important information necessary.
(2) The entries made in the section registers shall be brought up-to-date from time-to-
time and these shall be scrutinised in the beginning of every year by ADEN.
657 Permanent Way Plans and Diagrams:-
(1) ADENs shall have in their possession complete set of the following:
(a) The IRS Track manual or IRS type plans, pertaining to track sections and turnouts
over their jurisdictions.
(b) Plans and longitudinal sections of the line, to a scale of 50 metres to 1 cm
horizontal (1:5,000) and 5 metres to 1 cm vertical (1:500) and Index Plans and
sections to a scale of 0.5 km to 1 cm horizontal (1:50,000) and 10 metres to 1 cm
vertical (1:1,000) showing the physical features, alignment, grades, location of
bridges and level crossings.
The longitudinal section of the line shall be updated by surveying the longitudinal
profile of the line at least once in five years.
The necessary action for elimination of humps, sags and unevenness or providing
vertical curves as provided in Para 417 be taken if the survey reveals variations in
grades.
Such an action may also become necessary as a result of track works viz. renewal
of rail/sleepers, lifting/lowering of track, bridge works etc.
(c) Drawing of bridges, level crossings and protective works and yard layouts over
their jurisdiction.
(d) Working drawings or diagrams pertaining to track and components on their
sections, issued from time-to-time.
(e) The Permanent Way track diagram of the railway line showing the type of track and
fittings when laid, type of ballast, type of formation with classification of soil as per
RDSO’s Circular, blanket thickness, type of formation trouble (if any) and indication
of how the railway boundary is demarcated. Chainage points in the track diagram
shall be indicated correct to the nearest metre (details as in Annexure - 6/4).
(f) The Permanent Way diagrams of station yards showing complete dimension of
running lines, sidings, type of track and turnouts. (Details as per Annexure - 6/7).
(2) The SSE/P.Way(In-charge) shall have in their possession complete sets of drawings
and diagrams mentioned in item (a) and (d) to (f) pertaining to their jurisdictions; he
shall have in his possession the land plans pertaining to his jurisdictions covering
those between stations and unimportant station yards.
(3) Plans pertaining to their jurisdictions shall be maintained up-to-date by the ADEN
and SSE/P.Way (In-charge).
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658 Musters:-
(1) The attendance of the Permanent Way staff and artisans and others shall be checked
by the JE/SSE/P.Way under whom the staff are employed according to such
instructions as issued by the Administration.
(2) No over-writing in the muster sheet should be permitted. Corrections should be
attested and initialled by the JE/SSE/P.Way.
(3) Separate musters should be allotted and issued to each batch of workmen such as
Track Maintainer, Gatemen, Trolleymen and Artisans.
(4) The muster sheet should be kept by the head of each batch and at the site of work
for checking attendance by the JE/SSE/P.Way concerned.
(5) The muster sheet of Trolleymen and office staff should be kept and maintained in the
office concerned.
(6) For each wage period, the muster sheet should be collected and fresh ones issued.
Before commencement of a month, ADEN should issue requisite number of blank
muster sheet forms to each SSE/P.Way (In-charge) for the purpose of recording the
attendance.
(7) Before issue, ADEN, as a token of its authenticity, must initial on the top of each
blank muster sheet.
(8) The leave availed by each employee should be recorded in the leave register debiting
this leave to his account before the musters are dispatched to the DEN’s office.
(9) ADEN should check the musters of the staff on their sub- division and initial the
muster sheet at least once in two months during his trolley inspection.
659 Strength and jurisdiction of Gangs:-
(1) Formula for Gang Strength: The formula for calculation of gang strength based on
different activities being carried out by gang, working of track machine and other
factors is MCNTM (Committee on Manpower and Cost Norms for Track
Maintenance) formula of 2010.
(2) The strength of each maintenance gang shall be worked out by approved formula
and should be sanctioned. Yearly calculation of gang strength should be done for
each gang duly taking in to account any changes in track structure and
addition/alteration of ETKM or any other feature. Before any new track is
commissioned, the additional gang strength required for its maintenance should be
calculated and got sanctioned in advance through Divisional Office. A register should
be maintained by each SSE/P.Way (In-charge) and in the Office of the DEN and
ADENs having the required strength of manpower, sanctioned strengths of gangs,
Gatemen, Watchmen, Lookout men, Trolleymen and other staff. No deviation from
the sanctioned strength of gangs and other staff shall be permitted without the
approval of the Chief Track Engineer. All details related to gang strength shall be
entered in TMS.
660 Custody of Gang Tools:-For the safe custody of gang tools, boxes should be
provided at appropriate locations with proper locking arrangements. They may be
provided near gang quarters, gate lodges or in stations. The Gang Mate shall ensure
that all tools are deposited in the tool box after working hours and kept locked.
Track Maintainers should not leave any tool unprotected during the course of working
or during mid-day-break.
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661 Records of Material under Trial:-
(1) CTEs of Zonal Railways may order limited trials of simple items, which do not infringe
with existing provisions of standard specification or instructions laid down in
Manuals/Codes. Before undertaking the trial, complete scheme of trial should be well
chalked out including the Parameters to be periodically measured/checked, official
to measure/check, periodicity of measurement/checking as per proforma given in
TMS. All measurements/observations are to be recorded in TMS. CRS may also be
kept informed about such trials.
(2) The Zonal Railways should periodically inform RDSO through TMS about such trials
to maximize advantage.
(3) Recording – All observations related to Materials under trial duly indexed shall be
maintained by the SSE/P.Way and cross checked by Assistant Divisional Engineer.
(4) Particulars of entries – Particulars regarding each item should be completed in
regard to:
(a) Name of Material.
(b) Kilometerage where laid.
(c) Date of laying.
(d) Object of trial.
(e) Nature and condition of ballast.
(f) Nature and type of formation.
(g) Track details.
(h) Behaviour.
(i) Any other relevant information.
In the case of items designed for improved track performance, notes should be made
about the extent to which such appliances are producing the desired results,
particulars being quoted, whenever possible.
(5) Trial Lengths – Material under trial should, where practicable be laid near Assistant
Divisional Engineer’s headquarters. In the case of sleepers under trial, a special
kilometre or kilometres should be utilized for the purpose.
(6) Indication Plates – Materials under trial should be indicated by plates of suitable
dimensions fixed on the cess at either end of the trial length, the description and
number of item, date laid and kilometerage, being shown thus: (Back to Para 354)
Reconditioned sleepers
Nos. 1000, January 2021
Km 72/0 – km 72/12
(7) Removal of Materials under trial – In every case where sleepers or other Materials
under trial have to be removed because of relaying or alterations, the ADEN
concerned should report to the DEN and ask for disposal instructions. When Material
is removed for any reason, a full note should be made by the ADEN on its condition
after thorough examination. When Material under trial is removed and re-laid in
another ADEN’s length, the previous history of the Material shall be copied and
recorded in the TMS of the sub-division where it is now laid.
(8) The DEN should take interest in the trials in progress in his jurisdiction and ensure
that the stretch, where such Material is laid, is maintained to the desired standard.
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PART – ‘E’
MAINTENANCE OF TRACK IN TRACK CIRCUITED AREAS
662 Provision and Maintenance of Signalling Fixtures in Track:-
(1) Provision of signalling fixtures in track –
(a) No signal fixtures/installation, which interfere with maintenance of track should be
provided on track unless the approval for same is available from Track Directorate
of RDSO or Railway Board.
(b) S&T Department shall provide adequate number of personnel for opening of
signal rod, signal gears, other installations etc. to facilitate mechanized track
maintenance.
(2) Precautions to be taken while working in track circuited area –
(a) JE/SSE/P.Way should instruct the staff not to place across or touching two rails
in the track, any tool or metal object which may cause short circuiting.
(b) All gauges, levels and trolleys used in the track-circuited length should be
insulated.
(c) Steel or C.I. pipes used for carrying water/gas under the track should be run
sufficiently below the rails to prevent any short-circuiting.
(d) While carrying out the track maintenance, various S&T/Electrical installations
should be got removed, wherever they interfere with the maintenance activities so
as not to cause any damage of track circuit fittings like rail bonding wires, lead
wires to rails, boot leg, jumper wires etc. .
(e) Use of steel tapes should be avoided in track-circuited section.
(f) Pulling back of running rails in track should be done in track-circuited areas in the
presence of S&T staff, where signalling connections are involved.
(g) Proper drainage should be ensured so as to avoid flooding of track, during
rains, particularly in yards, where watering of coaches is done. It would be
desirable to provide washable concrete aprons on platform lines at originating
stations in track-circuited areas.
(h) Ballast must be kept clean throughout the track circuited section and care should
be taken to see that minimum ballast resistance per kilometre of track should not
be less than 2 ohms per km in station yard and 4 ohms per km in the block section
as per Para 17.28 of “Signal Engineering Manual”. On PSC sleepers track,
availability of insulated liners upto a minimum level of 97% shall be ensured.
(i) Any hole drilled in the rail for providing S&T fixtures should be at the neutral axis
of the rail and chamfered.
(j) In case of curves in track circuited area, efforts should be made to keep inner rail
as positive rail.
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PART – ‘F’
MAINTENANCE OF TRACK IN ELECTRIFIED AREAS
663 General Instructions to Staff:-
(1) General Knowledge of Engineering Staff –
(a) Every engineering official working in electrical traction area shall be in possession
of a copy of rules framed for the purpose of the operation of the Traction Power
Distribution system pertaining to Engineering Department and ensure that staff
working under him are also acquainted with the rules. He will ensure that rules
pertaining to carrying out engineering works are strictly observed.
(b) All electrical equipment, every power line or cable shall be regarded as being ‘live’
at all times. No work shall be commenced adjacent to any electrical equipment
except on authority issued in writing by a competent official of the Electrical
Department to the effect that the equipment has been made dead and earthed.
(2) Defects in Overhead Equipment – Defects or break-downs in the overhead
equipment including track and structure bonds noticed by the Engineering staff shall
be reported immediately to the Traction Power Controller. When defects in the
overhead equipment that are likely to cause damage to pantographs or trains, are
noticed and it is not possible to convey information to Station Masters or signalmen
to enable them to issue caution orders, the line shall be protected by the staff noticing
such defects according to GR 3.62.
(3) Traction Bonds – In electrified areas the return current fully or partially flows through
the rail. To ensure reliable electrical circuit continuity and also to ensure proper
earthing in case of leakage of current, various types of traction bonds as described
below are provided at suitable places and maintained by the Electrical Traction
Department.
(a) Longitudinal Rail Bonds – In the case of D.C. traction system, practically the whole
return current flows through the rail. Therefore, two flexible copper bonds offering
minimum resistance to the flow of current are provided at each rail joint under the
fish-plates. Two solid lugs at the two ends of the copper bonds are inserted in
holes drilled at the two rail ends between the fish bolt holes and are pressed by
using a bend press to rivet them firmly to the rail. On points and crossings and at
junction fish-plates where continuity bonds of the above type cannot be provided
due to space constraint, continuity of return current path is achieved by using mild
steel straps or G.I. wire ropes.
Absence of such bonds may cause unsafe working condition and in extreme
cases may damage the rail ends.
(b) Cross Bonds – Cross bonds are provided between adjacent tracks at regular
intervals to reduce resistance of the current to the minimum. Such cross bonds
are also known as transverse bonds.
(c) Structure Bonds – All structures supporting overhead equipment either in AC or
DC track circuited areas are connected to the running rails for ensuring good
earthing. Failure of insulator or leakage of current switches off the supply from the
sub- station so that men coming in contact with supporting structure etc. do not
get electric shock. Removal or tampering of such bonds can, therefore, result in
unsafe conditions. Since the structures are grouted in concrete, they are likely to
become charged in case such bonds are kept disconnected. Similarly, other steel
structures such as foot-over bridges, sheds, etc., in the vicinity of O.H.E. lines are
also connected to rails through similar structure bonds.
(d) Any hole drilled in the rail for providing OHE bonds should be at the neutral axis
of the rail and chamfered.
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(e) While carrying out the track maintenance, various OHE installations should be got
removed, wherever they interfere with the maintenance activities so as not to
cause any damage to such fixtures.
664 Special Instructions to Staff Working in Traction Area:-
(1) Need for Precautions – Precautions are required to be taken on account of following-
(a) Proximity of a Live Conductor – The risk of direct contact with live O.H.E. is ever
present while working in electrified sections such as for painting of steel work of
through spans of bridges and platform cover.
(b) Build up of potential due to return current in rails – The return current in the rails
may cause a potential difference –
(i) Between rail and the surrounding mass of earth.
(ii) Between two ends of a fractured rail.
(iii) Between the two rails at an insulated joint.
(iv) Between earth and any other metallic mass.
(2) The following precautions should, therefore, be taken while working in traction areas
–
(a) No work shall be done within a distance of two metres from the live parts of the
O.H.E. without a ‘permit-to-work’.
(b) For work adjacent to overhead equipment the Engineering Inspector shall apply
to the proper authority sufficiently in advance for sanctioning the traffic and power
block required.
The Traction Power Controller through Traction Foreman will arrange to isolate and
earth the section concerned on the date and at the time specified in consultation with
the Traffic Controller. He shall then issue ‘permit-to-work’ to the JE/SSE/P.Way. On
completion of the work the ‘Permit-to-work’ should be cancelled and Traction Power
Controller advised, who will then arrange to remove the earth and restore power
supply.
(c) No part of the tree shall be nearer than 4 m from the nearest live conductor. Any
tree or branches likely to fall on the live conductor should be cut or trimmed
periodically to maintain the safety clearances. The responsibility for wholesale
cutting of the trees, i.e. cutting of tree trunks, will rest with the Engineering
Department. In the electrified territories, however, the cutting of the trees shall be
done by the Engineering Department in the presence of authorized TRD staff to
ensure safety and satisfactory completion of the work. The day to day trimming of
the tree branches, wherever required, to maintain the 4 m safety clearances from
OHE shall be done by the authorized TRD staff and Supervisors.
In case of dispute, the decision whether to cut or trim a tree, shall be taken through
a joint inspection of Engineering and Electrical officials.
The modalities to be adopted for cutting/ trimming of the trees i.e. contractually or
departmentally, may be decided by the respective departments based on local
conditions. Accountal and disposal of trees cut wholesale will be done by the
Engineering Department. While the disposal of the trimmed tree branches will be
the responsibility of the TRD Department. The expenditure for cutting/trimming of
trees to maintain safe clearance for OHE, shall be debited to revenue grant of
TRD Department.”
(d) No fallen wire or wires shall be touched unless power is switched off and the wire
or wires suitably earthed. In case the wires drop at a level crossing, the
Gatekeeper shall immediately make arrangements to stop all road traffic.
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(e) Work on Station roofs and Signal Gantries – Staff working on station roofs and
signal gantries and similar structures adjacent to Live Overhead Equipment shall
not use any measuring tapes, tools and Materials when there is a possibility of
their being dropped or carried by wind on to the live overhead equipment.
(f) Earth Work – For excavation work adjacent to tracks, the following action is taken
–
(i) In D.C. traction areas, intimation should be given in writing sufficiently in
advance to the concerned Traction Distribution Officer to enable him to depute
the Traction staff to be present in order to prevent possible damage to the
traction underground feeder cables witch are always located near the running
lines.
(ii) In A.C. traction areas, intimation should be given to the concerned officers of
the Electrical General services and also S&T Department, since all the S&T
and Electrical lines are cabled on account of Electrical Induction.
In all A.C. and D.C. traction areas, cable markers showing location of cables are
provided by the Traction Department. In addition, the cables are protected by tiles and
bricks, and during excavation if workmen come across such tiles or bricks in an
arranged manner, they should at once report the matter to the higher officials. Any
further excavation should be carried out only in the presence of the authorised staff
of Electrical Traction and or S&T Department as the case may be.
(g) Alteration to Tracks – The relative alignments of the centreline of the track with
respect to the alignment of the contact wire must be maintained within the specified
tolerances. This applies to both horizontal and vertical clearances. Slewing or lifting
of track must not be done outside the agreed maintenance limits, unless the
position of the contact wire is altered at the same time. Adjustment of cant has a
magnified effect of the horizontal displacement of the centreline of the track with
respect to the alignment of the contact wire.
Horizontal clearances to structures within the limits laid down in the Schedule of
Dimensions must be maintained. For Slewing or alterations to track involving
adjustment of contact wire (outside the agreed maintenance limits) sufficient notice
should be given to the traction staff so that they arrange to adjust the overhead
equipment.
(h) Alterations to Track bonding – All bonds removed by the staff of the Engineering
Department shall be replaced by the staff of the Engineering Department and all
such removals and replacements shall be reported to the Assistant Electrical
Engineer, Traction Distribution in-charge, concerned without delay.
(i) Working of Cranes – No crane shall be worked except on the authorised ‘permit-
to-work’. In every case of working a crane, arrangement should be made for the
presence of authorised overhead equipment staff to ensure that all safety
precautions are taken.
(j) Inspection of Tunnels – For inspection of roofs and sides of a tunnel, the overhead
equipment shall be rendered ‘dead’. Special insulated apparatus should be used
if sounding the unlined portions to locate loose rock in the roof and sides, is
required to be carried out, when the overhead equipment is ‘live’.
(k) As far as possible closed wagons shall be used for Material trains. In case open
or hopper wagons are used, loading and unloading of such wagons in electrified
tracks shall be done under the supervision of an Engineering Official not below
the rank of a JE/P.Way, who shall personally ensure that no tool or any part of
body of the workers comes within the ‘danger zone’ i.e., within 2 m of O.H.E.
(l) Steel tapes or metallic tapes with woven metal reinforcement or metallic staff
should not be used in electrified tracks. Linen tapes are safer and, therefore,
should be used even though they are not accurate.
(m) The top foundation blocks in electrified structures should be kept clear of all
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Materials.
665 Maintaining Continuity of Track:-
(1) During maintenance or renewal of track, continuity of the rails serving electrified
tracks shall invariably be maintained. For bridging gaps which may be caused during
removal of fish-plates or rails, temporary metallic jumpers of approved design shall
be provided as under. The necessary jumper will be provided by the Electrical
Department on requisition.
(2) In case of rail fracture, the two ends of the fractured rail shall be first temporarily
connected by a temporary metallic jumper of approved design (as shown in the
sketch below). In all cases of discontinuity of rails, the two parts of the rail shall not
be touched with bare hands; Gloves of approved quality shall be used.
(3) In the case of track renewals temporary connection shall be made as shown in
Annexure - 6/8.
(4) In the case of defective or broken rail bond, a temporary connection shall be made
as shown in Sub-Para (2) above.
(5) Before fish-plates are loosened or removed temporary connection shall be made as
in sub-Para (3) above.
666 Additional precautions in A.C. Traction Area:-The following additional
precautions are required to be taken in A.C. traction areas:-
(1) Build-up of potential due to induction in metallic bodies situated close to O.H.E. – It
is important to note that dangerous voltages may be induced in metallic masses such
as fencing posts in the vicinity of traction conductors. To avoid possibility of shock
due to such voltages, the metallic structures are bonded together and earthed.
(2) Unloading of rails – When unloading rails along tracks, care shall be taken to ensure
that rails do not touch each other to form a continuous metallic mass of length greater
than 300 metres.
(3) Permanent way staffs are advised to keep clear of the tracks and avoid contact with
the rails when an electrically hauled train is within 250 m.
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667 Fire in Electrified Areas:-The Permanent Way Officials noticing a fire likely to
result in loss of life or cause damage to property shall take all possible steps to prevent
it from spreading and to extinguish it. In case the fire is on adjacent to any electrified
equipment, the Permanent Way Official shall make no attempt to extinguish the fire
but shall report the occurrence of fire to the nearest Station Master by most
expeditious means.
668 Catch Sidings:-Normally all catch sidings, except, those which are sanded, shall
be kept alive. On sanded catch siding, the rails shall be kept clear of sand for a length
of 21.5 metres, beyond the section insulators in the overhead lines and the switches
controlling the sanded catch sidings shall be kept in the neutral position. If an electric
engine or single or multiple unit train runs into the sanded length of a catch siding, it
may possibly be insulated from earth except through the buffers or couplings if
connected to other vehicles. Therefore, these sidings shall not be made alive when
an electric engine or single or multiple unit train or any vehicle coupled thereto are
standing in the sanded tracks, until, all staff have been moved away from positions
where they are likely to make contact between the Permanent Way formation and any
part of the locomotive or single or multiple unit train or coupled vehicles. No person
shall attempt to enter, or leave or in any other way make contact between the
permanent way formation and the electric engine or single or multiple unit train or any
vehicles coupled thereto while the overhead equipment of the sanded length of siding
is alive.
669 Permanent Way Tools:-Permanent Way tools (insulated and un-insulated) along
with gloves shall be used in manner as approved by the Chief Track Engineer of the
railway.
670 Treatment of Persons Suffering from Electric Shock:-When persons receive
electric shock, practically in every case they can be revived with prompt application
of First-Aid.
Method of Resuscitation – The method of resuscitation resorted to should be that
known as artificial respiration.
Continuity of Treatment – The efforts to restore breathing must be continued
regularly and with perseverance, and must not be discontinued until a Doctor has
taken charge of the case.
671 Accident to Power Lines of outside Bodies:-The Engineering Inspector shall
be in possession of the name and address of the officer-in-charge of each power line
across Railway land to enable an immediate report of any defect or accident
appertaining thereto being made, under advice to the Assistant Divisional
Engineer/Divisional Engineer.
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List of Equipment
(A) Communication Equipment 42 Axe 2 No.

1 Walkie Talkie 4 43 Motorized Wood Cutting Saw 2 No.
Sets
2 Portable field telephones 4 44 Hand Wood Cutting Saw 2 No.
Sets
3 CUG mobile Set 1 No. (I) Manual & Codes
(B) Rail cutting/Drilling Equipment 45 Working Time Table 1 No.
4 Abrasive Disc Cutter 2 No. 46 G & SR Book 1 No.
5 Rail Drilling Machine 1 No. 47 Accident Manual 1 No.
6 Chamfering kit 1 No. 48 IRPWM 1 No.
(C) Rail Welding Equipment 49 Track Machine Manual 1 No.
7 Rail Welding Equipment 2 50 USFD Manual 1 No.
Sets
8 Generator 2 No. 51 LWR Manual 1 No.
9 Weld Trimmer 1 No. 52 PN Book 1 No.
10 Rail profile Grinder for welded 1 No. 53 AT Welding Manual 1 No.
(D) Spot Tamping with lifting Lining 54 Small Track Machine Manual 1 No.
11 Off Track Hand Held Tamper 4 No. (J) Safety & Protection Equipment
12 Tamping Tools 4 No. 55 Detonators 20No.
13 Lifting Jack-hydraulic /mechanical 4 Sets 56 Banner Flag 4 No.
14 Lifting-cum Slewing Device 2 Sets 57 Red Flag 4 No.
(E) Material Handling Equipment 58 Green flag 2 No.
15 Rail Dolly 4 No. 59 Tricolour Torch 4 No.
16 Mono Rail Wheel Barrow 2 No. 60 First Aid Medical Box 1 No.
(F) Material Handling Equipment (K) Measuring Equipment
17 Joggled Fishplates 10No. 61 P.Way Kit 1 Set
18 C Clamps 20No. 62 Gauge-Cum-Level 2 No.
19 Fish plate 600 mm: 60kg/52kg each 63 Straight Edge 1 M 1 No.
10No.
20 Fish Plate 1 m:60kg/52kg each 10No. 64 Measurement Tape 15 m 1 No.
21 Fish Bolt 50No. 65 Rail Thermometer 1 No.
22 SEJ nut and bolts 20No. 66 Vernier Calipers 1 No.
23 Plate Screws 50No. 67 Micrometre 1 No.
24 Fire Extinguisher 1 Set (L) Miscellaneous
25 Wooden Blocks 10No 68 Welding Material Portion 20No.
26 Box Spanner 4 No. 69 Rail Closers of various lengths 10No.
27 Fish Plate Spanner (Small) 4 No. 70 Safety Belt 6 No.
(G) Gas Cutting Equipment with Accessories 1 Set 71 Aluminium Ladder 1 No.
(H) Tools: 72 Safety Goggles 6 No.
28 Crow Bars (IOW carbon with 20No. 73 Halogen Set 1 No.
alloy steel
29 Sledge Hammer 6 No. 74 Safety Helmet with miner light 10No.
30 Small Hammer 2 No. 75 Water Dispenser with cans 2 No.
31 Spanner (IOW Carbon steel, 2 No. 76 Tarpaulin 3 No.
chromium and vanadium alloy)
(in set)
32 Rail Tongue 6 No. 77 Rail Cutting Disc 10No.
33 Sleeper Tongue 6 No. 78 Grinding Wheel 10No.
34 Pick axe 2 No. 79 Mould Shoes(Pairs) 2 No.
35 Powrah 4 No. 80 Safety Apron for welding 10No.
36 Mortar Pan (Steel light weight) 10No. 81 Chain link 1 No.
37 Chisel 6 No. 82 Hand Gloves 10
Pairs
38 Sickle 3 No. 83 Wire Rope 15 M 1 No.
39 Wire Claw 10No. 84 2T oil
500 ml.
40 Tool Box 1 No. 85 Transmission Oil 5 Ltr.
41 Shovel 2 No. 86 Nylon Rope-15 m 1 No.
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Signature of SSE/P.Way/ Signature of ADEN Signature of DEN

(In-charge)
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Details of the 8 operations of Systematic Through Packing are as detailed below –

1. Opening of Road – Ballast should be opened out on either side of the rail seats to the
extent from end of sleepers to 450 mm inside of the rail seat to a depth of 50 mm
below the packing surface without disturbing the cores under the sleepers.
The ballast should be drawn by phowrahs/ shovels or rake iron ballast outwards and
inwards i.e. that portion of the ballast on the outside of the rail should be drawn
outwards, the portions between the rails being drawn towards the centre, care
however, should be taken to see that the ridge between the rails does not project
more than 50 mm above rail level.
2. Examination of Rails, Sleepers and Fastenings –
(i) Rails should be examined, the underside for corrosion, the ends for cracks, the
head for top and side wear, rail joints for wear on the fishing planes, fish bolts
for tightness.
1) If rails on curves wear at an unusually rapid rate, lubrication of the gauge
face should be done.
2) Rust and dust must be removed from the corroded rails by using wire
brushes.
3) Kinks in rails should be removed by Jim crowing.
(ii) Sleepers should be inspected for their condition and soundness particularly at
the rail seats.
(iii) Fastenings and fittings should be examined to ensure that they are in good
order, appropriately tightened so that they firmly hold the rails. Broken ones
should be replaced immediately.
3. Squaring of sleepers – Gauge variations and kinks inevitably result from sleepers
getting out of square, therefore the spacing of sleepers on the sighting rail should first
be checked and correctly chalk – marked. Corresponding marks should then be made
on the other rail using the square at every point.
The core of sleepers that are out-of-square should then be ‘picked’ with the pick ends
of beaters, the fastenings loosened and the sleepers levered and squared to correct
position.
Squaring should be done by using mechanical/hydraulic spacer or by planting the
crow bars firmly against the sleeper and pushing it. Under no circumstances should
sleepers be hammered. Sleepers that are squared should be re-gauged immediately,
the fastenings tightened and repacked.
4. Slewing of track to correct alignment –
(i) Heavy slewing will only be required during realignment of curves when it will be
necessary to loosen the rail, joints and the packing cores being broken with the
pick-ends of beaters. Slewing for normal maintenance will be of a small order and
should be done after opening out the road, loosening the cores at ends and
drawing out sufficient ballast at the ends of the sleepers.
(ii) Slewing of track shall be directed by the Gang Mate, who should sight the rail from
a distance of 30 to 60 meters on straight track. On curves, the Gang Mate should
sight the outer rail.
(iii) Slewing is best done in the morning unless it is cloudy, as later on, sighting
conditions become unfavourable.
(iv) Slewing should preferably be done using hydraulic/mechanical jacks or TRALIS. If
crow bars are used, these should be planted well into the ballast at an angle not
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more than 30 degrees from the vertical; otherwise lifting of the track may occur.
5. Gauging –
(i) Preservation of gauge is an important part of track maintenance especially through
points and crossings. For good riding, the basic requirement is uniform gauge over
a continuous stretch of track and such gauge should be allowed to continue so
long as it is within the permissible limits of tightness or slackness.
(ii) Gauging should only be done after ensuring that sleepers are truly square.
(iii) The track gauge cum level should be held firm with one lug against the base rail,
and the other end being swivelled over the opposite rails. The tightest position
obtained determines the correct point to test the gauge. The gauge cum level
should not be forced as that causes considerable wear on the gauge lug.
(iv) While it is desirable to maintain correct gauge, it may not be possible to maintain
correct gauge due to wear in rail and sleeper inserts. It is good practice to work
within the tolerances of gauge, as specified in Para 525 (1), provided generally
uniform gauge can be maintained over long lengths.
6. Packing of sleepers –
(i) The aim of packing is to have each sleeper firmly and uniformly packed to ensure
that the rails are at their correct relative levels i.e., level on the straight track and
to the required cant on curves and that no sleeper has any void between it and its
bed.
(ii) Before packing is commenced, it is necessary to ensure that all the fittings are
intact. Wherever feasible packing is to be done by worksite tampers. However, if
worksite tampers are not available, manual packing as detailed below may be
done.
(iii) The Gang Mate shall sight the base rail with eye along the lower edge of the head
of rail and any dip or low joint lifted correctly. The adjacent sleepers should then
be packed and the top checked. After two rail lengths have been attended to, the
rail on the other side should be brought to the correct level by checking cross level
with the gauge-cum-level at every rail joint and at every fourth sleeper. The next
two rail lengths should then be taken up and the process continued.
(iv) No joint or dip should be lifted higher than the proper level in the expectation that
it will settle to the correct level. Instead it will settle more under traffic as a result of
being high and cause rough running.
(v) Having aligned the track and the rail table adjusted, Track Maintainers should be
distributed in batches of two for packing all sleepers in a systematic manner,
commencing from one end. Four men should deal with every sleeper successively,
two at each rail seat. The ballast under the sleeper should be packed by the men
standing back-to-back and working their off track hand held tampers diagonally
under the rail seat at the same time to ensure firm packing. Where off track hand
held tampers are not available the packing can be done by crowbars / straightening
bars.
(vi) While using crowbars, it is important that the cores are thoroughly broken before
packing and re-packed.
(vii) After packing the rail seat, the packing should be continued outwards and inwards
to the requisite extent on each side of the rail seat i.e., end of the sleeper to 450
mm inside, the strokes being kept as nearly horizontal as possible. Care must be
taken to avoid forcing any large stone under the sleeper so as not to cause uneven
bearing and to avoid striking the edges of the sleepers. All men should aim to work
the crowbars from the same height so that the sleepers are uniformly packed.
Higher or lower lifting of the crowbars results in uneven compactness.
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(viii) Before final dressing is done, it should be ensured that no sleeper is centre-bound
by working the pick-ends over the central range. Centre bound sleepers cause
vehicles to roll from side to side.
(ix) Care must also be taken while packing to ensure that the work does not result in
the sleepers adjoining those being packed, lifted off their bed, thus creating artificial
voids under them.
(x) The packing on the inside and outside at every rail seat should, before boxing the
track, be checked by the Gang Mate by tapping with a rubberised Canne-a boule.
An inadequate rebound would indicate defective packing, which should be
attended to again.
(xi) As soon as the packing is completed, slight distortions in alignment and top should
be checked and corrected by the Gang Mate, the sleeper disturbed for this purpose
being finally repacked.
7. Repacking of joint sleepers – The joint and ‘shoulder’ sleepers should be repacked,
before boxing is done and the cross- levels at joints checked. The rail joint being the
weakest portion, firmness of its support is essential.
8. Boxing of Ballast section and Tidying –
(i) After completing the preceding operations in sequence, clean ballast should be
worked in with ballast forks or rakes. The ballast section should be dressed to the
specified dimensions, a template being used for the purpose. Hemp cords 6 mm
dia. of sufficient length should be used for lining the top and bottom edges of the
ballast section. Where the quantity of ballast is inadequate, full section of ballast
should be provided near the rail seat, the deficiency being reflected along the
centre of the track and not under the rails or in the shoulders.
(ii) The cess should then be tidied up.
(iii) Where earth ridging exists at the edge of the bank, it should be removed.
(iv) Cess should be maintained to the correct depth below rail level according to the
ballast-section and formation profile. Too high a cess affects drainage; too low a
cess results in ballast-spread and wastage.
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CHAPTER - 7
PERMANENT WAY RENEWALS
*********************
701 Classification of Renewals –
(1) All track renewals can be classified generally into one of the following categories:
(a) Complete Track Renewal (Primary) abbreviated as CTR(P)
(b) Complete Track Renewal (Secondary) abbreviated as CTR(S)
(c) Through Rail Renewal (Primary) abbreviated as TRR(P)
(d) Through Rail Renewal (Secondary) abbreviated as TRR(S)
(e) Through Sleeper Renewal (Primary) abbreviated as TSR(P)
(f) Through Sleeper Renewal (Secondary) abbreviated as TSR(S)
(g) Casual Renewal
(h) Through Turnout Renewal abbreviated as TTR
(i) Through Fitting Renewal abbreviated as TFR
(j) Through Fitting Renewal (R) abbreviated as TFR (R)
(k) Through Weld Renewal abbreviated as TWR
(l) Through Bridge Sleeper Renewal abbreviated as TBSR
(m) Scattered Renewal
(n) Through Ballast Renewal abbreviated as TBR
(2) Primary renewals are those where only new Materials are used and secondary
renewals are those where released serviceable Materials are used.
(3) Scattered Renewal – In this case, unserviceable rails, sleepers and fastenings are
replaced by identical sections of serviceable and nearly the same vintage track
components. These are carried out in isolated locations and not more than 10 rails
and/or 250 sleepers in a gang beat in a year. Such renewals are part of normal
maintenance operations.
(4) Casual Renewal – In this case, unserviceable rails, sleepers and fastenings are
replaced by identical sections of serviceable and nearly the same vintage or new track
components. These are carried out in isolated locations of continuous but small
stretches. Such renewals are not a part of normal maintenance operations and cannot
be covered under scattered renewals.
(5) Through Fitting Renewal (R) – In this case, through fittings renewal without
replacement of ERCs is carried out i.e. only liners and GRSPs/CGRSPs are renewed.
702 Factors Governing Permanent Way Renewal –
(1) Criteria for Rail Renewal - The following are to be considered in connection with the
criteria of rail renewals –
i. Incidence of rail fractures/failures.
ii. Wear on rails.
iii. Maintainability of track to prescribed standards.
iv. Expected service life in terms of Gross Million Tonnes of traffic carried.
v. Plan based renewals.
(a) Incidence of Rail Fractures/Failures – A spate of rail fractures on a particular
section having 5 withdrawals of rails per 10 km in a year due to fracture and/ or rail
flaws detected ultrasonically falling in the category of IMR will have priority while
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deciding rail renewals. In case the rail failures at fish plated/welded joints are pre-
dominant, end cropping with or without welding could be considered. Through Rail
Renewal is also allowed in locations of track where more than 30 defective welds
per track km are existing.
(b) Wear on Rails – (Back to Para 429)
(i) Limiting Loss of Section – The limiting loss in rail section, as a criterion for
recommending rail renewals shall be as on next page-
Rail Section Loss in section in percentage
52 kg/m 6
60 Kg/m 7
Rail wear may be determined by actual weighment, taking rail profiles at ends
after un-fishing joints and taking rail profiles with special profile measuring
gadgets.
(ii) Wear due to corrosion – Corrosion beyond 1.5 mm in the web or foot may be
taken as the criterion for wear due to corrosion. Existence of the localized
corrosion such as corrosion pits, especially on the underside of the foot and
liner biting etc. on rail foot, act as stress raisers for the origin of fatigue cracks
and would necessitate renewals.
(iii) Vertical wear is to be measured at the centre of the rail either by measuring the
height of the worn-out rail by callipers or by plotting the profile. In the first case,
the wear is the difference between the height of the new rail and the height of
the worn-out rails.
A typical profile showing the measure of vertical wear of the rail is given below
–
Limits of Vertical wear

Rail Section Vertical Wear
60 kg/m 13.00 mm
52 kg/m 8.00 mm
(iv) Lateral Wear – Limits of lateral wear from relaying considerations are as under
Section Category of track Lateral wear
'A' & 'B' Routes 8 mm
Curves
'C' & 'D' Routes 10 mm
'A' & 'B' Routes 6 mm
Straight
'C' & 'D' Routes 8 mm
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A typical profile of the worn rail showing the measurement of lateral wear is shown below –
Lateral wear is to be measured at 13 to 15 mm below the rail top table. Worn rail
profile should be recorded and superimposed over new rail profile to find out the
lateral wear.
(c) Maintainability of track to prescribed standards – There may be cases, where
renewals may be necessary on the following considerations viz,
(i) Poor running quality of track in spite of extra maintenance labour engaged for
maintaining the same,
(ii) Disproportionate cost of maintaining the portion of track in safe condition.
(iii) The condition of rails with regard to hogging/battering, scabbing and wheel
burns and other conditions such as excessive corrugation of rail as can be
ascertained by visual inspections, which affect the running quality of track, and
make the track maintenance difficult, should be taken into account while
proposing renewals.
Note: Renewals of rail due to hogged and battered rails ends should be considered
only if other remedies have not been found to be effective.
(d) Renewals on consideration of service life in terms of total GMT of traffic carried –
The rail shall be planned for through renewal after it has carried the minimum total
traffic as shown below –
Total GMT carried for
Rail Section
72 UTS rails 90 UTS rails
60 kg/m 550 800
52 kg/m 350 525
The service life in terms of total GMT of traffic carried for considering through rail
renewal on the bridge proper and in approaches (up to 100 m on either side) for
all the important bridges and such of the major bridges where height of bank is 5.0
m or more, all tunnels and their approaches (up to 100 m on either side) shall be
half of the GMT specified above. Fatigue life of the rail is likely to increase after rail
grinding.
(e) Plan based Renewals – Renewals to pre-determined plan with the objective of
modernizing the track structure on selected routes in the quickest possible time
may be planned even if it involves premature renewals.
(f) Renewal of special track components like SEJ, Glued joints etc. -Renewal of such
special track components to be planned after they have degenerated to a level
where they are not able to serve their desired purpose.
(2) Criteria for Renewal of Sleepers – (Back to Para 717, 721) Generally a sleeper is
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serviceable if it can hold gauge, provide satisfactory rail seat and permit rail
fastenings being maintained in tight condition, and retain the packing underneath
the sleepers. Concrete sleepers will be considered for replacement/renewal if they
have developed notches more than 3 mm at rail seat locations, their inserts are
broken or elongated, or they are not able to provide required toe load, sleeper
themselves are broken or any other reason for which they are not able to hold
gauge and level. Where re-sleepering only is justified, this should be carried out in
continuous stretches, the released serviceable sleepers being utilized for casual
renewals elsewhere. Through sleeper renewal should be considered if the
percentage of such sleepers exceeds 20% in a patch. On girder bridges when
several sleepers are defective, renewals should be carried out for the full span, the
released serviceable sleepers being used for casual renewals on the other spans.
The service life of PSC sleeper is given at Para 718.
703 Planning of Renewals – Renewals may be planned in as long and continuous
lengths as practicable, within the available resources with priorities to meet the
projected traffic. Short isolated stretches of 10 km and less, not due for renewal on
condition basis may be programmed along with the adjoining lengths, if these
stretches do not confirm to the required standards. Priority in planning renewals
should be given to busy and important lines.
Track renewal programmes shall be framed by the Chief Track Engineer of each
Railway taking into consideration the proposals submitted by the Divisional
Engineers.
704 Track Renewal Programme –
(1) Initiation of Proposals – Track renewal proposals are submitted to the DEN by the
ADEN on condition basis and on the basis of various inspections carried out during
the year. The DEN shall personally check the details submitted by the ADEN at site,
compile and initiate the track renewal proposal indicating the priorities. The
justification for track works shall be prepared on the basis of factually correct data and
submitted through IRPSM. It shall include an abstract estimate of the cost of work and
detailed narrative justification covering technical and financial aspects. The DEN
should personally satisfy himself about the reasonableness of the proposal and certify
that the justification furnished is factually correct. The ADEN should keep a close
watch on the condition of all track on their sub-divisions so that every length which
after careful and judicious examination requires renewal, is included in the proposals,
bearing in mind that the programme is prepared a year in advance and as much as
two years may elapse before renewals are carried out. The proposals should reach
the Chief Engineer’s Office as per the schedule prescribed under IRPSM from time to
time.
(2) Verification of proposals by the Track Cell in the Chief Engineer’s Office – Important
items relating to complete track renewal, through sleeper renewal or through rail
renewal shall be test checked by the nominated administrative officer of the
Headquarters who will –
(a) Co-ordinate the proposals received from the divisions;
(b) Frame programmes for renewal taking into account the sections planned for
renewal;
(c) Decide priority for the works;
(d) Satisfy himself that the renewal is unavoidable in the case of track renewal
proposals which are justified primarily on condition basis but are premature as far
as quantum of traffic carried (GMT) is concerned and ;
(e) Finalise the track renewal proposal and submit the same to the Chief Track
Engineer/Chief Engineer for his approval. On receipt of Railway Board’s sanction
to the track renewal proposal, arrangements will be made by the Headquarters for
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supply of track Materials to the Divisions and for co-ordinated execution and control
over the works.
705 Track Standards for Renewals – (Back to Para 715)
(1) Rails – The recommended section of rail to be adopted for track renewals shall be in
accordance with Para 205. In case of Secondary Renewals, if the condition of rail is
satisfactory, it is a good practice to crop the rail ends and weld them into SWR and
use them in lesser important lines. The rails should be ultrasonically tested before
use. The rails released from primary relaying and not fit for use in secondary relaying
should be used in sidings or non-passenger running lines in yards.
(2) Sleepers and Fastenings – The recommended types of sleepers and fastenings to be
adopted for track renewals should be as given below.
(a) All primary renewals in future shall be carried out with PRC sleepers.
(b) PRC sleepers to be used on loop lines and private sidings.
(3) Sleeper Density and Sleeper Spacing –
Sleeper density and spacing of sleepers shall be in accordance with the provisions in
Para 209.
(4) Ballast Section – The ballast section to be adopted should confirm to the standards
laid down in Para 212.
706 Planning for Posting of Staff and Other Facilities –
(1) Special JE/SSEs/P.Way with clerical staff at the executive and office levels as
provided in the estimates shall be posted. Provision of gazetted staff may be made in
the estimate in the case of large scale permanent way renewals according to the yard
sticks laid down.
(2) The JE/SSE/P.Way (In-charge) of track renewal will take over the maintenance of
suitable lengths of the section to be re-laid a few days in advance of the actual
commencement of the work. He will be responsible for its maintenance till the section
is handed over to the maintenance JE/SSE/P.Way after completion of the work.
(3) Watchman for Materials at site and at depots should be appointed. Watchman should
be drawn from the permanent gangs.
(4) The Special JE/SSE/P.Way shall make all arrangements for the transportation of
Materials, selection of camp sites etc. A fully equipped First Aid Box should be kept
at the site of work.
707 Traffic Facilities for Renewals –
(1) In the case of big relaying works, additional sidings as necessary should be provided
at the depots for receipt and dispatch of Materials as well as for working of track
relaying machines.
(2) Arrangements for special rakes for movement of rails and sleepers should be made
by the Divisional Engineer in consultation with the Operating Department. Where
necessary, separate power and crew should be arranged. Provision of additional
Engineering Time Allowance in the working time table should be arranged with the
Traffic Department.
(3) Traffic blocks may be necessary depending on the method of relaying adopted. In
such cases, the DEN should give adequate notice to the Operating Department well
in advance for the period during which the track renewal work will be carried out. Such
information is useful to the Operating Department in framing the timetable and making
the required time available by regulating certain trains, as necessary. In case of any
difficulty, the DEN should refer the matter to the Chief Engineer, who will arrange for
the required blocks in consultation with the Chief Operating Manager. A minimum
block of 2 to 3 hours duration is necessary where renewal works are carried out
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manually. In the case of mechanical relaying, a minimum block of 3-4 hours is
desirable depending upon the type of machines deployed for the work.
(4) When work is being carried out between trains in a location from where the JE/SSE/
(P.Way) cannot readily communicate with the Station Master at either side of the block
section, a field telephone, on controlled sections may be installed, in order to obtain
permit and utilize every suitable interval between trains.
(5) The DEN, in consultation with the Operating Department Officers, should manage to
carry out permanent way renewals with the minimum obstruction and detention to
traffic.
Whenever possible, the following arrangements should be made in consultation with
the Operating Department –
(a) On double line, the traffic of both lines may be worked over the unaffected line
under the “Single line-working” regulations.
(b) If there are triple or more lines, two lines may be worked as the up line and the
down line respectively, subject to compliance with single line working regulations
in respect of the line over which trains run in a direction contrary to the normal
usage of that line.
(6) Arrangements should be made for –
(a) Notification by the Operating Department to all concerned regarding work to be
executed by Engineering Department.
(b) Imposition of blocks and protection by temporary Engineering fixed signals.
(c) Issue of caution orders to Drivers by Station Masters on daily advice of actual
kilometerage received from the SSE/JE in-charge of the work.
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708 Speed Restrictions – (Back to Para 714) The speed restrictions to be imposed
during various sequences of work are given in Table I and II which are as shown below:
Table I
Manual Packing
Day Sequence of events Speed in Kmph
1st Opening, relaying and initial packing 20
2nd 1st through packing 20
3rd 2nd through packing 20
th th 45
4 to 9 Picking up of slacks as required
(after 2nd through packing)
10th 3rd through packing 45
th th
11 to 19 Picking up of slacks as required 75 (after 3rd through packing)
Speed raised to normal sectional speed, only after one round of tamping by machine in design mode
and stabilisation in controlled settlement mode
Note – The work of Track renewals on double line should normally proceed in the direction
opposite to Traffic.
Table-II (A)
Machine Packing followed by stabilisation using DTS
(Manual laying of sleepers)
1st Opening , Relaying and Packing 20
2nd Ballasting and Manual packing 20
1st Tamping in smoothening mode and 1st 40
3rd
stabilisation in maximum settlement mode. (after tamping and stabilisation)
4 & 5th
th
Ballasting 40
2nd tamping in smoothening mode and 2nd 75
6th
Survey of track for design tamping as per
7th & 8th 75
IRTMM, boxing of ballast etc.,
3rd tamping in design mode and 3rd Speed up to 110
9th
stabilisation in controlled settlement mode. (after tamping and stabilisation)
checking ride quality and attention as
10th Normal speed
required
Table-II (B)
(Mechanised laying of Track by TLE)
1st Opening, Relaying and equalisation of ballast 20
2nd& Rail renewal and welding & attention to track as
20
3rd required
1st tamping
40
4th in smoothening mode and 1st stabilisation in
(after tamping and stabilisation)
maximum settlement mode.
5th Ballasting 40
2nd tamping in smoothening mode and 2nd 75
6th
Survey of track for design tamping as per IRTMM,
7th& 8th 75
boxing of ballast etc.
3rd tamping in design mode and 3rd stabilisation Speed up to 110
9th
in controlled settlement mode. (after tamping and stabilisation
10th checking ride quality and attention as required Normal speed
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Table-II (C)
(Mechanised laying of Track by TRT)
1st Opening, Relaying and equalisation of ballast 30
2nd Welding and Manual attention to track as required 30
3rd 1st tamping 40 (after tamping and
in smoothening mode and 1st stabilisation in stabilisation)
maximum settlement mode.
4th Ballasting 40
5th 2nd tamping in smoothening mode and 2nd 75
6th& 7th Survey of track for design tamping as per IRTMM, 75
boxing of ballast etc.
8th 3rd tamping in design mode and 3rd stabilisation in Speed up to 110
controlled settlement mode. (after tamping and stabilisation)
9th checking ride quality and attention as required Normal speed
Note: The above schedule for relaxing speed is based only on expected track Parameters and
consolidation likely to be achieved after tamping and stabilisation. Other factors like ballast
deficiency, rail condition or joints in track may further restrict the speed mentioned above
709 Project Report for Track Renewal Works – Systematic and meticulous planning
for various items of execution of track works is essential for achieving quality,
economy and timely completion of works. For every sanctioned track work e.g. CTR,
TSR, TRR, deep screening, bridge sleeper renewal etc., a detailed project report
should be prepared. The report should, inter alia, cover the following aspects:
(1) Details of Work – Pink book detail, scope of work, location details, cost and estimate
particulars etc.
(2) Existing track structure – Inventory of existing track structure including the rails,
sleepers, fittings, turnouts, SEJs, Glued Joints, ballast quantity/deficiency in track,
width of formation, details of level crossings, bridges, electrical fittings, curves, height
of bank/ cuttings, yards, sidings, etc. and other details should be taken as prescribed
in P.Way diagram.
(3) Classification of Track Materials – During inventory of the existing track structure by
foot by foot survey, identification, classification and colour marking of existing track
Materials as second hand and scrap would be done as provided in Para 721 & 722.
The classification should be approved by the competent authority. Action plan for
stacking/ storage and disposal of the released Materials should be clearly indicated.
Inventory of existing track Materials would normally be prepared jointly by the
SSE/P.Way of the section and the SSE/JE/P.Way (Spl).
(4) Proposed Track Structure – The proposed P.Way diagram of the affected length
should be prepared in the same format as done for the existing track structure and
incorporated in the project report.
(5) Existing/Proposed Gradient Profile – The levels of existing track should be taken at
every 20 metres and a gradient diagram prepared. Introduction of vertical curves
should be critically examined and to be shown in the diagram where required.
Lowering of track should be avoided. Precise lift of track at girder bridges should be
worked out and a separate scheme developed for lifting of girders on each of the
affected bridges. Similarly, the magnitude of lifting at level crossing should be worked
out and indicated in the report. Care should be taken to keep the road surface at one
level on level crossings spanning to across multiple tracks. This may require regrading
of adjacent lines too.
(6) Realignment of Curves – All curves should be measured afresh and slews worked out
for realignment wherever necessary, keeping the obligatory points in view.
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(7) Method of execution – The work should be executed “bottom upwards” i.e. sequence
of execution of works will be in the following order –
Formation Ballast Sleepers Rails
(8) Formation –
(a) Repair and widening of cess – The project report should indicate the requirement
of and plan for widening of formation in both banks and cuttings wherever
necessary. Provision of proper drains in cuttings should also be planned.
(b) Formation treatment – Areas needing formation rehabilitation should be identified
and a study for possible solutions and method of execution of the rehabilitation
scheme should form part of the project report.
(9) Ballast – The requirement indicating bifurcation of cess supply and depot supply and
the source and means of each should be spelt out clearly (mode of providing ballast
cushion i.e. deep screening or raising should be identified along with sketches of cross
sections present and proposed). Sleeper renewal would normally not be started
unless adequate arrangements for supply of ballast have been made.
(10) Transportation of P.Way Materials – The mode of transportation for various track
components and unloading of rails and sleepers in particular, at the work sites should
be indicated in the project report.
(11) Welding – The complete details of welding requirements, the arrangements need to
be made for its execution whether departmentally or through contract should be
clearly indicated in the report.
(12) Renewal of Turnouts, Bridge Sleeper, etc. – The project report should cover the
complete details of turnouts, bridge sleepers, level crossings, etc. where renewal is
to be carried out. Whether turnouts are to be laid manually or by mechanized means,
should be clearly brought out indicating the arrangements made(the report should
also include the mode and agency for overhauling, track laying and making up of road
surface at the level crossings).
(13) Use of Machines – The requirement of machines for renewal (if mechanized renewal
is planned) deep screening (if mechanized deep screening is planned) and tamping/
stabilizing and the duration for which the machines are required should be indicated.
The machines that would be deployed should be identified and staff nominated. The
planning for repair of machines at the works site, supply of fuel and other
consumables should be planned. The requirement of additional lines in the existing
yards for making base depot and arrangements made for the same should be
indicated.
(14) Contracts – The contracts that are required to be entered into for various activities of
works and the activities, which are to be done departmentally, should be spelt out.
The planning for deployment of staff/supervisors for execution at various activities
should be indicated.
(15) Material Planning – The Material requirement should indicate the Materials to be
arranged by the headquarters and by the Divisions. Against each Material, the proper
nomenclature and drawing number should be indicated. Rails nos. and sizes
(including lead rails, checkrails etc.), sleepers (including specials), rails and sleeper
fastenings, switches and crossings, level crossing and bridge sleepers and fittings,
etc. should be fully covered. The consignee particulars and the destination, the mode
of transport should also be indicated.
(16) Manpower Planning – The requirement of manpower including the officers,
supervisors, artisan and other staff should be worked out with minute details. The
arrangements made for camping of these officials and mobilization should be
reflected.
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(17) LWR/CWR plans – For welding of rails into LWR/CWR, the LWR plan should be got
approved by the competent authority in advance. Such plan should form part of the
project reports.
(18) Requirement of Speed Restrictions, Traffic Blocks and other Material Train – Planning
for execution of track renewal works should be such that the time loss on account of
speed restriction is minimal and is within the permissible limits. The report should
indicate requirement of speed restrictions and traffic blocks together with duration.
The corridor for blocks is required to be planned in consultation with the Operating
Department and accordingly reflected in the report after obtaining the approval of
DRM. Arrangements made for various types of wagons for transportation of ballast,
sleepers, etc. together with requirement of locomotives should be indicated in the
report in consultation with Sr. DOM and with the approval of DRM.
(19) Monitoring Mechanism – The list of all activities involved and the time estimation for
each activity should be worked out. These activities should be sequenced and co-
related in logical manner and network diagram prepared duly identifying the critical
activities. These should form part of the project report.
(20) The detailed project report covering the various points as mentioned above should be
prepared as soon as the approval of Board to include the works in FWP is conveyed
to the Railways. These reports should be submitted to headquarters for scrutiny and
approval.
710 Preliminary Works –
(1) Where complete track renewal or through sleeper renewal is planned, deep screening
of ballast should also be planned and executed. The progress of deep screening
should match with the progress of renewals and should precede complete track
renewal or through sleeper renewal by a couple of days.
(2) Treatment of bad formation should be carried out in advance of the relaying.
(3) Reference for Centre line and level for realignment of curves and straight should be
fixed beforehand. Where necessary, curves should be realigned and transitioned.
Longer transitions should be provided to cater for future increase in speed wherever
possible. In case heavy slewing is necessary for providing longer transitions, centre
line indicating revised alignments should be fixed and new track laid accordingly. The
formation should be suitably widened.
(4) On sections where creep is noticeable, joints should be squared and gaps rectified
for short length at the point of commencement.
(5) On section with single rail and 3 rail panel, as a preliminary measure, the
JE/SSE/P.Way should actually mark out the position of the new rail joints with a tape.
The lengths marked out should be the length of the new rail together with one
expansion space. On a curve, the rail lengths should be set out along each rail,
starting from a point on the straight where the sites of the two joints have been set out
opposite one another by means of square. The square should be used at each joint
on the curve to determine the amount by which the inner rails gaining over the outer
rail. As soon as the lead of the inner rail is equal to half the distance between fish bolt
holes, a length shall be sawn off the end of the rail equal to the full distance and a
new fish bolt hole drilled. The length of cut rails varies according to the degree of each
curve, and should be determined beforehand; a cut rail will be required after every
two or three full length rails depending on the curvature.
(6) Sufficient track gauges, gauge-cum-levels, spanners, keyman hammers, insert
cleaning brush, wire basket, crow bars, tommy bars, claw bars, beaters, ballast rakes,
wire claws, forks, wire brushes, ballast screens, rail thermometers, expansion liners,
slotted fish-plates, rail closures, combination fish-plates, and all tools and equipment
necessary for efficient execution of work including that for rail cutting, rail drilling and
mechanical tampers where used, should be arranged by the JE/SSE(P.Way), in
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advance. Before starting and during the course of work, the track gauges and the
gauge-cum-levels should be checked periodically for their accuracy.
(7) Labour should be properly organized and suitably distributed to ensure maximum
efficiency.
(8) Before carrying out track renewal work in electrified areas sufficient notice should be
given to the Electrical Traction Distribution Department so that they can arrange for
adjustment of overhead wires to conform to the new alignment and level. They will
also arrange for bonding the new track. In track circuited sections and in yards where
change in yard layout is contemplated notice should be given to the Signalling
Department for getting assistance in executing joint works. Advance Notice as laid
down by the respective railway should be given to the Operating Department of the
actual commencement of work by the JE/SSE/P.Way, for sending advice to all
concerned. The safety of traffic is of Paramount consideration.
711 Unloading of Rails, Sleepers and Fastenings –
(1) It should be ensured that Materials are unloaded fairly opposite to the position where
they are to be laid. Care should be taken to avoid unloading of Materials in excess of
the actual requirement, so as to avoid double handling.
(2) Utmost care should be exercised in unloading rails. Ramps made of unserviceable
rails should be used for unloading. Short welded panels as well as rail panels for laying
welded rails may be unloaded by “end-off-loading” method, wherever possible.
(3) The unloaded panels should be carefully stacked on a level base; care being taken to
prevent formation of kinks. Flat footed rails, as a rule should rest on the foot. Any
carelessness in unloading and stacking is liable to cause irreparable damage,
resulting in bad running. While carrying rails they should be supported at several
places by rail tongs or rail slings. Carrying of rails and heavy articles on the head or
shoulder should be avoided. Kinked rails must be jim-crowed and straightened. Punch
marks on rails or marking by chisel should be prohibited as these cause incipient
failures.
(4) New rails and sleepers for the next day’s work should be hauled from the place of
unloading to opposite to the place, where they are to be laid.
(5) Material new or old, lying alongside the track is always a potential source of danger
and efforts should be made to remove the same as soon as possible.
(6) Detailed guidelines on unloading of rails and related to operation of End Unloading
Roller Rakes as contained in RDSO’s Guidelines for Handling and Stacking of Rails
October 2014 (CT-35) shall be followed.
712 Methods of Carrying out Renewal – Complete track renewal is carried out by
any one of the following methods –
(1) With Mechanical equipment.
(2) Manual Method of Relaying.
Detailed instructions shall be issued by the Assistant Divisional Engineer regarding
the method of relaying, which depends on the site conditions and availability of
machines.
713 Relaying with Mechanical Equipment – This method should be adopted while
carrying out track renewals with concrete sleepers, as the manual handling of
concrete sleepers is difficult and may cause damage to the sleepers. It can be used
with advantage for carrying out relaying with other types of sleepers also.
The preliminary (preparatory) work prior to relaying at site, the actual relaying
process at site and the post relaying operations as described in IRTMM should be
followed.
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714 Manual Method of Relaying -
The method described can be followed for single rail, 3 rail panel and LWR track. For LWR
track, in addition to the following, the precautions described in Para 346 & 347 shall also
be followed.
(1) General – In this method Through Sleeper Renewals (TSR) is carried out first.
Through Rail Renewal (TRR) is carried out after the track gets consolidated by three
rounds of through packing and also on account of passage of trains. This method can
be carried out when the section of the new rail is the same as the existing rail or where
52kg/m rails are renewed by 60 kg/m rails.
(2) Preparatory Work before Relaying –
(a) The exact position of rail joints after allowing for one expansion gap each is marked
accurately with steel tape on the base rail.
(b) Position of new sleepers is then marked on the base rail with white paint and
transferred to the opposite rail by means of T-square.
(c) A speed restriction of 20 Kmph is imposed and temporary Engineering restriction
boards are fixed at appropriate places.
(3) Work during Relaying –
(a) Deep screening is carried out under speed restriction. While carrying out the deep
screening work, renewal of sleepers is also carried out simultaneously. The work
is so programmed that at the end of a day’s work both deep screening and re-
sleepering is completed in a continuous stretch without leaving any gap.
(b) At the end of the day’s work, the track is lifted and packed to the final level and
suitable ramp should be provided to meet with the levels of the existing track.
(c) After three rounds of through packing, through rail renewal is carried out under
suitable short block.
(d) The final round of through packing is undertaken and the speed relaxed to normal
in accordance with the time scheduled described in Para 708 Table I.
Note – If adequate blocks are available for carrying out the work of deep screening,
both the deep screening and sleeper renewal works are carried out in a
continuous stretch. If, however, the work is carried out under speed restriction, as
described above, every fifth sleeper is renewed leaving at least four sleeper space
in-between intact.
(4) Post Relaying Works –
During this period, special attention is given to the following items –
(a) Alignment, surfacing, gauging, cross-levels, tightening of fittings & greasing of
ERCs.
(b) Boxing and providing full ballast section.
(c) Making up cess to the required width.
(d) Providing curve boards over each curve, providing correct super-elevation on
curves.
(e) Cleaning of side drains,
(f) Removal of all released Materials and clearing the site.
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715 Essential Points to be observed During Linking –
(1) Laying of Rails –
(a) Correct expansion gap should be provided according to the temperature at the time
of laying, in accordance with the existing instructions as contained in Para 319 in
the case of SWR. In the case of free rails (single rails) the recommended initial
laying gap for 12/13 m rail length for various temperature ranges is as follows:
Rail temperature range Recommended initial laying gap for12/13 m rail length
0 to 10°C 10 mm
10 to 25°C 8 mm
25 to 40°C 6 mm
40 to 55°C 4 mm
55 to 70°C 2 mm
Above 70°C Zero
(b) Fishing surfaces of rail and fish-plates should be greased before putting the fish-
plates in position.
(c) Bent rails shall on no account be put into the track. These should be straightened
with a jim crow, before laying.
(d) The rails used at Level Crossings and Station Yards should be given a coat of
anticorrosive painting as per Para 613(2) before laying.
(e) The shortest length of rails to be used in track shall be as per Para 614.
(f) Rails of the same length should be used in pairs.
(2) Rail Joints –
(a) Rail joints shall be laid square to track. Provisions of Para 421 and 422 will apply
while laying track on curves.
(b) Provision of rail joints at Level Crossings and approaches will be governed by
provisions in Para 918.
(c) Provision of rail joints on Bridges and approaches will be governed by provisions
in Para 226.
(3) Spacing of Sleepers – Para 209 lays down the standard spacing to be adopted in the
case of fishplated track, SWR and LWR.
(4) Gauge on Straights and Curves – The standards laid down for gauge in Para 520 (3)
(a) may be followed while relaying is carried out.
(5) Provisions of Creep Posts – Provision in Para 321(5) may be followed.
716 Track Laying standards –
(1) Utmost care should be taken during linking to ensure good quality of work, which on
no account should be allowed to suffer.
(2) As a good practice, the laying standards of track geometry during primary renewals
should be achieved (Track laid with new Materials). The track geometry will be
recorded three months after the speed is raised to normal.
(a) Track Parameters to be measured in floating condition (refer Para 520 (3))
(b) Standard Deviation and Peak based limits for unevenness and alignment as
measured by TRC, shall be as per Para 520(2).
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717 Renewal of Points and Crossing –
(1) Renewal of Points and Crossing shall be planned under following conditions:
(a) Wear on switches and crossing reaches as per Para 429 (2) (c) and Para 429 (3)
(e).
(b) After it has carried the minimum total traffic as shown below or on condition basis
S. No Item GMT carried
52 Kg 60 Kg
1 Fabricated switch (ORS) 150 200
2 Thick Web Switch 500 500
3 CMS crossing 300 300
(c) Renewal of Sleepers when they become due as per Para 702 (2)
(d) When the rail section on either side is changed to a higher section in through
running lines.
(2) Any modification in the layout of passenger lines should be carried out with the
sanction of the Commissioner of Railway Safety.
(3) The following aspects should be considered while relaying points and crossings in
station yards –
(a) When points and crossings are renewed, particular care should be taken to effect
improvements in the lay out.
(b) The renewal should as a rule be carried out with standard rail sections, in
accordance with the standard drawings and not with obsolescent sections. Special
crossing in main line, loops and sidings should be replaced with standard
crossings.
(c) At least one rail length on either side of the turnout should have the same section
of rail as the turnout.
(d) References must be fixed for the centre line of new assembly, particular care being
taken to fix accurately the inter-section point of the turnout track and the main line
track, from which measurements are taken to fix other points.
(e) Joints on the SRJ and lead rail should be welded.
(f) Gauge tie Plates – New gauge tie plates in replacement of the unserviceable ones
should be fitted jointly by the JE/SSE/P.Way and the JE/SSE (Signal). The
JE/SSE/P.Way will be responsible for the correct gauging of the switches and the
JE/SSE (Signal) for the correct fixing of the interlocking apparatus.
(g) Switches – Before stretcher bars are connected, each tongue rail should be
examined to see that it lies properly housed against the stock rail upto JOH, without
any pressure being applied to keep it in position. If a tongue rail does not fit properly
against the stock rail, it should be carefully jim-crowed.
In case of interlocked points close co-ordination should be maintained by the
JE/SSE/P.Way with the JE/SSE (Signal) and JE/SSE (Elect/TRD) (in case of
electrified sections) and work should be carried out jointly.
(4) Actual procedure of carrying out renewals –
(a) Before renewing points and crossings, the ballast in the layout should be deep
screened. After deep screening, the ballast should be laid only up to the bottom of
the sleepers and extra quantity of ballast kept ready by the side of the layout for
fully ballasting the layout, after renewal. Equipment for rail cutting and rail drilling
should be kept ready at site.
(b) Renewals can be carried out by any of the following methods –
(i) Building up at the site (Manual) – In this method, all the Permanent Way
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Materials for the turnout are brought to the site and the turnout assembled at
site in its correct position after dismantling the old turnout.
(ii) Slewing of Pre-assembled turnout at site (Manual) – The layout is assembled
by the side of the existing layout. The ground on which the turnout is to be
assembled is levelled first. If necessary room is not available, additional space
is created by doing extra earthwork or by constructing a working platform with
the old rails and sleepers. The assembly is usually built on a rail grid, the top
surface of which is greased beforehand to facilitate easy slewing. During the
block period, the existing layout is dismantled and removed and the pre-
assembled layout is slewed in its correct position, aligned and packed.
(iii) Preassembling &laying with mechanical (Machines) – IRTMM may be referred
for mechanized laying of turn out.
718 Renewal of Track Fittings and other track components- (Back to Para 702)
Renewal of track fittings to be planned after they have degenerated to a level where
they are not able to serve their desired purpose. Service Life of different fittings are
as under:
S. Item Location Criteria for Renewal
No
1 GFN-66 Liners Plain Track 200 GMT or 4 years whichever is earlier or on condition basis
2 Metal Liner Plain Track 300 GMT or 8 years whichever is earlier or on condition basis
3 ERC Plain Track 300 GMT or 8 years whichever is earlier or on condition basis
4 GRSP Plain Track 200 GMT or 4 years whichever is earlier or on condition basis
5 CGRSP Plain Track 300 GMT or 8 years whichever is earlier or on condition basis
6 PSC Sleepers Plain Track 2000 GMT or 35 years whichever is earlier or on condition basis
Note: The service life of P.Way components at special locations like turnout, CC aprons, Curves
sharper than 6 Degree, SEJ, Gradient sharper than 1 in 100, coastal areas, station yards
including approaches etc. is 50 % that of plain track or on condition basis as decided by CTE.
719 Sleepers in Yards and Running Lines –
(1) Sleeper Density –
(a) For loop lines, sleeper density would be as per Para 209(2).
(b) For other running lines and busy lines in the yards, sleeper density would be
M+4.
(c) Other yard lines should have a sleeper density of M + 2.
Where, M is the length of free rail (of 13m) in Meters
(d) For symmetrical splits where speeds on the main and loop lines will be the same,
the sleeper density to be adopted on the loop line shall be the same as that on
the main line.
(2) Types of Sleepers –
Concrete sleepers should be used for both running lines and yard lines.
720 Rails in Station Yards –
(1) In non-running lines of yards, only class II rail will be used.
(2) While carrying out through rail renewals or complete track renewal in yards, short
welded panels of 3 rail length may be used. However, it is preferable to weld them
into LWR.
(3) LWR may be provided in yards in terms of and subject to conditions laid down in
Chapter No 3, Part D pertaining to provisions on LWR.
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721 Classification and Use of Released Material – (Back to Para 709)
(1) Need for Classification-
(a) After a section of track has been renewed, the released Material shall be carefully
sorted out so that greatest possible use may be made of them. They should then
be classified by the SSE/P.Way. Tools and plant left over should also be classified
and action taken on their disposal.
(b) The rails should be graded according to their weight and condition into groups
suitable for re-use in running lines, non-running lines and for conversion into posts
or structural members for various purposes or for sale as scrap. Where rail-ends
are worn or hogged, the feasibility of “Cropping” the ends should be considered if
the condition of the rail is otherwise satisfactory.
(c) The sleepers should be sorted into various grades suitable for re-use in the track
or as unserviceable Material not fit for use in track works.
(d) Fish-plates, fish-bolts, ERCs & Liners should be sorted into those suitable for re-
use and the rest as scrap.
(e) If the switches and crossings themselves are badly worn to be re-used, the small
fittings such as stretcher bars, switch anchors, stud-bolts and blocks can generally
be used. Switches and Crossings should be reconditioned by welding, if the wear
is not excessive.
(2) Basis for Classification – For the purpose of classification, Permanent Way Materials
should be divided into three classes depending upon the section and condition as
detailed below –
(a) Class I Material is that which is new and of standard section. New items of
obsolescent sections, which are interchangeable with standard Materials and are
purchased from time to time to prevent wastage of other serviceable Material,
should be brought on to the stock account as Class I Material. These items should
be included in the price lists for the miscellaneous and common items.
No other Material of an obsolescent section is to be treated as Class I, even though
it may never have been put in the track.
(b) Class II Material includes all new Material of obsolescent sections other than those
included under Class I and all standard and obsolete Material released from the
track and fit for further use on track.
Class II released rails should be classified and sub-divided as under –
Class II (a) rails fit for use in running lines.
Class II (b) rails fit for use in non-running lines.
(c) Class III Materials shall include all Materials that has become unserviceable. This
is either metal scrap or unserviceable sleepers. This class will include all rails which
are neither Class I nor Class II.
(3) Accountal of released P.Way Materials –
(a) The quantity of released Materials from every work included for track renewal/
gauge conversion will be based on yardsticks for loss of weight to be fixed on the
basis of data collected during foot by foot survey. If there is more than one work on
the same route, near to each other and under similar ground conditions, only one
set of yardsticks would suffice.
(b) List of Materials likely to be released will be prepared indicating the quantum of
such Materials separately as second hand (SH) and scrap following the instructions
given in sub Para (2) above.
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(c) While second hand Materials will be indicated only in length/nos. in case of scrap
Materials, the accountal will be following:
(i) Rails – in length, then converted to weight.
(ii) Sleepers – nos. separately as whole and in parts.
(iii) Fittings & fastenings – by weight.
(d) During foot by foot survey, actual observations will be recorded jointly by
SSE/P.Way and ISA/Stock Verifier giving the percentage loss of weight over the
new component for each and every Material likely to be declared as `SCRAP’. This
can be done by actual weighment of few representative samples. Concrete
sleepers that have been replaced on condition basis as per Para 702 (2) shall be
declared as scrap.
(e) The yardsticks will then be approved by the Sr.DEN/DEN personally based on the
report duly test checked by ADEN or DEN. These will specify the maximum
percentage loss of weight for different components under different ground
conditions as per format given in the Annexure - 7/1.
(f) The conversion to weight in case of each of the items for purpose of accountal will
then be done by the SSE/P.Way on the basis of the specified percentage loss of
weight over the new components. In case, however, some abnormal variation of
weight is observed after the Materials have been released and the percentage loss
is more than that specified for that category, specific justification will have to be
recorded for the same by the SSE/P.Way and all such cases would have to be
certified by DEN/Sr.DEN after actual sample checking at site.
(g) In case, however, the actual loss after release is seen to be lower than the yardstick
the accountal will be done on the basis of the actual.
(h) After actual releases of Materials, the SSE/P.Way will take the releases on books
on the basis of summary sheet as per Annexure - 7/2.
(i) The sectional ADEN will carry out test checks to the extent of 20% of each item
and make entries to this effect in the summary sheet. The sectional DEN/ Sr.DEN
will also carry out random checks to ensure that the category and weight of
releases are correct to the maximum possible extent.
(j) The periodical returns for track renewals/gauge conversions are to be submitted at
the laid down periodicity as per rules and the existing procedure for checking
should be streamlined to ensure that the returns are looked into detail in the
ADEN’s office in nos.as also their conversion in weight. The returns will be
specifically checked with regard to the correctness of input/output Materials having
been prepared on the basis of instructions given in Sub Para (2) above.
(k) As an internal check by the department, one of the works accountants in the
division with engineering department or with construction department should be
made responsible to carry out methodical checks of all MAS (Material At Site)
accounts of track renewals/gauge conversion works.
(l) In cases where the track work is to be done by contractor, the list of released
Materials shall be jointly prepared on the basis of a field survey to be conducted by
the SSE/P.Way and contractor’s representative after the work has been awarded
but before the dismantling work is allowed to commence. The contractor shall be
bound to hand over the Materials according to the said agreed list and should be
responsible for any shortages.
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722 Marking of Permanent Way Material – All Permanent Way Material should be
distinguished as follows or as otherwise directed – (Back to Note of Annexure - 2/1,
709)
(1) Class I – No marks.
(2) Class II
(a) For rails –
(i) Class II (a) Second hand rail fit to be re-laid in running lines – Ends to be painted
with a daub of white.
(ii) Class II (b) Second hand rail fit for use in non-running lines – Ends to be painted
with a daub of yellow.
(b) For other track Materials like sleepers etc., -Second hand fit for use in track works
to be painted with a daub of white.
(3) Unserviceable Material Class III - not fit for use – Ends to be painted with a daub of
red.
It should be ensured by the ADEN and JE/SSE/P.Way that the Materials of each class
including fittings, are separately stacked for convenience of accounting and despatch
and indication plates erected accordingly.
723 Works to be attended after completion of relaying –
(1) Classification and loading of released Materials – Materials as and when removed
during the progress of relaying should be collected and classified and despatched to
the destination. No released Material should be left at the site of the renewals.
Relaying work shall not be considered complete until all released Materials are
removed from site and necessary credit accorded.
(2) Temporary strengthening of gangs – After the relaying is completed it would be
necessary to strengthen the regular maintenance gangs temporarily to maintain it to
the required standard for the maximum permissible speed on the section.
(3) Description Boards – Boards displaying information in regard to track Materials laid
for special or experimental purposes should be erected at each end of the length over
which the trial is being conducted & maintained only for so long as the Materials
remain under trial.
(4) Revision of Permanent Way Diagrams – As soon as the rail or the sleeper
replacement work is completed, the Permanent Way diagrams, the station yard
diagrams and the index section that embody the detailed particulars of the track in
regard to the year of laying, section of rail, type of sleepers, fish-plates& fittings should
be amended up-to-date in the Divisional office and head-quarter. The same should be
advised to all concerned. The daily progress details will also be updated in TMS.
Copies of amended diagrams should be issued by the DEN to the ADEN &
SSE/P.Way concerned for record in their offices.
(5) Closing of the Accounts – The account for relaying works should be closed within 3
months of completion of the work & completion report submitted.
Page 290 of 417

Annexure - 7/1- Para 721
LOSS OF WEIGHT OF RELEASED SCRAP (P.Way COMPONENTS)
DESCRIPTION OF WORK: __________________________________

FOOT BY FOOT SURVEY CARRIED OUT BY: ________________________________
DATE: _____________________
DIVISION: _________________
S. Description of Material Weight of Max.% loss of Weight of Remarks
No. (Rail, Sleeper, Fittings New item weight on release released
etc.) item
(1)
(2)
(3)
(4)
Annexure - 7/2-Para 721
Summary of P.Way Material to be released
Name of work
Division….…………………section…………………..SSE/P.Way………………………
DEN/Sr.DEN
Period of execution of work from dd/mm/yy to dd/mm/yy
List of Material to be released Remarks for Sign. of Test

Category Name
Km of section If scrap abnormality, JE//SSE/P check Remarks
of Service- if any .Way by
Material able or No/ Rate
Wt. (In charge/ ADEN
scrap Length (/Wt.)
Spl)
Page 291 of 417

CHAPTER – 8
ENGINEERING RESTRICTIONS & INDICATORS,
WORKING OF TROLLIES, LORRIES & MATERIAL TRAINS
PART – ‘A’ ENGINEERING RESTRICTIONS & INDICATORS

801 Work Involving Danger to Train or Traffic – A gang shall not commence or
carry on any work which will involve danger to trains or to traffic without the previous
permission of the JE/SSE/P.Way or of some competent Railway servant appointed
on this behalf by special instructions. The Railway servant who has given the
permission should be himself present at site to supervise the work.
802 Carrying Out of Works, in case of Emergency – In the case of emergency,
when the requirements of safety warrant the commencement of the work by the
railway servant at site, he shall himself ensure that Engineering signals are exhibited
at specified distances according to rules and flagmen are posted with necessary
equipment to man them, before commencing the work.
803 Responsibility of the Railway Servant In-charge of the Work – The Railway
servant in- charge of the work, who is present at the site of work, shall ensure that
Engineering signals are exhibited at the specified distance according to rules and
flagmen are posted with necessary equipment to man them. Trains shall be permitted
over the track under repair at such restricted speed as is specified, only after the track
is rendered safe for the traffic. He should ensure that the provisions of Para 804 are
fulfilled before commencing the work.
804 Works, which Obstruct the Line –
(1) Precautions before commencing operations, which would obstruct the line – No
person employed on the way, works or bridges shall, cause discontinuity in track,
disconnect points or signals or commence any other operation which would obstruct
the line without obtaining the written permission of the Station Master who shall
ensure that all necessary signals have been placed at ‘ON’. In addition, the employee
mentioned above shall also ensure that the necessary stop signals like banner flags
,detonators and hand signal flags have also been placed/exhibited at the prescribed
locations as per Para 806.
Provided further that in emergent cases the persons undertaking such operations
shall first bring the train to stop as stipulated in Para 812 and advice the driver of the
train about the need to stop the train through a written memo. The railway servant
shall simultaneously arrange to send a message to the Station Master for the need to
block the track as per Para 810 and obtain written confirmation of the same. The work
which may lead to obstruction to the track shall however be done only during the traffic
block, the written confirmation for which shall be obtained from the concerned Station
Master. On completion of the work again the authorized railway servant shall advise
the driver through a written memo to proceed at the prescribed speed.
(2) Works requiring complete block protection – The following category of works will
necessarily require complete block protection:
(a) Category of works where track is required to be occupied:
(i) Working of on-track machines
(ii) Working of Material trains or girder specials
(iii) Working of dip-lorries
(iv) Working of motor trollies
(v) Working of push trolley in heavily graded sections.
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(vi) Working of push trolley in sections where visibility is obstructed
(vii) Push trolley in long tunnels.
(b) Works where discontinuity in track is created or such conditions are created which
may result in discontinuity or obstruction to running track:
(i) Through rail renewal
(ii) Casual replacement of rail
(iii) Replacement of SEJs or replacement of buffer rail with SEJ
(iv) Insertion or replacement of glued joints
(v) Temporary/Permanent repairs of rail fractures
(vi) Temporary/Permanent repairs of rail on account of buckling
(vii) Replacement of switch/crossing or any part of turnouts
(viii) De-stressing of LWRs
(ix) In-situ welding of rails
(x) End cropping and welding
(xi) Through renewal of bridge sleeper
(xii) Replacement of girders with slabs
(xiii) Removal of rail from track for any purpose
(xiv) Renewal of sleeper on important and major bridges,
(xv) Changing of guard rails on important and major bridges.
Note:
1. Some of the works listed above may also necessitate mandatory imposition of speed
restrictions.
2. The list of works indicated above is indicative only and other works may be required to
be done under block protection based on site-specific conditions as decided by P.Way
officials.
805 Categories of Engineering Works: Engineering works can be broadly divided
into three categories –
(1) Category 1 – Works of routine maintenance, requiring no speed restriction, not
necessitating exhibition of hand signals and involving no danger to trains or traffic.
These include works of routine maintenance such as through packing, picking up
slacks and overhauling of track etc.
(2) Category 2 – works of short duration –
(a) Works such as casual renewals of rails and sleepers, adjustment of creep and
lubrication of rail joints which are completed by sunset of the day of
commencement and no restriction of speed thereafter is required, are termed
“works of short duration”.
(b) Hand-signal and banner flags and fog-signals shall be used at specified distances
to protect the trains.
(3) Category 3 – Works of Long Duration –
(a) Works such as relaying and deep screening of track, bridge construction,
diversions which extend over a few days or weeks during which period a
continuous restriction of speed is to be in force, are termed as “works of long
duration”.
(b) Temporary Engineering fixed signals shall be used at specified distances to protect
the trains. These works should be carried out to a programme, about which all
concerned will be advised in advance.
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806 Works of Short Duration (Back to Para 114(9), 114(17), 321(7), 619, 804,868)
Protection in block section and procedure for passing of trains – Before commencing
any work of such category the JE/SSE/P.Way or authorised Railway servant should
issue a notice to the Station Master/Block-hut in-charge at each end of the Block
section and obtain their acknowledgment. Depending as to whether the train is to be
passed through the work site after stopping or at a restricted speed, the line should
be protected in the following manner –
(1) When the train is required to stop at the site of work (in Block section) –
(a) Post a flagman with hand signals at a distance of 30 metres in rear of the place of
obstruction, to show stop hand signals.
(b) Post a flagman with hand signals and place a banner flag across the track at a
distance of 600 metres in rear of the work. The flagman will show stop hand
signals.
(c) Post a flagman with hand signals and detonators at a distance of 1200 metres in
rear of the work. The flagman shall fix three detonators on the line 10 metres apart
and stand at a place not less than 45 metres from the three detonators, from where
he can obtain a clear view of the approaching train. He will show stop hand signals.
(d) The man at the site of obstruction shall give proceed hand signal to indicate to the
Driver, when he may resume normal speed after the train has been hand signalled
past the obstruction (Annexure - 8/1).
(2) When the train can pass over the work spot at restricted speed in Block section - The
following protections should be adopted in the above cases –
(a) Post a flagman exhibiting caution hand signals at a distance of 30 metres from the
place of obstruction.
(b) Post a flagman exhibiting caution hand signals at a distance of 1200 metres for
Broad Gauge from the place of obstruction.
(c) Post an intermediate flagman with hand signals at a distance of 600 metres for
Broad Gauge from the place of obstruction. He will also place a banner flag across
the track. The intermediate banner flag must be kept across the line until the speed
of the train has been reduced, after which the banner flag shall be removed and
the train hand signalled forward.
(d) The railway servant at the site of work should give proceed hand signals to indicate
to the Driver, that he may resume normal speed after the train has been hand
signalled past the site of work- (Annexure - 8/2).
(3) The following points should be kept in view, while protecting the track in the cases
mentioned in sub-Para (1) and (2) above –
(a) On single line, the line must be so protected on both sides of the work.
(b) At places where there are curves or falling gradients and at times of poor visibility
the distances laid down in Sub-Para (1) and (2) above may be suitably increased
wherever necessary and intermediate flagman posted to relay hand signals.
(c) The location of the banner flag, detonators and hand signals should be so selected
as to avoid stopping of trains, as far as possible, on continuous steep rising
gradients.
(d) If in an emergency, it becomes necessary to carry out such works at night, the
provisions for protection of line as detailed in Sub-Para (1) and (2) must be
complied with except that red light must be exhibited in the direction of approaching
trains in place of red hand signalling flags and banner flags.
(e) In an Emergency, when it is necessary on considerations of safety, the
JE/SSE/P.Way, or authorised railway servant may commence such work after
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protecting the line as per GR 15.08 and 15.09, before issuing notice to the Station
Master. If the work is likely to be prolonged, he should notify the Station Master as
soon as possible.
(4) Works to be carried out in station limits –
(a) No work should be commenced on running line at a station without the written
permission of the Station Master and until the relevant signals have been placed
at ‘ON’.
(b) Before commencing a work on a line which can be isolated from the other running
lines, the JE/SSE/P.Way should ensure that the line has been isolated and retain
the keys of locking device in his possession. Where isolation is effected by the
setting of points, they must be locked by means of clamps or bolts and cotters.
(c) Before commencing work on a line which cannot be isolated from other running
lines as provided for above, the JE/SSE/P.Way should provide the prescribed hand
signals, detonators and banner flags as detailed in Para 806 (1) &(2).
(5) Works in Automatic Territory, Para 15.09 (3) (a) of General Rules 1976- – In automatic
territory, if the distance from the place of works/obstruction to the automatic signal
controlling entry of a train into the signalling section is less than 1200 metres and the
automatic signal is secured at ‘ON’ the banner flag and three detonators may be
provided at 90 and 180 metres respectively.
807 Works of Long Duration –
(1) Preliminary arrangements –
(a) For doing such works the Engineering Department will arrange with the Operating
Department for the issue of the circular/ notice as per extant instructions.
(b) The concerned Divisional Engineer will be responsible for obtaining the sanction
of Commissioner of Railway Safety wherever necessary and sending Safety
Certificate on completion of such works.
(c) The SSE/P.Way (In-charge) should obtain permission to commence work from
DEN/ ADEN and should arrange to block the line when work is proposed to be
done under block with the permission of the Controller/Chief Controller on the day
of block and issue a notice to the Station Master on either side.
(d) Caution orders will be issued by the Station Masters concerned as necessary.
(e) The necessary temporary Engineering fixed signals as prescribed should be
provided.
(f) In an emergency, when it is necessary on considerations of safety, the
JE/SSE/P.Way or authorised railway servant may commence such work before
issuing the notice, under the protection of hand signals and banner flags as per
GR 15.08 and 15.09. As soon as possible, he should issue the notice and replace
the hand signals and banner flags by temporary engineering fixed signals.
(2) Protection of line in block section –
(a) In case where stop dead restriction is to be imposed when restriction is to last for
more than a day, the following temporary Engineering indicators should be
exhibited at the appropriate distance –
(i) Caution indicator.
(ii) Stop indicator.
(iii) Termination indicators.
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(b) In case where the train is not required to stop (non-stop restriction) and the
restriction is likely to last for more than a day, the following temporary Engineering
indicators should be exhibited at the appropriate distances –
(i) Caution indicator.
(ii) Speed indicator.
(iii) Termination indicators.
Note –
(i) Annexure - 8/3 and 8/3 A indicate the distances at which these are to be
fixed.
(ii) When during the course of the work, on consideration of safety it is not
desirable to pass trains over the site of work for the time being, the track
should be further protected by hand signals and banner flags, by the
authorised railway servant.
(3) Protection of line in station limits, Para 15.09(2) of General Rules, 1976 - Protection
of the line as prescribed for block section may be dispensed with if the affected line
has been isolated by setting and securing of points or by securing at “ON” the
necessary manually controlled signal or signals and approach signal shall not be
taken ‘OFF’ for a train unless the train has been brought to a stop at the first stop
signal, except in cases where the loco pilot has been issued with caution order at the
station in rear, informing him of the obstruction and the details thereof.
808 Temporary Engineering Fixed Signals – Location and Details –
(1) These consists of
(a) Caution indicator.
(b) Speed indicator.
(c) Stop indicator.
(d) Termination indicators (T/P &T/G).
(2) (a) Multi Speed Restriction (i.e. existence of two or more than two speed restrictions
in continuation) – When work of deep screening or sleeper renewal is in progress,
there is situation of having two or more than two speed restrictions in continuation. In
such situation, placement of speed boards for following speed restriction shall be as
under:
(i) In case of following speed restriction being more restrictive, a minimum of
200 m track should be under earlier speed restriction zone. If not, then only
one SR board should be provided, considering that the previous speed
restriction is at par with the following SR, which is more restrictive.
(ii) In case of following speed restriction being less restrictive, corresponding
speed indicator board for following speed restriction shall be placed at a
distance equal to the length of the longest goods train operating on the
section after termination point of previous speed restriction zone.
(b) The details and position of fixing each indicator are detailed in Annexure - 8/3,
8/3A and 8/4.
(3) For intermediate tracks on triple or multiple lines, Engineering indicators should be
fixed between tracks to within 300 mm from rail-level, to avoid infringements of
standard dimensions.
(4) All indicators should be placed on the left hand side as seen by the Drivers except on
Centralised Traffic Control (CTC) sections (single line) where they should be placed
on Right hand side.
(5) One termination indicator bearing letters T/G should be located at a distance equal to
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the length of the longest goods trains operating on the section from the place of work.
Another Termination indicator bearing the letters T/P should be located at a distance
equal to the length of the longest passenger train operating on the section from the
place of work, which will help the passenger trains to pick up speed after reaching T/P
indicator, without losing time. The Guard of a passenger train shorter than the longest
passenger train will exhibit an “all-clear” signal to his Driver when the rearmost vehicle
has cleared the restricted length and the Driver will resume normal speed. In the case
of light-engines or single unit rail cars, the Drivers will resume normal speed after
clearing the restricted length.
809 Procedure for Passing Trains at Stop Dead Restrictions – The flagman at
the stop indicators shall present his restriction book to the Driver who should stop in
the rear of the stop indicator.
The “Restriction Book” should be to the following form:
Engineering indicator at km…………………
Date Train No. Time Signature of the Driver
After the flagman has obtained the signature of the Driver at the indicator, he should
exhibit proceed with caution signal to the Driver. The Driver will then be authorised to
pass the stop indicator and continue at this speed until his train has cleared the
restricted length, after which he will resume normal speed.
810 Procedure for Blocking Line for Engineering Purposes – (Back to Para 804)
(1) Arrangements for block –
(a) Except in very urgent cases arrangements for blocking the lines between stations
shall be made by the DEN in consultation with the Divisional Operating Manager,
sometime before the block is imposed.
(b) The Divisional Operating Manager will issue instructions to the Station Masters on
either side of the section to be blocked and Station Masters/Yard Masters of train
ordering stations concerned about the last train to pass over the section before the
block is imposed, the trains to be cancelled because of the block and any other
particulars and will conclude by stating which official of the Engineering
Department will impose and remove the block. The instructions will be
acknowledged by those to whom issued.
(c) In an emergency when there is no time to refer to Divisional Operating Manager or
where block will not interfere appreciably with the traffic the Station Master (after
consulting control on controlled section) will arrange block directly.
(2) Imposition of Engineering Block –
(a) The JE/SSE/P.Way or authorised railway servant who wishes to block the line
should transmit a message to the nearest Station Master on section to be blocked,
copy to the DEN, ADEN, SSE (Loco), Controller of controlled sections and
Divisional Operating Manager, advising them the time from which the block is to
be imposed and the kilometerage and asking for acknowledgement from the
concerned Station Masters.
(b) The Station Master receiving the message for transmission will sign for it, noting
the time of receipt and shall transmit the message to the Station Master on the
other side of the block section, which is to be blocked, and to the Controller. The
Station Master on the other side will acknowledge receipt by a message addressed
to JE/SSE/P.Way or authorised railway servant and the Station Master of the
transmitting station.
(c) On receipt of this message the Station Master of the station from which the
message was transmitted will block the line in the manner prescribed and hand
over a signed copy to the JE/SSE/P.Way.
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(d) Field telephone should be used for liaison with the Control during the block.
(3) Removal of Engineering Block –
(a) When removing a block, the JE/SSE/P.Way or authorised railway servant
responsible will transmit a message to any one of the Station Master on either side
of the block section blocked, copy to the DEN, ADEN, SSE (Loco), Controller and
Divisional Operating Manager, advising them that the block has been removed and
asking for acknowledgement from Station Masters. Particulars of kilometerage,
restriction of speed and position of Engineering Indicators should be given in the
telegram.
(b) The Station Master who receives the message for transmission will sign for it,
noting the time of receipt and transmit the message to the Station Master of the
other station. The message must be acknowledged by the latter, addressed to the
JE/SSE/P.Way and Station Master of the transmitting station.
On receipt of this acknowledgement the Station Master who originally imposed the
block, will remove it in the manner prescribed. The Control or the Divisional
Operating Manager will advise the Station Masters on the train ordering stations
when a block is finally removed.
(4) Issue of Caution Orders to Drivers – Caution order to Drivers of all trains will be issued
by the Station Masters for temporary engineering restrictions. Caution order will
indicate the exact kilometrages, speed restrictions, stops, as the case may be, but will
not include permanent restrictions that are notified in the working time-table.
811 Works at Times of Poor Visibility – In thick foggy or tempestuous weather
impairing visibility, no rail shall be displaced and no other work, which is likely to cause
obstruction to the passage of trains shall be performed except in case of emergency.
When such work has to be undertaken and the site is protected by temporary
engineering fixed signals, 2 detonators on the line 10 metres apart should be fixed
not less than 270 metres in rear of the caution indicator and a caution hand signal
exhibited to approaching trains.
812 Temporary Signals in Emergency – ( Back to Para 114(9), 114(17), 804,
1005)
(1) Whenever in consequence of an obstruction of a line or for any other reason it is
necessary for a railway servant to stop approaching train he shall plant a danger
signal at the spot and proceed with all haste in the direction of an approaching train
with a danger signal (red flag by day and red light by night) to a point 600 metres from
the obstruction and place one detonator on the line after which he shall proceed
further for not less than 1200 metres from the obstruction and place three detonators
on the line 10 metres apart. He should then take a stand at a place not less than
45metres from there, from where he can obtain a good view of an approaching train
and continue to exhibit the danger signal, until recalled. If recalled, he shall leave on
the line three detonators and on his way back pick up the intermediate detonator
continuing to show the danger signal.
(2) On single line the line must be protected on each side of obstruction.
(3) Where there are adjacent lines and it is necessary to protect such lines, action should
be taken on each such line in a similar manner.
813 Periodical Notice of Engineering Restrictions – For works involving restriction
of speeds of trains the Divisional Engineer will arrange publication in the periodical
gazette of the railway furnishing following details –
(1) The names of the block stations on either side of the site where the engineering work
will be undertaken in order that caution orders may be issued.
(2) Kilometerage of site of work.
(3) Restricted speed and stop dead restriction to be observed by the Driver.
(4) Nature of work being undertaken or reasons for restriction.
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(5) Probable duration.
814 Permanent Speed Restriction Indicators –
(1) Permanent speed restrictions boards –
(a) Permanent speed restrictions in force are notified in working time-table. The speed
indictors are erected to indicate to the Drivers the speed restrictions to be observed
e.g., between stations, and at stations due to weaker track/bridges, restrictions on
curves, grades and points and crossings etc.
(b) The indicators to be used are similar to those used for temporary restrictions,
namely, caution indicator, speed/stop indicators and termination indicators (T/P &
T/G). The details of the indicators and the distance at which they are to be fixed
are the same in both the cases (Annexure - 8/3 & 8/4).
(2) Siding Boards – When speed restriction has been imposed on account of facing points
of an outlying siding an ‘S’ marker (a circular board of1 metre dia. painted yellow, with
300 mm letter ‘S’ painted in black on it) should be fixed at the points in addition to the
speed and caution boards fixed in rear of the points. Where however, the sanctioned
speed of the section does not exceed 50 Kmph the speed indicator and the ‘S’ board
need not be provided except where the speed over the points is less than sanctioned
speed of the section. ‘S’ marker should be so fixed that the centre of the board is 2
metres above the rail level.
(3) Board indicating speed over points – Where the speed over the points at a station is
less than the speed sanctioned at other stations on the same section, a permanent
speed indicator should be fixed on the first approach signal of the station.
(4) The posts of permanent speed indicator marker boards should be painted with 300
mm high bands in white and black.
(5) Where a permanent speed restriction is in force on any intermediate track on triple or
multiple lines, the engineering indicators should be fixed between tracks to within 300
mm from rail-level to avoid infringement of standard dimensions.
815 Indicators (General):
(1) Where indicators are provided under special instructions to furnish information to
Drivers, these should be in black letters or figures on yellow back ground.
(2) Whistle indicator –
(a) Whistle boards should be provided in rear of all places where the view of the
Drivers is obstructed by cuttings or tunnels or curves and where it is necessary to
give audible warnings of the approach of a train to those working on the track. The
whistle boards are fixed at a distance of 600 metres.
(b) Whistle indicator for Level Crossings – Whistle boards are also provided on the
approach of all level crossings, where a clear view is not obtained. These bear the
letters W/L. The details of these whistle boards are described in Para 915.
(3) Shunting Limit Boards (SLB) – They are provided at an adequate distance in advance
of the trailing points. This shall consist of 600 mm x 1000 mm rectangular board
painted yellow with a black cross on the top and words “shunting limit” written in black
below it. Its height should be 2 metres from the rail level to the underside of the portion
containing the cross and the post on which it is fixed, painted with 300 mm high bands
in white and black. It should be fitted with a lamp/light showing white light in both
directions.
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816 Detonating Signals – Detonating signals otherwise known as detonators or fog
signals are appliances, which are fixed on the rails, and when an Engine (or vehicle)
passes over them, they explode with a loud sound so as to attract the attention of the
Driver.
(1) Care and Custody –
(a) Detonators should be protected against dampness. They should be stored in tin
cases with papers wrapped over them, a layer of waste cotton must be kept at
bottom and top of the tin cases to avoid contact with the metal.
(b) In one tin case not more than ten detonators should be kept.
(c) The tin cases should be stored in wooden boxes which should be kept in dry places
and not left in contact with the brick walls, damp wood, chloride of lime or other
disinfectants; these should not be exposed to steam or other vapours.
(d) Unexploded detonators should not be, as far as possible, sent from place to place
by consignment; they should be conveyed personally or by a messenger.
(2) Stock with Engineering Official –
(a) Each P.Way, Works and Bridge Engineer shall have a stock of detonators sufficient
to recoup the number annually tested and any which may be exploded for works
and emergency. The SSE/P.Way (In-charge) shall ensure that all Gangs,
Gatemen, Keymen, Patrolmen and Watchmen are equipped with the specified
number of detonators.
(b) Every ADEN, Gang Mate, Keyman, Gateman, Patrolman and Watchman, whose
duties include protection of track shall carry the specified stock of detonators with
him on duty, for use during an emergency.
(c) The month and year of manufacture are shown on the label outside each case and
also stamped on each detonator. Detonators should be used in the order of the
dates stamped on them, the oldest being used first. To facilitate ready withdrawal
in this sequence, they should be stored also accordingly.
(3) Use of Detonators –
(a) The staff in possession of detonators shall not make any improper use of them. All
Engineers are responsible to ensure that the staff working under them know how
and when to use detonators.
(b) A detonator when required to be used shall be placed on the rail with the label or
brand facing upwards and shall be fixed to the rail by bending the clasps around
the head of the rail.
(4) Testing –
(a) Once a year, one detonator shall be taken by the SSE/P.Way (In-charge) from his
own stock and from Gang Mate, Keyman, Gateman, Patrolman and Watchman for
testing, one also from each of the lots in the personal custody of DEN, Bridge
Engineer, ADEN, SSE (Works), JE/SSE/P.Way where the headquarters of these
officials falls within the SSE/P.Way's jurisdiction. The oldest detonators should be
selected for the test.
(b) The testing of detonators should be done under an empty 8-wheeled wagon
propelled by an engine and moving at walking speed under the direct supervision
of the SSE/P.Way (In-charge), who shall ensure safety range during testing.
Results of tests should be entered in a Register.
(c) The SSE/P.Way (In-charge) shall submit by the end of the year (31st December)
a certificate in duplicate to the Assistant Divisional Engineer to the effect. “I certify
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that I have tested the detonators from stocks mentioned below in accordance with
standing orders for the year ending ….. and append a list of those that failed to
explode.” The ADEN shall countersign and forward one copy of the certificate to
the DEN with remarks, if any. Orders regarding the return or destruction of those
lots, the samples from which failed to explode, shall be issued by the DEN.
(5) Life of Detonators – The normal life of detonators is five years. The life of the
detonators can be extended to eight years on a yearly basis subject to the condition
that two detonators from each lot of over 5 year old ones are tested for their
effectiveness as discussed above and the results being found satisfactory. Such time
extended detonators can be used on all sections after satisfactory testing. In case the
results are not satisfactory, they should be destroyed as envisaged in Sub-Para (6)
below. In any case, no detonator should be kept in use after 8 years.
(6) Disposal of Time-barred Detonators – No detonator that bears any sign of rust
and is time- barred shall be held in stock. Such detonators shall be destroyed by one
of the following methods
(a) By soaking them in light mineral oil for 48 hours and then throwing them one by one
into fire with due precautions.
(b) By burning them in incinerator.
(c) By detonating them under wagon during shunting operations.
(d) By throwing them in deep sea.
The destruction of time-barred detonators should be done in the presence of a
JE/SSE/P.Way who should ensure that every care is taken to see that splinters of
detonators do not cause any injury to life and property. They should not be buried or
thrown in places from where they could be recovered.
(7) Safety Range – When detonators are being tested, no person should be allowed
within a radius of 45 metres from the detonators to be exploded; the engine crew shall
remain well within the cab. In practice, splinters from detonators when exploded
seldom fly in a direction to the rear of the wheel, which detonates them. Staff should
therefore, when observing the safety radius, place themselves, as far as possible on
the rear side.
817 Warning Signal - Descriptions – (Back to Para 910) The signals to be used to
warn the incoming train of an obstruction shall be red flashing hand signal lamp at
night or red flag during day as per Para 3.65 of General (Amendment) Rules, 1976.
818 Use of Warning Signals – When it becomes necessary to protect an obstruction
in a Block section, a warning signal may be used, as prescribed under Para 3.66 of
General (Amendment) Rules, 1976 while the railway servant proceeds to place
detonators. A warning signal is to be shown to give timely warning to a driver of
approaching train of any obstruction such as derailed train obstructing adjacent lines,
breaches, wash away, floods, landslides etc., when the railway servant does not have
adequate time to do the protection in the normal manner with the detonators as
envisaged under rules. The knowledge and possession of warning signals shall be
ensured by every railway servant concerned with the use of warning signals as
stipulated in Para 3.67 of General (Amendment) Rules, 1976.
819 Safe Working of Contractors – A large number of men and machinery are
deployed by the contractors for track renewals, gauge conversions, doublings, bridge
rebuilding etc. It is therefore essential that adequate safety measures are taken for
safety of the trains as well as the work force. The following measures should invariably
be adopted:
(1) The contractor shall not start any work without the presence of railway supervisor or
his representative and contractor’s supervisor at site.
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(2) Wherever the road vehicles and/or machinery are required to work in the close vicinity
of railway line, the work shall be so carried out that there is no infringement to the
Railway’s Schedule of Dimensions. For this purpose, the area where road vehicles
and/or machinery are required to ply, shall be demarcated and acknowledged by the
contractor. Special care shall be taken for turning/reversal of road vehicles/machinery
without infringing the running track. Barricading shall be provided wherever justified
and feasible as per site conditions.
(3) The look out and whistle caution orders shall be issued to the trains and speed
restrictions imposed where considered necessary. Suitable flagmen/detonators shall
be provided where necessary for protection of trains.
(4) The supervisor/workmen should be counselled about safety measures. A competency
certificate to the contractor’s supervisor as per proforma annexed shall be issued by
ADEN which will be valid only for the work for which it has been issued. (Annexure -
8/5).
(5) The ballast/rails/sleepers/other P.Way Materials after unloading along track should be
kept clear off moving dimensions and stacked as per the specified heights and
distance from the running track.
(6) Supplementary site-specific instructions, wherever considered necessary, shall be
issued by the Engineer in-charge.
(7) The Engineer in-charge shall approve the methodology proposed to be adopted by
the contractor, with a view to ensure safety of trains, passengers and workers and he
shall also ensure that the methods and arrangements are actually available at site
before start of the work and the contractor’s supervisors and the workers have clearly
understood the safety aspects and requirements to be adopted/ followed while
executing the work.
There shall be an Assurance register kept at each site, which will have to be signed
by both, i.e. Railway Supervisor or his representative as well as the contractor’s
supervisor as a token of their having understood the safety precautions to be
observed at site.
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PART - ‘B’ - WORKING OF TROLLIES, MOTOR TROLLIES AND LORRIES
820 The Rules for working trollies, motor trollies and lorries are contained in Para 15.18
to Para 15.28 of Chapter XV-B of General Rules for Indian Railways (1976),
supplemented by the Subsidiary Rules issued by individual railways. The instructions
contained in this chapter are in amplification of these rules and will not supersede the
General and Subsidiary Rules of Railways.
821 Distinction between Trolley, Motor Trolley and Lorry –
(1) A vehicle which can be lifted bodily off the line by four men shall be deemed to be a
trolley. Any similar but heavier vehicle (which includes Dip Lorry) shall be deemed to
be a lorry.
(2) Any trolley which is self-propelled, by means of a motor, is a motor trolley.
(3) A trolley shall not, except in cases of emergency, be used for the carriage of
permanent way or other heavy Material, and when a trolley is so loaded, it shall be
deemed, to be a lorry.
822 Certificate of Competency-
(1) No trolley, motor trolley or lorry shall be placed on the line except by a qualified person
appointed by special instructions.
(2) Such qualified person shall accompany the trolley, motor trolley or lorry and shall be
responsible for its proper protection and for its being used in accordance with special
instructions.
(3) The qualified person shall hold a certificate of competency which shall be issued
according to prescribed instructions in Chapter 14.
(4) Staff in whose favour a certificate is issued should be literate, having knowledge of
Hindi or other local languages, should have passed the prescribed Medical test and
should be conversant with the rules for working of trollies, motor trollies and lorries,
as the case may be. The certificate of competency will be issued for a specified period
by an officer authorised to do so and renewed periodically.
823 Officials Permitted to use Trollies, Motor Trollies and Lorries – Subject to
their being certified competent, the following officials of the Engineering Department
are permitted to use Trollies/Lorries:
(1) Trollies/Lorries –
(a) All officers and JEs/SSEs of Engineering Department.
(b) Gang Mates, Head Trolleymen as may be authorised.
(2) Motor Trollies – All officers of Engineering Department, motor trolley Drivers and such
JEs/SSEs as may be authorised.
824 Responsibility for Safe Working –
(1) The official-in-charge of Trolley/Motor Trolley/ Lorry is responsible at all times for its
safe working. When more than one person holding competency certificate travels in
a trolley, the official-in-charge of the trolley is responsible for its safe working.
(2) It shall be clearly understood by officers and staff that they are to take every possible
precaution and protection against accidents. When entering a tunnel or cutting or
proceeding over a long bridge or curve, the official-in- charge will make sure that no
train is likely to be met. While approaching a level crossing the official-in-charge,
should look out for road traffic and ensure safe passage of his vehicle over the level
crossing.
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825 Efficient Brakes – No Lorry, Trolley or Motor Trolley shall be placed on the line
unless, it is fitted with efficient brakes. The brakes should be tested before the
commencement of each journey. It is desirable that trollies and lorries working on
Ghat section are fitted with screw down brakes in addition to ordinary hand/foot
brakes. It will be the responsibility of the official-in-charge to ensure the adequacy of
braking.
826 Attachment to Trains Prohibited – No Trolley/Motor Trolley/Lorry shall be
attached to a train.
827 Working on Track Circuited Sections and Sections Provided with Axle
counters – Each Railway shall issue subsidiary rules for the working of
Trollies/Motor Trollies/Lorries in sections where axle counters or track circuits form
part of the Block instruments or where automatic signalling has been provided.
828 Numbering of Trollies/Motor Trollies/ Lorries – Each Trolley/Motor Trolley and
Lorry shall be marked with its number, code, initials of the department, the designation
and headquarters of the official-in-charge.
829 Conveyance of Trollies/Motor Trollies/ Lorries by Trains –
(1) No Trolley/Motor Trolley / Lorry should be loaded in a train without the consent of the
Guard in-charge of the train, who will direct where it is to be placed.
(2) In the case of an accident/emergency, Trollies / Motor Trollies may be carried by Mail
/ Express trains on which there are restrictions normally for loading of Trolley/Motor
Trolley.
(3) When loading a motor trolley with petrol in the tank, it shall be ensured that
(a) The flow of petrol in the carburettor has been cut off;
(b) Any pressure has been released from the tanks;
(c) The tank is in sound condition and closed by a well fitted cap;
(d) The engine has been run by the official- in-charge until the carburettor has
become exhausted and the engine stops automatically.
830 Trollies, Motor Trollies and Lorries not in use –
(1) A trolley, motor trolley or lorry, when not in use shall be placed clear of the line, and
wheels thereof secured with a chain and padlock.
(2) When a trolley/motor trolley is placed on a platform to be loaded into a train, it should
be under the charge of a Trolleymen and placed where it will not be in the way of
passengers or working staff.
(3) Whenever possible, motor trollies, should be placed in a shed, the key of which, shall
be in the possession of the official-in-charge.
831 Conveyance of Non-Railway Officials – Trollies shall not be used for the
conveyance of persons other than railway officials. In special cases, Magistrates,
Police, Civil, Telegraph, Military, Medical and Forest Department Personnel or a
person requiring medical aid, may be conveyed by trolley by order of the competent
authority (ADEN or above), after a bond on form in Annexure - 8/6 is signed
indemnifying the Railways against all liabilities and risks.
Contractors and their Agents may be conveyed on trolley in connection with works,
provided they have executed a general indemnity bond similar to Form Annexure -
8/6.
832 Trolley-Permits for Private Sidings – A non-railway official is permitted to use a
trolley on private sidings when he is in possession of a permit signed by the competent
authority. Such permits are granted for use of the trolley on sidings where there is no
passenger traffic. The party shall execute a bond on Form Annexure - 8/7
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indemnifying the Railways against all liabilities and risks. The issue of trolley permits
will be subject to such rules as may be prescribed. In such cases, the Head
Trolleyman shall hold a certificate of competency issued by the authorised Railway
Official.
833 Military Officers Using Trollies in Ordnance Depots – Railway shall not
accept any liability whatsoever for damage or compensation arising out of accidents
caused in the working of trollies used by Military Officers on duty in Ordnance
Factories in respect of claims of Officers themselves or third persons.
834 Trolley Refuges and Observation Posts –
(1) Trolley Refuges – Trolley refuges over long Bridges should be provided at such
intervals, as prescribed in the Schedule of Dimensions. In cuttings and high banks
trolley refuges should be provided at suitable intervals.
(2) Observation Posts – Where, owing to curves in cuttings or other causes view of the
line is restricted, “observation posts” should be established at such sites as command
the best view in both directions for the use of Flagmen, thus enabling hand signals
being conveyed to the trolley on line.
835 Equipment for Trolley / Motor Trolley / Lorry – Each trolley/motor trolley/lorry
shall have the following equipment:
(1) Two hand signal lamps/Tri colour LED Flashing hand signal lamp
(2) Two red and two green hand signal flags;
(3) Detonators 10 Nos;
(4) A chain and a padlock;
(5) A copy of the Working Time Table and all correction slips and appendices, if any, in
force on that section of the railway over which the trolley, lorry or motor trolley is to
run;
(6) A motor horn and a search light (for motor trolley only);
(7) Two banner flags and additional detonators (for lorry only); and
(8) Such other articles as may be prescribed by the Railway Administration in this behalf.
Note – The official-in-charge of the trolley/motor trolley/lorry shall also be in
possession of a watch in addition to the prescribed equipment.
836 Signals for Trolley / Motor Trolley / Lorry –
(1) Day Signal – Every trolley, Motor trolley or Lorry when on the line shall show a red
flag by day, fixed to a staff which will be placed on a socket and conspicuously visible
in both directions.
(2) Night Signal – On a double line the night signal shall be red light in the direction from
which trains are expected and white in the other direction and on a single line, red in
both directions. Where on double line, single line working is introduced, the night
signal should be as per a single line. When working within the station limits, the light
displayed at night shall be red in both directions.
(3) Signals within long tunnels – On sections where there are long and dark tunnels, the
night signals prescribed must be displayed during the day in addition to the red flag,
in the case of Trollies, Motor trollies and Lorries. In the case of thick foggy or
tempestuous weather impairing visibility, light signals must be displayed in addition to
the red flag.
(4) Removal of Trolley/Motor trolley/Lorry – As soon as a Trolley/Motor trolley/Lorry is
removed from the track and placed clear of it, the red flag or light signal shall be
removed, but care should be taken to see that this signal is not taken off before the
lines have been cleared of all the obstructions.
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837 Working of Trollies –
(1) Manning of trollies – Trollies in all cases shall be manned by four men.
(2) Mode of working of trolley – Trollies in all cases should be pushed and not pulled.
(3) Working under Block Protection –
(a) Trolley may be worked under Block protection wherever it is possible to do so
without interference to train service.
(b) Trollies should be worked under Block protection in the night.
(c) During daytime in foggy weather and during dust storm, when the visibility is
poor, a Trolley should be worked under Block protection.
(d) Sections with restricted visibility due to curves, cuttings or due to other local
conditions specified by Railway Administration, wherever practicable, should be
traversed under Block protection.
(e) When working under Block protection Trollies will be worked in the same
manner as trains.
(4) Working without Block protection – (Back to Para 838)
(a) During day time in sections with normal visibility the official-in-charge shall
before leaving a station/Block post, ascertain the whereabouts of the trains likely
to be met and set off on trolley.
(b) In sections with restricted visibility specified sections, (Ref- Sub-Para (3) (d))
when the official-in-charge, is not able to block the section and work under Block
protection, he will follow the following procedure:
(i) The Station Master/Signalman will on receipt of advice from official- in-charge
(in triplicate on form Annexure - 8/8) giving his trolley programme ascertain and
fill in particulars of trains running on the section, retain one copy and return the
other two to the official-in-charge of the trolley.
(ii) As a reminder that the block section is occupied by the trolley and caution orders
must be issued, a small placard with words “Trolley on line”, will be hung in front
of the block instrument, until advice of the removal of the trolley is received.
(iii) If telegraph and telephone communications are interrupted and the Station
Master/Signalman is unable to communicate with the station at the other end of
the block section, the official-in-charge of the trolley will be advised of this fact
and form Annexure - 8/8 endorsed accordingly. When communication between
the two stations is restored, the messages referred to above will be exchanged,
if the trolley has not cleared the section or removal report has not been received.
(iv) From the time of exchange of the messages, until intimation has been received
that the trolley has cleared the block section, the Station Master/ Signalman at
both ends of the block section shall issue caution orders to Drivers of all trains
entering the block section. On the double line, caution order should be issued
for both up and down trains.
(v) The issue of caution orders in no way relieves the official-in-charge of the trolley
of the duty of complying strictly with the rules for protecting the trolley.
(vi) On arrival of the trolley at the other end of the block section, the person- in-
charge of the trolley shall fill in the removal report and send it to the Station
Master/Signalman who will return the third copy signed. The Station
Master/Signalman will then advise the Station Master/ Signalman at the other
end of the block section of the trolley having cleared the section.
(vii) If the trolley is removed from the track at the station not provided with telegraph
or telephone instruments or in the block section and if it is not intended to place
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it on the track again, the official-in-charge of the trolley shall fill in the removal
report and send it to the Station Master/Signalman at the nearest block station.
In the former case, the Station Master will send written advice by the first train
in either direction to the next block station. The Station Master/Signalman at the
latter station should then advise the Station Master/Signalman at the other end
of the removal of the trolley.
(viii) Station Masters/Signalmen at the both ends, of the block section will enter
remarks in the train registers pertaining to the block section concerned showing
the times at which the trolley entered and cleared the block section and the
number of the trolley.
(5) Protection in Block Section – (Back to Para 838)
(a) When a trolley is worked other than under the rules for working of trains i.e.,
without block protection and when a clear view is not obtainable for an adequate
distance of 1200 m, the following precautions should be taken (Annexure - 8/9)
(i) On a double line, he must depute a Flagman with detonators to precede or
follow the trolley, and to exhibit a hand danger signal at a distance of not less
than 1200 m in the direction from which trains may approach.
(ii) On single line, depute a Flagman with detonators to precede and another to
follow the trolley and to exhibit hand danger signals at a distance of not less
than 1200 m.
(iii) Where necessary, intermediate Flagman should be posted to relay signals.
(b) The flagman should only be withdrawn when a clear view of at least 1200 m can
be obtained in the direction from which trains may approach.
(c) When a train is sighted, the Flagman should wave the red flag vigorously to
warn the official-in-charge of the trolley of the approach of the train, and at the
same time place three detonators 10 m apart on the line to protect the trolley.
The detonators should be removed only on receipts of hand signals from the
official- in-charge by waving of a green flag to withdraw the danger signal
indicating that the trolley has been removed.
When conditions are such that the Flagman cannot be seen by the official- in-
charge of trolley, the latter must arrange before entering the section to take with
him sufficient men with hand signals who will be placed in suitable positions
between the trolley and the Flagman so that the signals from the Flagman can
be repeated to the person- in-charge of the trolley and vice-versa.
(d) On sighting an approaching train or the Flagman’s signal, the trolley must be
removed clear of the line and kept in such a manner that it cannot roll towards the
line.
(6) Trollies travelling together – When two or more trollies are running together in the
same direction in the same line, care should be taken to ensure that they are kept at
least 100 m apart to safeguard the trolley in rear from colliding with the front one, in
case the front trolley has to be stopped suddenly for any reason.
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838 Working of Motor Trollies –
(1) A motor trolley shall only be run in accordance with special instructions.
(2) A motor trolley may be worked under block protection or without block protection, as
may be prescribed by the Railway Administration.
(3) Working under block protection –
(a) A motor trolley should be run only under block protection (i) during night; (ii)
during day time, when the visibility is poor due to fog or dust storm.
(b) Sections of restricted visibility should invariably be traversed under block
protection. A list of “sections of restricted visibility” may be specified for the
guidance of all concerned, either in the subsidiary rules or in the working time
table.
(c) When a motor trolley that is worked under block protection breaks down in the
block section, the official-in-charge should remove it clear of the line and send
a written advice to the nearest Station Master/Block Hut -in-charge returning the
line clear ticket or token or in the case of a motor trolley when the token has
been clamped for a preceding train the key of the padlock. He should not replace
the motor trolley on the line without the written permission of either Station
Master/Block Hut-in-charge at the end of the block section concerned. On arrival
at the other end, the official- in-charge will deliver the authority to the Station
Master after the trolley has arrived complete.
(4) Following a Train/Motor Trolley – Motor trolley may follow a fully vacuum/air brake
train or a Light engine or another motor trolley in the same block section during day
light hours and in clear weather under special instructions issued by the Railway
Administration.
(5) Working without block protection –
(a) When a motor trolley is worked without block protection, it should be manned
by at least four men.
(b) In case a motor trolley is worked without block protection, the procedure outlined
in Para 837(4) for trollies shall be followed for working of the motor trollies.
(c) When a motor trolley is worked without block protection, as per special
instructions, the procedure outlined in Para 837(5) should be followed for the
protection of trolley in block section.
839 Working of Lorries –
(1) Mode of working of lorry – Lorries should be worked only under block protection.
Lorries in all cases should be pushed and never pulled. Riding of persons on the same
is prohibited.
(2) Manning of Lorries – , Lorry must be accompanied on foot by not less than four men
in addition to the number of men required for expeditiously loading and unloading
Materials being conveyed on the lorry.
(3) Actual working of lorry –
(i) Before obtaining line clear, the official-in-charge of a lorry should advise the
Station Master/Block Hut- in-charge, whether it is his intention to return to that
station, to run to the other end of block section, or to remove the lorry in mid-
section.
(ii) The official-in-charge, after getting the authority to proceed in the form of line
clear ticket/token, double line certificate or shunting key, as the case may be,
should work his lorry.
(iii) He should, after completion of his work, hand over the authority to proceed to
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the concerned Station Master/Block Hut-in-charge and remove his lorry.
(iv) In case the lorry is off loaded in the mid-section, the authority to proceed should
be returned by a special messenger to the nearest station after ensuring that
the lorry is kept clear off the line.
(v) On the double line, the official-in- charge should run the lorry on the proper road.
The lorry should be taken along the line in the direction in which the trains will
run; except when returning to the original starting station/Block Hut.
(4) (a) Working in Station limits – When a lorry is required to work within Station limits,
the permission of the Station Master shall be obtained in writing before working
the lorry and the lorry should be worked as per the approved special
instructions.
(b) Protection in Station limits – When a lorry works in a station yard the Flagman
must exhibit danger signals at such a distance on both sides as will ensure
safety. When the lorry is required to remain stationary for more than 15 minutes,
it must be protected by banner flags placed at an adequate distance
supplemented by three detonators on both sides.
(c) When a lorry has to work on a section with a steep down gradient (gradients
steeper than 1/100), the same should not only be controlled by hand brakes,
but by a rope tied in the rear and held in tension by men following a lorry.
840 Working of Moped Trollies –
These are light motor trollies, which can be lifted off the track normally by three men.
They should be manned by at least three men including the Driver. These may be
worked as per the rules pertaining to a Motor Trolley, for which the Railway
Administration may issue special instructions, as necessary.
841 Rail Dolleys –
(1) Rail dolley is a device with two or more wheels, which in balanced condition, can be
moved manually on one rail of track and can carry one rail/sleeper in suspended
condition. When necessary, the suspended Material can be dropped and rail dolley
cleared off the track.
(2) Manning of Rail Dolley –
Every rail dolley shall be manned by not less than 2 able bodied persons. The person-
in-charge for the working of rail dolleys shall be a railway servant not lower in rank
than a Keyman. The official in-charge should have passed in medical category A-3
and must hold a valid certificate of competency for working rail dolleys. Certificate of
competency shall be issued by SSE/P.Way of the section who must satisfy himself
that the person to whom competency certificate is being issued is fully aware of the
rules for the working of rail dolleys and is also well acquainted with the concerned
section.
(3) Working of Rail Dolleys –
(a) The railway servant in-charge of rail dolleys must inspect the section in advance
particularly in reference to heaping of ballast, girder bridges and any other
special features which make it difficult to drop the Material and remove the rail
dolley in the event of an approaching train. He shall get the ballast heaps
cleared and work the dolley(s) only when the visibility is clear for at least 1200
metre and the rails/sleepers can be dropped off safely without affecting the
safety of trains and workers both.
(b) Rail dolley shall not be worked on sections having gradients steeper than1 in
200.
(c) Not more than 6 rail dolleys should be worked in a group in any one block
section.
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(d) Normally, not longer than 3 rail welded panels should be carried by rail dolleys.
The rail dolleys must not be worked after sunset and before sunrise and in bad
weather when the visibility is poor. Rail dolleys should not be worked in deep
cuttings, steep grades, sharp curves and heavily built up areas where the
visibility is not clear for 1200 metres. In such locations, the rail dolleys should
be worked under block protection.
(e) In case, a rail dolley is to carry rails longer than 3 rail panel or it is required to
move over x-overs in yard crossing more than one line in deep cuttings and
curves then it should work under block protection.
(f) No traffic block or caution order is normally necessary for working of rail dolleys
except as indicated in Sub Para (3) (d) & (e) above.
(g) Every rail dolley/group of rail dolley when on line shall exhibit a red flag.
(h) The rail dolley shall be protected by a flagman at a distance of 1200 metre from
the rail dolley, on a double line in the direction from which trains may approach,
and by two flagmen one on either direction on single line. The flagmen shall also
carry three detonators for use in any emergency.
(i) Where necessary intermediate Flagman should be posted to relay signals.
(j) When a train is sighted, the Flagman should wave the red flag vigorously to
warn the official-in-charge of the dolley of the train and at the same time place
three detonators 10 m apart on the line to protect the rail dolley(s). The
detonators should be removed only on receipt of hand signals from the official-
in-charge by waving of a green signal to withdraw the danger signals from
indicating that rail dolleys have been removed.
(k) The official-in-charge of the rail dolley shall keep a look out for approaching
trains and will get the rail dolley(s) and Materials cleared off the track as soon
as an approaching train is sighted.
(l) While approaching level crossings, the official in-charge shall look out for road
vehicles and ensure safe passage of rail dolleys.
(m) The official in-charge shall be fully responsible for the safe working of rail
dolleys.
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PART – ‘C’
WORKING OF MATERIAL TRAINS AND TRACK MACHINES
842 The rules for the working of Material trains are outlined in Appendix IX of the
Indian Railway Code for the Engineering Department and Para 4.62 to 4.65 of
General Rules for Indian Railways (1976) and Subsidiary Rules thereto –
When the quantity of Material is such as could be conveniently trained out in stages,
wagon- loads may be attached to goods trains by arrangement with the Operating
Department.
843 Material Train – Material Train means a departmental train intended solely or mainly
for carriage of railway Material when picked or put down for execution of works, either
between stations or within station limits. The railway Material may include stone
boulders, ballast, sand, cinder, Moorum, rails, sleepers and fittings etc.
844 Economical Working – Material train should be expeditiously and economically
worked. The ADEN should arrange to form a train of maximum capacity consistent
with the haulage capacity of the engine and tonnage approved for the section. In
consultation with the Operating Department, the running of goods trains should be
suitably regulated so as to provide as long a working time for Material train as
possible. Delays in working should be traced to their source and remedies applied as
circumstances demand.
845 Restrictions in Running –
(1) Except with the permission of the Assistant Divisional Engineer or Divisional Engineer,
a Material Train should not be permitted to work during periods of poor visibility due
to fog, storm or any other cause.
(2) Except in an emergency such as, an accident or breach of the railway line, working of
Material trains carrying labour should not be permitted between sunset and sunrise.
If due to certain circumstances it is necessary to work Material Trains during night,
permission to do so should be obtained from the Divisional Operating Manager.
846 Brake-vans and Shelter Wagons –
(1) A Material train must be equipped with at least one brake-van in the rear. When
running through between stations the engine should be marshalled at one end of the
train, and the brake-van at the other end.
(2) Covered wagons to afford shelter to the labour may be coupled to the Material train
as required.
847 Ordering of Material Trains –
Operating Department is the authority for ordering a Material train. On receipt of
requisition from the ADEN/DEN, the Divisional Operating Manager shall advise the
staff concerned by letter, detailing the composition of train, the loading kilometrages,
the sections over which the train will work, the date of commencement of work, the
station at which the rake will be stabled and the engineering official who will be
deputed to be in-charge of the train. The notice to be given by the Engineering
department should not normally be less than a week.
848 Issue of “Fit-to-Run” Certificate – Before a Material train is allowed to work, the
complete rake should be examined by the carriage and wagon staff and a “fit-to-run”
certificate issued to the Guard. The rake may also be examined by the carriage and
wagon staff each time it arrives at the train examining station and whenever possible,
once a week.
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849 Official – in – charge of Material Train – Whenever a Material train is worked, it
shall be accompanied by a Guard. As the Guard is not qualified to carry out such
duties as working of hoppers, distribution of ballast/Materials, supervising loading and
unloading, maintaining muster rolls and daily reports of labour and preparation of daily
reports on Material train working, a qualified engineering official (not be below the
rank of JE/P.Way) should be deputed on the train to ensure working of Material train
to the programme specified by ADEN.
850 Equipment – Every Material train Guard must have with him while on duty:
(1) A copy of General and Subsidiary Rules or such of them as related to his duties.
(2) An up-to-date copy of Working Time Table with correction slips and appendices,
relating to the section of the Railway over which the Material train is to be worked.
(3) A watch.
(4) Hand signal lamps/ Tri colour LED Flashing hand signal Lamp
(5) Two red flags and a green flag.
(6) A whistle.
(7) Not less than 10 detonators in a tin case.
(8) A carriage key.
(9) Padlocks as prescribed by special instructions.
(10) A set of clamp for point locking and/or other locking devices.
(11) A spare pair of glasses if he is required to wear glasses.
(12) First aid box.
(13) Wedge/Skid and chains.
(14) A tail lamp/L.V. Board.
(15) Portable telephone (on controlled sections), and any other equipment and stores
prescribed by special instructions.
851 Testing of Brake Power –
(1) Before starting from a station, the Guard should ensure that the train is equipped with
requisite brake power prescribed for the load.
(2) Each vehicle of Material train whether or not provided with vacuum brake, must be
provided with an efficient hand brake capable of being fastened down.
852 Working in Block Section –
(1) A Material train shall be worked with the permission of the Station Master on either
side and in accordance with the provisions and system of working in force on the
section. Before a Material Train enters a block section for work, the Station Master
should advise the Driver and the Guard in writing of the time by which the train must
clear the block and whether it is to proceed to the block station in advance or return
to the same station.
(2) On double line, a Material train must not push back to the Station in rear but should
run through to the station in advance and return on proper running line except when
otherwise directed.
Where provided, lever collars or other visual indicators must be used to remind Station
Master that the Material train is working in the block section.
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(3) The Guard/Engineering official-in-charge shall ensure efficient and proper working
and adhere to sanctioned time and occupation of block section. Materials should not
be left fouling the track, signal wires and interlocking gears. If it is necessary for the
train to leave the site of work before this is done, it should be ensured that sufficient
labour is left to do so, in-charge of a competent railway servant and that the site is
protected until the work is completed.
(4) When a Material train enters a block section to work under instructions of other than
under the normal system of working, the Guard and the Driver of the train shall ensure
that the train is protected from the direction a train is approaching on double line and
in both directions on a single line in accordance with General Rules.
If for any reason, it becomes necessary to detach the engine of a Material train in the
block section to run to the station in advance, the Guard should ensure that the train
is protected both in front and rear.
(5) On stopping a Material train on a grade, the Driver should give a long blast of the
whistle to call the attention of the Guard and thereafter three sharp blasts, the signal
for application of hand brakes. The brakes must not be released until the Driver has
signalled for this by giving two sharp blasts.
Before entering a section on which a ballast train is required to stand on a grade of 1
in 50 or steeper, the engine should be so attached that when the train is standing the
engine is at the down-hill end of the train.
(6) A Material train should not be divided outside station limits except in an emergency.
Before the train is divided the Guard should put the hand brake in the brake-van hard
on, and pin down the hand brakes of sufficient number of vehicles and if necessary,
lock by means of safety chains or sprags a sufficient number of wheels, in each portion
of the train. He should further ensure that the workers/labour are detrained before
dividing the train. Vehicles should not be detached from a Material train on a grade of
1 in 100 and steeper. The engine itself may be detached with the Guard’s permission
after he has ensured that hand brakes on each vehicle are properly applied and the
wheels spragged against any movement.
853 Pushing of Material Trains – On down gradient steeper than 1 in 100, pushing is
not permitted. On gradient easier than 1 in 100 ascending or descending pushing may
be permitted at a speed not exceeding 25 Kmph provided the brake-van occupied by
Guard is the leading vehicle. The speed will be restricted to 10 Kmph, if the brake-
van is not leading.
854 Procedure to be Followed while Pushing Back – When it is necessary for a
Material train to push back into the station from which it started to work in the block
section, the following procedure should be observed –
(1) No train must be allowed to push back without a written authority from the Station
Master of the station from which it entered the section. Where line clear tickets are in
use, the Station Master shall endorse the line clear ticket as follows “to push back to
this station”.
(2) The Station Master of a station where the train starts from and pushes back to, must
advise the station in advance on the telephone or telegraph instrument and also the
Controller on controlled sections that the train will push back to the station. He will
then obtain the acceptance of the “Is line clear for a train stopping in the section”
signal on the block instruments or on the Morse instrument, where block instruments
are not provided from the station in advance and then give the “train entering section”
signal in the usual way.
(3) On the return of the train, the Guard will intimate that the whole of the train has
returned to the station complete, from the section and sign in the trains register book
to the effect and return the “authority to push back” to the Station Master which must
be cancelled by the latter. The Station Master will then give “cancel last signal” signal
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on the block or on the Morse instrument, as the case may be, and endorse the
remarks that “train pushed back” in the trains register book or the line clear enquiry
book against the entry of the train.
(4) When it has been arranged for a train to push back from the section, it must always
do so and not go through to the station in advance.
(5) Before starting, a green flag must be tied to a convenient fixture in front of the engine
and also at the back of the rear brake-van to indicate to men working on the line that
the train will push back.
(6) On the double line, when the train is required to be pushed back into a station, the
train must come to a stand outside the advance starting signal and the Driver shall
whistle, when, if a line is clear for its reception, it must be piloted into the station. If
there is no advance starting signal, the train must be brought to a stand opposite the
outer signal pertaining to the opposite direction and then be piloted into the station.
(7) On the single line, when a train is required to be pushed back into an interlocked
station, it must come to a stand outside the outer signal and whistle, when, if a line is
clear the home and the outer signals may be taken “off” for its reception. At a non-
interlocked station, the train must also come to a stand outside the outer signal
whence it must be piloted into the station on signals being lowered.
(8) Except in an emergency, Material trains may push back during day-light only. If in
case of an accident or for any other unavoidable reason, a train has to push back
during the night, it must do so at a walking pace and the Guard or a competent railway
servant must walk at least 600 metres in advance, exhibiting a danger signal until the
train comes to a stand as detailed in Sub-Para (6) & (7) above.
855 Running on Ghat Section and Descending Grade –
(1) On Ghat sections, it may be necessary to attach an engine to bank the load in addition
to the engine in front.
(2) When a Material train is descending a long and continuous steep grade, the brake
levers of as many wagons as may be necessary to assist in controlling the speed,
should be notched down by the Guard in consultation with the Driver.
856 Passage over Points – The Driver of a Material train should stop the train short of
all catch, loop or spring points which are facing for his train and which are not
protected by signals. The Guard should ensure that these are correctly set and locked
and then hand signal the Driver past the points.
857 Speed of Material Trains –
(1) When running between block stations with the engine leading, the speed of Material
train shall not exceed that prescribed for a goods train with a similar load.
(2) When the engine is pushing the train and when as in the case of emergencies the
brake-van is not leading –
(a) The speed must not exceed 10 Kmph.
(b) The Guard must travel on the leading vehicle and exhibit hand signals to the
Driver.
(c) When passing over points, the Guard should take action as in Para 856 above.
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858 Stabling of a Material Train
(1) Material train shall not be stabled on running lines at a station, except in unavoidable
circumstances.
(2) When a Material train is stabled at a station, it shall be protected in the following
manner and Station Master shall ensure that –
a) The vehicles of the Material train have been properly secured and are not fouling
any points and crossings,
b) All necessary points have been set against the line on which the Material train is
stabled and such points have been secured with clamps or bolts and cotters and
padlocks and
c) The keys of such padlocks are kept in his personal custody until the Material train
is ready to leave the siding or line.
(3) The Guard shall not relinquish charge until he has satisfied himself that the Material
train has been protected as prescribed in this rule.
(4) When the train is ready to leave, the Guard must advise the Station Master in writing.
The Station Master must then arrange for correct setting of the points.
(5) When a Material train is stabled in an outlying siding, the Guard must ensure that it is
inside the trap, clear of fouling marks and clear of running line. He must pin down
sufficient number of brakes and if necessary, lock by means of safety chains or sprag
the wheels.
859 Reporting Deficiencies and Damages – The Guard of the Material train should
at once bring to the notice of the Train Examiner under advice to the Assistant
Divisional Engineer, any deficiency or damage which may have escaped the attention
of the train examining staff. The Guard will also keep a record of all damages caused
to the vehicles during the work and report to the Assistant Divisional Engineer the
circumstances in which they occurred.
In every case, the Assistant Divisional Engineer on receipt of such reports should
arrange for the train-examining staff to attend to the damages and deficiencies
expeditiously.
860 Warning to Workers on Material Trains –
(1) The Guard of a Material train shall, before giving the signal to start, see that all the
workers are on the train, and warn them to sit down.
(2) Before moving his trains, the Driver must sound the whistle, according to the
prescribed code, as a warning to the labourers that the train is about to move.
(3) Before commencing any shunting with his train, the Guard must ensure personally
that all labourers have been de-trained.
(4) In the event of it being necessary to part a Material train, the Guard must ensure
personally that all labourers have been detrained before doing so.
861 Engine Crew’s Hours of Duty – Drivers, Assistant Drivers employed on Material
train should be relieved according to their duty rosters. Only in exceptional and
emergent cases such as breaches on the line, may the engine crew be kept on duty,
for long hours, in which case, a special certificate should be given to the Engine Crew
by the Engineering Official-in-charge.
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PART – ‘D’
LOADING AND UNLOADING FROM HOPPER BALLAST WAGONS
862 Staff Responsible -The staff at the ballast depots are responsible to ensure that
the wagons are loaded to the correct level.
863 Working Trip –
(1) The train Guard or Engineering official-in- charge shall be responsible for working the
train to the instructions issued by the ADEN. The JE/SSE/P.Way shall arrange for the
inspection and clearing of track behind the train.
(2) A “Working Trip” is a trip when one or more wagons are to be unloaded between two
stations. A “Running Trip” is a trip from one station to the other when no wagons have
to be unloaded on the way. Before departing on a ‘Working Trip’ the JE/SSE/P.Way
shall supply the Material Train Guard/Official-in-charge with a memo furnishing the
kilometrages at which the wagons shall be unloaded and the quantity to be unloaded.
864 Operation of Hoppers – The hopper valves shall be operated according to the
prescribed instructions under the direct supervision of the train guard or official-in-
charge. As far as possible one hopper may be unloaded at a time moving at walking
speed. The official-in-charge should walk on the side and instruct the labour as to
when to open or close the hopper valves. The train should not be stopped, while
ballast is being discharged; labour should not be moved from the platform without first
stopping the train.
865 Training out Material and Daily Reports of Working –
(1) Training out of Material and ballast should be done to a programme sanctioned by the
Divisional or Assistant Engineer.
(2) The Guard/Engineering official-in-charge should adhere to the sanctioned programme
and submit daily report on prescribed form Annexure - 8/10 (Material Train Journal)
to the Assistant Engineer through the concerned JE/SSE/P.Way. Where the contract
for the working of the Material train provides for the employment of a minimum number
of labourers and the contractor is paid for the actual labour so supplied for loading
and unloading of ballast, permanent way or other Materials the daily report should
show the correct number of labourers of each class employed and the nature and
approximate quantity of work done. Muster rolls should be maintained by the Guard
or Engineering Official-in-charge and checked and initialled frequently by the
JE/SSE/P.Way concerned when the training out is done by departmental labour.
(3) In cases where the Material is not loaded in bulk, the actual weight and number loaded
should be given in the daily report.
(4) Sufficient number of copies of daily reports should be prepared by the Guard/
Engineering Official-in-charge and submitted to the concerned officers e.g.,
Engineering, Operating, Mechanical etc.
(5) The number of wagons on the train with their capacity and painted numbers should
be indicated on the form of daily report. Particulars of detention to the train other than
for Engineering work should also be indicated.
(6) Before forwarding the daily reports of Material train working to the Assistant Engineer,
the JE/SSE/P.Way may add relevant remarks as considered necessary. The
Assistant Engineer should scrutinise the daily reports and take such action as
considered necessary to avoid or minimise detentions in the working of the Material
train, before forwarding the same to the Divisional Engineer for allocation, initials and
record.
866 Charges for Material Train Working – For purposes of debiting the charges on
account of Material train working to the heads of revenue working expenses
concerned a monthly or fortnightly “Material Train Return” in standard proforma will
be prepared by Operating Department and sent to the Divisional Engineer for
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completion and submission to the Accounts Department, for necessary action. On this
return, the hire charges for wagons and engine will be separately shown.
867 Register of Engineering Vehicles –
(1) When Engineering wagons are not in use, these should be stabled in the siding
allotted for this purpose in specific station yards.
(2) The DEN and ADEN should maintain subdivision-wise a complete inventory in the
form of a register of all closed wagons, open wagons, hoppers, etc., on the division.
The register should contain:
Vehicle numbers;
Type of vehicle;
Capacity;
Condition of vehicle;
Locations and particulars of periodical overhaul, when carried out and due.
The register should be kept current to facilitate issue of instructions when ordering a
Material train.
(3) A monthly return of engineering vehicles on the sub-division should be submitted by
the Assistant Divisional Engineer to the Divisional Engineer with complete particulars
of each vehicle for record in his office. It should be the Assistant Divisional Engineer’s
responsibility to keep track of all Engineering vehicles allotted to his sub-division and
see that those that are sent to workshops for periodical overhaul are returned
expeditiously.
868 Working of Track Maintenance Machines –
(1) All ‘On Track’ machines shall be worked only under traffic block with the permission
of the concerned Station Masters and in accordance with the special instructions
issued in this regard.
(2) (a) Each machine shall be in direct charge of a nominated track machine operator.
The operator shall be responsible for the working of the machine under his charge.
He shall be fully conversant with the rules of working of trains and of protection in
case of emergency. He shall also ensure that the other staff deployed on the machine
are fully conversant with the protection rules. He shall hold a valid certificate of
competency for driving and working of the machine.
(b)The track machine shall work under the direct supervision of an engineering official
not below the rank of JE/SSE/P.Way who will be responsible for taking the traffic
block, for protection of the line while the work is in progress and clearing of the block
after completion of the work when the last machine clears the block section and
certifying that the track is fit for train movement.
(c)When the track machine is required to move from one block station to another block
station, the operator shall run the machine with the proper authority to proceed as
defined in Para 1.02 (6) of General Rules 1976.
(3) Each unit shall carry all safety equipment as specified under IRTMM.
(4) When more than one track machine is running in a block section, there should be a
minimum distance of 200 metres between two units.
(5) While working on double/multiple lines, the engineering officials supervising the work
of track machine shall ensure that no part of the machine fouls the adjacent track. In
case infringement to adjacent track is inherent to the machine working which can be
cleared at a short notice, the work should be carried out by protecting the infringed
line by Engineering signals by JE/SSE/P.Way as envisaged in Para 806.
(6) Each unit will run within the maximum permissible speed sanctioned for that type of
machine on that section.
(7) All track machine shall work as per provision given in Para 4.65 of General Rules for
Indian Railways (1976) supplemented by Subsidiary Rules of Railways. For detailed
working of track machines provisions in IRTMM may be referred.
Page 317 of 417

Annexure - 8/1 - Para 806(1)
Page 318 of 417

Annexure - 8/2 - Para 806(2)
Page 319 of 417

Annexure - 8/3 Para 807, 808, 814
RETRO REFLECTIVE TYPE BOARDS - TO BE PROVIDED IN NEW
CONSTRUCTION AND DURING REPLACEMENT OF EXISTING BOARDS
Page 320 of 417

Annexure - 8/3A Para 807 & 808
RETRO REFLECTIVE TYPE BOARDS - TO BE PROVIDED IN NEW
CONSTRUCTION AND DURING REPLACEMENT OF EXISTING BOARDS
Page 321 of 417

Annexure - 8/4 Para 808, 814
Page 322 of 417

Annexure - 8/5 Para 819(4)
COMPETENCY CERTIFICATE
Certified that shri.............................................. P.Way supervisor of M/s

...................................................... has been examined regarding P.Way working on
.......................................... work. His knowledge has been found satisfactory and he is capable of
supervising the work safely.
Assistant Divisional Engineer
Annexure - 8/6 Para 831
INDEMNITY BOND IN CONNECTION WITH THE PERMISSION GRANTED TO TRAVEL

ON A RAILWAY
.........................Trolley/Motor Trolley
In consideration of my being granted permission to travel between

....................................................... and .......................................... on ...........................................
Railway ................................................ Trolley/Motor Trolley, I ....................................................
hereby undertake and agree that the Railway shall be free from all responsibility or liability for any
delay or detention or for any injury or loss to me or to any property of whatsoever kind
accompanying me occasioned during the journey for which the permission is granted or whilst I
am or the said property is within Railway limits.
I further undertake that I shall not interfere with or obstruct

......................................................... on his duties and shall obey all reasonable directions he shall
give me to be subject to the bye-laws and other general regulations of the Railway.
I further undertake to indemnify and keep indemnified and save harm less the Railway
Administration for and against any loss or damage done to the property of the Railway through any
act or omission on my part or on the part of my agent or servants while so travelling on the
Trolley/Motor Trolley.
Dated .................... …………. Name .............................
Witness – Designation…….. ……
1. ................................................... Address ...................................
2. ....................................................................................... ......
................................................................... (To be executed on stamp paper)
Page 323 of 417

INDEMNITY BOND IN CONNECTION WITH USING TROLLEY IN PRIVATE SIDING BY NON-

RAILWAY MEN
THIS INDENTURE made the .............................................................. day of

.................................. between...................................................of the one part and the
President of India as owner of and administering
the...............................................Railway(hereinafter called “the Administration”)of the other
part WHEREAS by an Agreement dated the..........................................day of............................
and made between the Administration of the one part and the said...................................of the
other part, the President of India agreed to allow the
said............................................................................ to use and work a private trolley the
railway line of the said................ Railway between ............................................and whereas
prior to the execution of the agreement the said ............................................... agreed to
execute these presented.
NOW THIS INDENTURE WITNESSETH AS follows:
The said ...............................................................................shall henceforth at all times

perform and observe the stipulations, provisions and conditions on his part to be performed and
observed and contained in the aforesaid agreement.
The said ........................................................................................ shall observe and

perform the bye-laws, rules and regulations of the.......................... ............Railways for the time-
being in force.
Thesaid......................................................................................shall not in any way

interfere with or hamper the working of the ..............................................Railway.
The said........................................................................shall from time-to-time and at all

times hereafter indemnify and keep indemnified the Administration from and against all actions,
rd
claims, demands, costs, losses, damages and expenses including claims by 3 parties Workmen’s
Compensation and Employees’ liability which may be brought against or made upon the
Administration or which the Administration may, pay, incur, sustain or be put to by reason of any
loss of life or injury or damage to any person or property caused by or arising out of or from the
user and for working of a private trolley by the
said.........................................................................on the said railway line and the user of
permanent way in pursuance of the said agreement.
IN WITNESS where of the said .....................................................................has hereunto

set his hand and seal the.................................................day and....................year first
herein/above written.
Signed, Sealed and Delivered by the said ......................................... In the presence of:
Page 324 of 417

Annexure – 8/8 Para 837(4)
Page 325 of 417

Annexure – 8/9 Para 837(5)

DAILY REPORT OF MATERIAL TRAIN WORKING
Material Train Report of...............................................train, ordered vide Divisional
Engineer’s/ Assistant Divisional Engineer’s No......................................working from
kilometre..................................... to kilometre................................Engine
No............................Class.....................composition of train ......................... labour
........................ Gang Mates .....................Men .....................................Women
Name of the Contractor..................................................................................................
Contractor or JE/SSE/P.Way Material Train Assistant Divisional Divisional

his authorised No. ................. Guard/ Engineer. Engineer.
agent Section Official. Sub-Division Division
.......... 20 ...... ........... 20 ...... ......... 20...... ........ 20...... ........ 20......
Note – On reverse of this form the class, capacity and number of each wagon should be shown;
also, particulars of detentions to train other than for Engineering Work.
Page 326 of 417

CHAPTER - 9
LEVEL CROSSINGS AND GATEMAN
*********************
901 General Location: – As far as possible, new Level Crossings may not be provided
in the interest of safety of road users and public on any line. However, in case of new
line projects sanctioned on socio-economic considerations with Rate of return (RoR)
less than 10%, provision of manned Interlocked level crossing may be considered
with the approval of Railway Board. The Level Crossing would be located outside the
outermost facing points. Level crossing at cuttings or near cuttings should be avoided
as far as possible.
For Level Crossings already located within busy station yards affecting Railway
operations and causing heavy detention to the road traffic, efforts should be made to
replace them by Road Over/Under Bridges as per extant rules or shift them outside
the outer most facing points, especially during planning of gauge conversions, yard
re-modeling and doubling works.
902 Classification of Level Crossings: –
(1) The classification of level crossings, based on the volume of rail and road traffic, shall
be as under:
Class of LC Criteria
Special…….for roads TVUs greater than 50,000
‘A’ class……for roads TVUs from 50,000&up to 30,000; or
Line capacity utilization 80% (on single line) and number
of road vehicles greater than 1000
‘B’ class…….for roads TVUs less than 30,000 and up to 20,000 and number of
road vehicles greater than 750
‘B’ Class is further subdivided as following –
B1 class… TVUs less than 30,000 and up to 25,000
B2 class… TVUs less than 25,000 and up to 20,000
‘C’ class…… for roads All other level crossings for road, not covered in above
classes
(2) Level crossings over colliery, factory and other similar sidings where Railway traffic is
light may, however, be dealt with according to local conditions, subject to the approval
of the Commissioner of Railway Safety being obtained in each case to the measures
adopted for the safe working of trains.
903 Categories of Roads: –
For the purpose of this standard, Roads shall be categorized as under –
(a) Class I roads –
(i) National Highways,
(ii) State Highways,
(iii) Important roads with in municipal towns, and
(iv) Roads in and around towns where road and rail traffic is heavy.
(b) Class II roads –
(i) Major and other District roads,
(ii) Unimportant (Other than important) roads within municipal towns,
(iii) Roads within Non-Municipal towns including those within shunting limits of Railway
stations, and
(iv) Other surfaced roads.
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(c) Class III roads –
(i) Earth roads, and
(ii) Cart tracks.
904 Standards for Different Classes of Level Crossings: – The standards to be
followed (within the Railway limits) for the various Parameters in respect of different classes
of level crossings will be as shown in Annexure - 9/1. These standards are applicable to all
new constructions and also in the case of up-gradation of the existing level crossings. The
existing level crossings which are of a lower standard than those prescribed in Annexure -
9/1 need not be altered or modified merely to suit these standards.
905 Gates and Locking Arrangements: –
(1) Gates –
(a) The gates shall be in the form of lifting barriers or swing gates of approved design.
In the event of any damage, Chains or sliding boom may be used as a temporary
measure.
(b) At new manned level crossings, lifting barriers should normally be provided which
are coupled so as to operate simultaneously. Chains or swing gates at existing
manned level crossings should be replaced by lifting barriers on a programmed
basis, giving priority to the important and busy level crossings.
(2) Locking arrangements –
(a) Lifting barriers, swing gates or chains when closed against road traffic shall be
securely locked.
When the locking arrangement is of the hasp and staple type with padlocks, two
spare chains with loops at both ends should be provided for locking the gates when
the locking arrangement goes out of order.
(b) Stops should be provided to prevent level crossing gates from swinging towards
the track and causing infringement. Catches should be provided to secure gates
when in the open position to avoid obstruction to road traffic.
(c) In the case of all manned level crossings, two long spare chains with loops at both
ends should be kept as reserve for use as an alternate to the barrier/ gate, in case
of damage to them. Two discs painted red with the words “stop” with arrangements
for fixing them on the ground should also form part of the spare equipment.
Separate rail posts should be erected near the gate, so that the chains can be fixed
on them (Annexure - 9/2).
906 Skew Level Crossings: –
(1) All roads should preferably cross the railway line at right angles. In special cases,
when modification is required to suit the road approaches the angle of crossing should
not be less than 45°.
(2) At all level crossings the gate posts shall be fixed square to the road.
907 Normal Position of Gates: –
(1) General – Subject to such Special Instructions in that behalf as are permitted by GR
16.03, all gates at level crossings shall be kept constantly closed and securely
fastened across the through fare on both sides of the railway and shall only be opened
when it is necessary and safe to open them for the passage of road traffic; provided
that any Railway Administration may from time to time issue special instructions for
any particular level crossing or class of level crossing and may by such special
instructions permit the gates at any level crossing or class of level crossings to be
normally kept open to road traffic and may therein prescribe the conditions under
which gates are to be kept closed against road traffic for the passage of a train or
trains or for the purposes of any other railway operation.
Page 328 of 417

(2) Based upon classification of level crossings over which trains are required to pass,
the normal position of gates may be as under –
(a) Interlocked level crossings:
All interlocked level crossings shall be kept ‘Normally Open to Road Traffic’ and
may only be closed against the road traffic for the passage of trains or for any other
Railway operation by taking off the signals.
(b) Non-Interlocked Level crossings:
The gates must normally be kept closed and securely fastened against road traffic and
may only be opened for the passage of road traffic when it is necessary and safe to
do so. The Railway Administration may under special instructions permit gates of level
crossings not protected by signals to be normally kept open to road traffic prescribing
the conditions under which they may be kept closed against road traffic for passage
of trains or any other railway operation.
(c) The normal position of gates at level crossings within station limits shall be as Sub-
Para (a) and (b) above, fixed station signals not being regarded as affording any
protection unless the gates are interlocked with signals.
(d) Level crossings having heavy seasonal traffic:
In case of level crossings having heavy seasonal road traffic with normal position of
gates closed to road traffic, the Railway Administration may permit gates of such level
crossings, to be kept open to the road traffic during the busy season, when road traffic
is heavy, by issuing special instructions and prescribing the conditions, under which
they may be kept closed to road traffic for passage of trains or any other railway
operation. The special instructions should be incorporated in the working rules for the
gates and stations concerned.
(3) Gateman shall at all level crossings be prepared, wherever level crossings be open
to road traffic, to show a danger signal to any approaching train and for this purpose
invariably keep a hand signal lit during night to show Red throughout the period the
level crossing is open to Road traffic.
908 Signals for road users:-
(1) Type of signals for road users – Preferably, electric signals should be provided at
gates to give correct indication to road users. As an alternative, Gate lamp along with
blinders may be mounted preferably in rectangular sockets over gates so as to give
correct indication to road users vide item 6 of Annexure - 9/1. The lamp should be
lighted by the Gateman at sunset and remain lighted till sunrise.
(2) Drivers of trains shall get no light indication from the road signal/gate lamp, except in
case of level crossings on non-important lines like sidings where normal position of
level crossings may be kept closed for railway
909 Traffic and Engineering Gates: –
(1) Traffic Gates –
(a) The manning and operation of the gates at level crossings located within the
outermost stop signals shall be under the control of Operating Department. The
level crossings and structures pertaining thereto shall be maintained by the
(b) When protected by signals the equipment shall be governed by the signals of the
station/block hut and the operation as per the station working rules.
(2) Engineering Gates –

(a) Level crossings beyond the outer most stop signals shall be under the control of
Page 329 of 417

the SSE/P.Way (In-charge) both as regards to their operation and maintenance.
(b) Where the level crossing is protected by Signals, fixed signals shall be provided in
each direction in accordance with the relevant General Rules (GR 3.34 New
Rules) and approved special instructions.
(3) The maintenance of signals, interlocking, lifting barriers at interlocked gates and
communication equipment will rest with the Signal Department in the case of all level
crossing gates, whether located within or outside the outermost stop signals.
(4) The gate working instructions in English, local language and Hindi (wherever required)
for manned gate including the signaling diagram for interlocked gate shall be
incorporated in Station working Rules. A copy of gate working rules, for both
interlocked and non-interlocked gates, shall also be kept at gate lodge.
910 Equipment at Level Crossings: –
(1) The equipment for a Level Crossing shall be as follows; in addition to such others as
may be prescribed by special instructions –
(a) Two hand signal rechargeable LED lamp with tri-colour light /K Oil H S lamp, tri-
color provided with bright reflectors
(b) 1 hand signal flag, green
(c) 2 hand signal flags, red
(d) 1 staff suitable for exhibition of red lamp or red flag
(e) 2 long spare chains with “stop” marked disc attachment at the centre to cover the
full width of the gate, for use in case the gates/ barriers are damaged (Annexure
- 9/2).
(f) 2 spare small chains and padlocks for locking gates, in case locking arrangements
of gates become defective.
(g) 10 nos. detonators in tin case.
(h) 1 tin case for flags.
(i) 2 nos. Banner flags.
(j) 1 canister for muster sheet.(For Engineering gates only)
(k) 1 can for oil (Only at gates where K oil hand lamps are still in use)
(l) 1 tommy bar.
(m) 1 water pot or bucket.
(n) 1 mortar pan.
(o) 1 powrah.
(p) 1 rammer.
(q) 1 pick-axe.
(r) 1 tool list (with columns drawn for checking of tools).
(s) 1 book of safety rules in English and Regional language and English(This is already
part of gate working instructions)
(t) Duty roster.
(u) Complaint book for road users.
(v) Inspection register.
(w) Level crossing working instructions containing safety rules
(x) Two gate lamps (Electric/ Kerosene type).
(y) Gatemen working on double line/multiple lines, ghat sections, suburban and
automatic block territories shall be provided with three warning signals as
prescribed in Para 817 Gatemen working on single line sections shall be supplied
with two warning signal. Gates provided with rechargeable lamps with flashing red
Page 330 of 417

light, will serve the above purpose.
(z) Diagram indicating the method of protection to be adopted, in case of obstruction
in the level crossing (Annexure - 9/7)
(z)(i) Wall clocks to enable the gateman to correctly record the time of exchange of
private number, expected and actual time of passage of train, time for opening and
closing of level crossing, etc.
(z)(ii) Whistle thunderer – 1 No.
Note – In case of Level Crossings in multiple lines the hand signal flags/lamps,
detonators and banner flags shall be increased suitably.
(2) In place of physical private number books, it is preferable to provide automatic Private
Number generating device, which generates Private Number only after closure of LC
gates and thus enhances safety.
(3) There should be sufficient supply of kerosene oil, wicks and matches at the gate-
lodge provided with HS lamps/ gate lamps. The Gateman should always keep their
hand signal lamps trimmed and ready for lighting and use at a moment’s notice.
During night, one of the hand signal lamps should be kept lit through-out to show
danger stop signal to an approaching train. When the level crossing is closed to road
traffic, the hand signal lamps should be kept lit dimly only.
(4) At every Level Crossing there should be distinct indication at 600 meters and1200
meters on Broad Gauge on either side to guide the Gateman for placing the
detonators in case of obstruction at the level crossing. Indicator posts should be
provided with one dot and three dots at these distances to indicate the number of
detonators to be placed. Arrangements for exhibiting the danger signal at a distance
of 5 meters during emergency should be made at each level crossing.
(5) Height Gauges on Electrified Sections –
(a) Adequate arrangements shall be made to erect standard height gauges on either
side of the overhead equipment or other equipment at every level crossing so as
to ensure that all vehicles and moving structures passing under the height gauge
also pass under the overhead equipment or other equipment with adequate
clearance.
(b) The adequate clearance referred to in Sub-rule Para (a) shall be sanctioned under
approved special instructions.
(c) Height Gauges should be located at a minimum distance of 8 meter from gate
posts. In exceptional circumstances where site conditions do not permit, Principal
Chief Engineer can give exemption in these standards subject to a minimum of 8
meter distance from the centre line of the track. Road surface up to this point may
be at the same level as the road surface inside the gate posts.
(d) Vehicles and moving structures, which cannot pass under the height gauge without
striking or touching it, shall not be permitted to pass the overhead equipment or
other equipment except in accordance with special instructions.
911 Location of Gate-Lodge: –
(1) Gate-Lodge shall be so located that a clear and unobstructed view is obtained of all
approaching trains and road vehicles, care being taken that allowance is made for all
future extensions, e.g., doubling of line or widening of roadway.
(2) Where the level crossing is on a curve, the gate-lodge should be built on the outside
of the curve.
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912 Appointment of Gatemen, Rosters and Medical Fitness Certificates: –
(1) Before appointment, the SSE/P.Way (In-charge) should ensure that competent track
maintainers elected as gate men have been certified fit in class A3 by the Medical
Department and that they are examined thereafter at periods stipulated by the rules
in force. In all level crossings, literate Gateman capable of exchanging private
numbers should be posted.
(2) The selected gatemen will be given initial and periodical training in Divisional training
Centre and competency certificate shall be issued as specified in Chapter 14.
(3) The hours of duty for the Gateman should be laid down and must confirm to the
regulations in force. The rosters detailing the hours of duty and rest for each Gateman
shall be maintained at the gate-lodge. The roster should indicate clearly as to which
Gateman is required to be on duty at any particular time. No Gateman shall change
his hours of duty without the order of the SSE/P.Way (In-charge).
(4) Full particulars regarding the periodical medical examination and vision test of each
Gateman shall be maintained at the gate- lodge.
(5) When handing or taking over charge, the Gateman and their relievers should jointly
check all the equipment and test all the gears to see that they are in order.
(6) Every Gateman shall be fully conversant with the use of hand signals, detonators and
protection rules.
913 Maintenance of Level Crossing, Examination of Gate Equipment and
Gateman in Rules: –
(1) By SSE/P.Way (In-charge) –
(a) Obstruction of view – All trees, bushes or undergrowth that interfere or tend to
interfere with the view from the Railway or road way when approaching level
crossings, should be cut down taking care to comply with the procedure laid down
in Para 648.
(b) Inspection and Maintenance –
(i) Level crossings laid with PSC sleepers should be overhauled with each cycle
of machine packing or more frequently as warranted by condition and in no case
shall opening be delayed by more than two years. In all cases, rails and
fastenings in contact with the road shall be provided with galvanized fittings.
Alternatively, non-galvanized fittings should be thoroughly cleaned with wire
brush and a coat of coal tar/anti-corrosive paint applied. Flange way clearances,
cross level, gauge and alignment should be checked and corrected as
necessary, and the track packed thoroughly before reopening the level crossing
for road traffic.
(ii) The painting of gates and discs should be done at regular intervals.
(iii) SSE/P.Way (In-charge) should keep a manuscript register of repairs for all level
crossings on his section. This register should show the date of opening, the
condition of sleepers with their age and time, the date and type of each sleeper
changed and other requisite particulars.
(iv) SSE/P.Way(In-charge) will be responsible for the proper upkeep and
maintenance of ‘Whistle Boards’ and ‘STOP’ Boards provided on the
approaches to level crossings.
(v) Check rails of level crossing are required to be removed for tamping operations,
overhauling of level crossings, destressing of LWR or track renewals etc. Check
rails should be re-fixed as quickly as possible and preferably before leaving site.
Should a situation arise where check rails cannot be re-fixed for any reason and
trains have to be passed, a speed restriction of 30 Kmph should be imposed
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besides ensuring that road traffic is diverted till the check rails are put in place.
In case such diversion is not possible, temporary arrangements should be made
for passage of road traffic till the check rails are put in place. However, in both
these cases, the check rails should necessarily be provided latest by close of
next day. In such cases, a stationary watchman shall be posted to ensure safety.
(c) Checking equipment and examination of Gateman in rules –
(i) The equipment with the Gateman shall be checked by JE/SSE/P.Way once in
a month by rotation.
(ii) JE/SSE/P.Way shall ensure that the Gatemen have correct knowledge of rules
by examining them periodically during his routine inspection and on
appointment, promotion or transfer. He should not only educate them in rules,
but also conduct practical demonstration of protection of level crossing in case
of emergency.
(d) Surprise day/night inspection of level crossing should be carried out to ensure
presence and alertness of Gateman.
(2) By ADEN –
ADEN should inspect the equipment at every manned level crossing on the sub-
division once in six months, and examine the Gateman in rules during his inspection.
ADEN should scrutinize the manuscript register of level crossings maintained by the
SSE/P.Way (In-charge) and inspect as many level crossings as possible, when they
are completely opened out during the year.
914 Level Crossing Registers: –
In the office of the DEN, ADEN and SSE/P.Way(In-charge) complete particulars of
level crossings in serial order should be maintained in a register as shown in
Annexure - 9/3.
Whenever additions and alterations or improvement to level crossings are made, the
level crossing registers should be amended and where necessary a copy of the new
or revised working instructions with the revised signal and interlocking diagram
pasted at the gate-lodge.
915 Level Crossing indicators: – (Back to Para 815)
At the approaches of all level crossings, bilingual whistle boards as per design
(Annexure - 9/4) should be erected at 600 metres along the track from the level
crossing to enjoin the Drivers of approaching trains to give audible warning of the
approach of a train to the road users. The Drivers of approaching trains should whistle
continuously from the time they pass whistle boards to the time they cross the level
crossing.
916 Provision of Speed Breakers on the Approaches of Level Crossing –
Provision of rumble strips on approaches of level crossings as per the standard
design is the responsibility of Road authorities. Matter may be pursued with all State
Governments/Road authorities to ensure that rumble strips are provided on all level
crossings as per standard design over the total width of the road i.e. edge of the
berm to edge of berm with proper road warning signs as per the standard design.
However, it is incumbent upon Railways to provide speed breakers as per the
standard design on level crossings irrespective of whether the approach road is
metalled or un-metalled, as a temporary safety measure, till such time these are
replaced with rumble strips of proper design by the Road authorities. While providing
speed breakers, following guidelines may be observed –
(1) One speed breaker should be provided on either approach of level crossings at a
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distance of about 20 m from the gate post of the Level Crossing, covering full width of
the road including berms as per Annexure - 9/5. This may require construction of
speed breaker by Railway outside Railway boundary. For roads with central
median/One-Way Roads, speed breaker is to be provided on the entry side of the
road only. For safety reasons, the paint marking should be provided and their
maintenance ensured.
(2) Standard warning signs for speed breakers as per Annexure - 9/6 should be
invariably provided at a prescribed distance as indicated in item 19 of Annexure - 9/1.
(3) Speed breakers should be constructed with suitable Material depending on the type
of road and traffic. On berms and un-metalled roads, the speed breakers should be
supported on proper base of compacted road metal.
917 Census of Traffic at Level Crossings –
(1) Periodical census of traffic at all level crossings shall be taken once every three years.
This shall be carried out for 7 days and total Train Vehicle Units (TVUs)/Day (Train
Units × Road Vehicle Units) are worked out. Train, Road Vehicle, Bullock Carts and
Tongas being considered as one unit, Cycle rickshaw/Auto rickshaw being considered
as half unit and Motorized two wheelers being considered as 0.25 unit. The census
shall be carried out by a multi-disciplinary inspectorial team consisting of
representative of Engineering, S&T and Traffic Departments. The mechanism shall
be setup by the Divisional Railway Manager to ensure that the representatives are
present for the census by laying down advance timetable for carrying out of census
of level crossings.
(2) In the case of manned level crossings, the periodical census should be substituted by
a census-cum-job analysis so as to avail of the opportunity of checking up the
adequacy of men on consideration of Hours of Employment Regulations.
918 Track Structure at Level Crossings (Back to Para 318, 715)
(1) Rail joints should be avoided in check rails and on the running rails, within the level
crossings and three metres on either side from the end of level crossing.
(2) In the case of SWR, the short-welded panel may be continued through the level
crossing, avoiding fish plated joint on the level crossing and within six metres from the
end of level crossing.
(3) The level crossing should not fall within the breathing length of LWR.
(4) Concrete sleepers to relevant RDSO drawings along with fittings should be provided
at LC Gate.
919 Level Crossings on National Highways/ State Highways and Other
Important roads.
(1) In case of National Highway/State Highways or their by passes and important city
roads, no new Level Crossing to be provided and only grade separators to be
provided.
(2) In case of the important roads, it is preferable to provide grade separators. However,
depending upon the traffic density envisaged, manned Level Crossings can also be
considered.
(3) Relaxation of the above (1) will require Board’s prior approval.
920 Elimination of Level Crossing –
A detailed review/survey of the existing level crossings should be carried out with a
view to eliminate them by-
(a) Construction of Subways, along with adequate drainage arrangements.
(b) Construction of roads along Railway boundary to divert road traffic to the nearest
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level crossing/grade separator. The roads for closure of LC gates can be
diverted through existing water way bridges if the water way remaining after
treating one span as closed is sufficient to cater to the requirement of design
discharge.
(c) Closure of low TVU gates,
(d) Construction of ROB/RUB as per Para 921 below
(e) During execution of Gauge conversion & doubling works, etc.
921 Criteria for Replacement of Existing Level Crossings (other than those
provided on deposit terms) with Road Over/Under Bridges on Cost
Sharing Basis: –
(1) Minimum Train Vehicle Units (TVU) on a Level Crossing should be 1 lakh per day to
become eligible for replacement with Road Over/Under Bridges on 'Cost Sharing'
basis. However, this could be relaxed in the following cases :
(a) Suburban sections having high frequency of train services and
(b) Near stations where detentions to road traffic are very high on account of either
shunting operations or multi-directional receipt/dispatch of trains or stabling of
trains etc.
(2) Preference should be given to the Level Crossings located on trunk routes vis-à-vis
those located on branch lines. In any case, minimum number of times the level
crossing is required to be closed against the road traffic should at least be 12 times
per day.
(3) Subject to (1) and (2) above, priority should generally be accorded by the concerned
State Government giving preference to Level crossings on National/State Highways.
(4) In case of Road Over/Under Bridges constructed in replacement of busy level
crossings situated in Municipal/Corporation/ Metropolitan areas where Light Vehicular
traffic is considerable and where the Railways are satisfied that closure of the level
crossings would cause hardship, additional provision may be made for construction
of the subway or a light Over Bridge with ramps for the use of light vehicular traffic at
the time of framing the proposal for the construction of Road Over/Under Bridges. The
proposals for providing the ramps/sub-way should be examined critically and should
be provided for, only in the case of genuine hardships and not as a matter of course.
The cost of these ramps/subway will be shared equally with the Sponsoring Authority
on 50:50 basis.
(5) Closure of the Level Crossings should be ensured before commissioning of the Road
Over/Under Bridges. All such cases where State/Local Authorities do not agree to
abide by this should be reported to the Railway Board promptly.
(6) Railways may, based on specific request of concerned Road authorities, consider
sharing cost of constructing new FOUR lane Road Over Bridge in lieu of level
crossings having minimum TVU of 3 Lakh per day comprising not less than 6000 Road
vehicle units. The cost sharing of Four lane Road over bridge should be resorted to
only if the concerned Road authorities have converted the approach road into four
lane or are simultaneously doing four laning of approach portion.
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Annexure - 9/1 Para 904, 908, 916
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Annexure - 9/7 (Para 118(5)(b), 910)
PROTECTION DIAGRAM FOR LEVEL CROSSINGS
........................
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CHAPTER – 10
PATROLLING OF THE RAILWAY LINE
*********************
1001 Types of Patrolling – The following types of patrolling are in vogue
(1) Key man’s daily patrol.
(2) Gang patrol during abnormal rainfall or storm.
(3) Monsoon Patrolling.
(4) Hot/Cold weather patrolling for long welded rails/continuous welded rails
(5) Watchmen at vulnerable locations
(6) Security patrolling during civil disturbances and special occasions.
1002 Key man’s Daily Patrol – Every portion of the permanent way shall be
inspected daily on foot by the key man of the beat in which the portion of the track falls.
Provided that, the interval between such inspections may, under special instructions, issued
by Chief Engineer be increased to once in two days in the case of specified section of lines
with light and infrequent traffic. The Keyman shall preferably be provided with a GPS
tracking device, to monitor his movements so as to ensure effective patrolling.
1003 Gang Patrol during Abnormal Rainfall or Storm – In the event of abnormal
rainfall or storm during day or night, the Gang Mate should, on his own initiative, organize
patrolling over the length affected, independently of other patrolling, if any, being done. This
patrol should, in case of heavy rainfall, confine its inspection to known points of danger,
such as cutting or culverts likely to scour, banks affected by tanks likely to breach and bridge
approaches. In case of high winds, the Patrolman should inspect the length of track likely
to be fouled by falling of tree etc.
Arrangements exist with the Meteorological Department of the Government of India for
sending electronic communication regarding warning, wherever storms, gales or heavy
rainfall is expected. On receipt of such information from the Control, the JE/SSE/P.Way will
arrange to advise monsoon patrolmen, watchmen and Gang Mates to be extra vigilant and
be prepared to introduce patrolling, as necessary (for detailed instructions regarding
weather warning and action to be taken Para 1129 may be referred to). The beat length of
Gang Patrolling shall be similar to the monsoon patrolling.
1004 Monsoon Patrolling – (Back to Para 1005) During the monsoon, certain
section of the railway line, as may be specified, shall be patrolled to detect damage by flood,
such as breaches, settlements, slips and scours and immediate action be taken to protect
trains, when so warranted.
(1) Commencement and Termination – The sections, which are normally to be patrolled
during monsoon will be identified and notified by the Divisional Engineer. For every
such section, the Divisional Engineer shall prescribe the period of year, when normal
monsoon patrolling is to be done; patrolling should be started on these notified
sections on the dates specified. If the local conditions warrant, the JE/SSE/P.Way of
the section concerned may introduce or continue monsoon patrolling outside the
stipulated dates, duly advising all concerned.
(2) Preparation of Patrol Charts –
(a) The Divisional Engineer will issue patrol charts for each of the sections where
monsoon patrolling is required to be done, taking into consideration the train
timings of the timetable in force during this period. The principles governing the
preparation of patrol charts shall be –
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(i) Ordinarily patrolling will be carried out by a single Patrolman, but in regions
where danger from wild animals, dacoits and other risks exist, as in Ghat
sections, suburban section or other specified sections, patrolling in pairs may
be introduced with the approval of Sr DEN Co.
(ii) All trains carrying passengers between sunset and sunrise get the maximum
protection possible.
(iii) As far as possible, each block section will be treated as a unit and the length
will be divided into equal beats. The length of each patrol beat should not
normally exceed 5 km where the block section is more than 10 km an
intermediate flag station, if any, or any other suitable point may be fixed as
intermediate station, to keep the length of beat at about 5 km.
(iv) The walking speed of a Patrolman may be taken as 3 Kmph.
(v) The maximum distance covered by a Patrolman should not normally exceed 20
km in a day.
(vi) A period of at least half an hour rest is desirable between consecutive beats.
(vii) For giving better protection to passenger trains between sun-set and sun-rise,
it would be advantageous to plot the scheduled paths of all passenger trains
and then plot the patrol movement in such a way, so as to minimize the time
interval between patrolling of the beat and passage of train.
(viii) Patrol charts should show all vulnerable locations where stationary watchmen
are posted.
(b) Sample patrol charts are appended for guidance, as Annexure - 10/1, 10/2, 10/3.
(3) Distribution of Patrol Charts –
Before commencement of the monsoon, requisite number of copies of patrol charts
should be supplied by the Divisional Engineer to the Assistant Divisional Engineers,
SSE/P.Way (In-charge), the Divisional Operating Manager (for distribution to the
Control staff), Station Masters and Loco Inspectors of running rooms. The Loco
inspectors will acquaint Loco pilot of passenger trains, when they may expect to pass
patrolmen, if running to time. By inviting Loco pilots to lookout for patrolling, an
immediate and practical means of supervising the patrolmen is introduced. The task
of dispatching patrolmen at the right time and signing their patrol book when they
arrive at or depart from a station devolves upon the Station Master/Block Hut-in-
charge.
(4) Patrol Books and Systematic Patrolling –
A patrol book containing sufficient number of pages should be supplied to each
patrolman with a tin case. The books shall be serially numbered to correspond with
the number of patrol beat on each section. The first page of the book shall contain the
name of Patrolman, kilometerage of patrolling section and its number. The remaining
pages will contain columns for date, station, time of arrival and departure and
signature of Station Master.
Patrolmen shall be on duty at the time specified in the patrol chart.
The Patrolman whose beat commences/terminates at a station shall present the
patrol-book in his possession to the Station Master/Block hut In-charge who will enter
therein the time of arrival and departure and sign the book. The Station Master/Block
hut-in-charge will also record the time of arrival and departure in his Diary/Train
Register Book. The Patrolman shall then patrol his length at the end of which, he will
exchange his patrol book with that of the next Patrolman and retrace his beat. The
intermediate patrolman shall do likewise. In this way each patrol-book will be conveyed
from one station to the other and back again. Owing to close proximity of stations,
patrol books may be passed through one or more intermediate stations, before it is
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returned to the original station.
If a Patrolman on arrival at the end of his beat does not find the next Patrolman to take
over the book, he must proceed ahead, until he meets him. The Patrolman should
report the absence of any Patrolman from his beat to the Gang Mate the next day.
Station Masters will see that the Patrolmen come on duty sober and fully equipped,
their lamps are trimmed and filled with oil or the batteries are fully charged (in case of
rechargeable lamps ) and they leave for their patrol duty in time.
If a Patrolman who is due to arrive at a station does not turn up in time or does not
turn up at all, the Station Master/Block hut-in-charge will advise Station Master/Block
hut-in-charge at the other end of the block section about the absence of the Patrolman
and both Station Masters/Block hut-in-charges will issue caution orders to all trains
entering the section until the Patrolman from the other end of the “patrol-section”
arrives at the station and reports that all is well.
The Patrolman shall preferably be provided with a GPS tracking device, to monitor his
movements so as to ensure effective patrolling.
(5) Equipment of Monsoon Patrolmen –
(a) Each Patrolman shall be provided with the following equipment and such other, as
may be prescribed by special instructions:
(i) One staff (preferably foldable).
(ii) Number plate 15 cm Square (to be numbered consecutively from the beginning
of each SSE/P.Way (In-charge) length in white letters on black background).
(iii) 10 detonators in a tin case.
(iv) Warning signals (a red flashing rechargeable LED torch/hand signal lamp at
night or red flag during day as per Para 3.65 of GR). Three warning signals on
double/multiple lines, Ghat sections, suburban and automatic block territories
and two warning signals on single line sections
(v) Protective clothing according to local dress regulations including industrial
safety shoe / Gum boots, Safety jacket, Rain coat, Helmet with Head light.
(vi) One match box.
(vii) Two red flags and one green flag (day patrol only).
(viii) Patrol book in a tin case.
(ix) One three cell Electric torch.
(x) Whistle thunderer.
(xi) One haversack.
(b) Where patrolling is undertaken in pairs or stationary patrol consists of two men, the
equipment need not be duplicated but the additional Patrolman will be provided
with an extra rechargeable LED torch/hand signal lamp, whistle thunderer,
protective clothing and one spanner, hammer and light crowbar for emergency use.
(6) Selection of Patrolman – (Back to Para 1124)
Literate, Intelligent, experienced and trustworthy track maintainer should be selected
from the Permanent Gangs by JE/SSE/P.Way to work as Patrolmen and Watchmen.
Twice the number required should be selected to serve as relief, in case of illness, to
provide for rest giver Patrolman etc. The track maintainer selected from each gang
should be sent to the Divisional Medical Officer for vision test and shall not be
employed as patrolmen unless they have passed the requisite medical test.
(7) Certificate to be submitted by SSE/P.Way (In-charge) –
The SSE/P.Way (In-charge) shall submit a certificate to the DEN through ADEN, a
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month in advance before the commencement of the monsoon that he has made all
arrangements for monsoon patrolling and for watching vulnerable locations/bridges
and that the patrolmen and the watchmen have been made conversant with their
duties, rules for the protections of the line and vulnerable locations in their beats. He
will also submit to the ADEN a list of names of patrolmen and watchmen with their
duties/locations assigned during the patrolling season.
(8) Action When Damage is observed – (Back to Para 117 (1) (c), 117(4)(a), 1006)
In the event of any portion of the line being breached or otherwise rendered unsafe for
traffic the following procedure shall be observed
(a) In the case where two patrolmen are employed –
(i) Protecting the line –
(a) The danger signal must be exhibited in both the directions
(b) The two patrolmen shall then proceed in opposite directions showing the
danger signals (red flag by day and red light by night) and when at 600 m
from the point of danger, each should place one detonator on to the rail; they
shall then proceed to a distance of 1200 m from the point of danger where
they should place three detonators on the rail about10 metres apart. On the
double line the detonators must be placed on the line, in the direction on
which the trains will approach.
(c) Should the nature of obstruction be such as to render it impossible for either
of patrolmen to get across the gap, as for instance a wash away with strong
flood, one of the men should show the danger signal and endeavour to stop
trains approaching the gap from the other side while the other man should
proceed towards the station on his side of the gap, fix the detonators and act
as in (b).
(ii) Reporting the damage to Station Master and Gang Mate –
(a) After protecting the track one of the two patrolmen who is nearest to the
station and in case mentioned in (c) above, the patrolmen who has protected
the track will proceed in all haste, showing the danger signal, to the station
and inform the station master of the danger. On his way back, if he meets
with any gang quarter, he should inform the Gang Mate of the occurrence
and the gang must immediately proceed to the affected kilometerage and
take necessary action to attend to the repairs.
(b) After protecting the track, the other Patrolman will proceed to the site of
obstruction, and remain there showing the danger signal, until the first
Patrolman joins him. In case the other Patrolman has not been able to
locate the gang hut on his way back from the station, one of them should
proceed to the gang hut and inform the Gang Mate.
(b) In case where One Patrolman is Employed –
(i) Protection of line –
(a) When damage is detected on single line –
(1) Place a red lamp during the night and a red flag during the day in a prominent
position to warn a train, which may approach from one direction. Then run in
the opposite direction from which train is likely to come, with a danger signal
(red flag by day and red light by night) and place one detonator at 600 m and
three detonators at 10 metres apart at 1200 m from the site of obstruction/
damage.
(2) Return to the site of obstruction/ damage, and protect the other side with
detonators similarly.
(3) In the event of it being impossible to get the other side of the obstruction/
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damage (as in a wash away)place the red lamp so that it can be seen from
as great distance as possible by a train approaching from that direction and
protect the other side with the detonators etc. as detailed in Sub-Para (a) (1).
(b) When damage is detected on double line –
(1) Place the red flag/lamp in prominent position so as to warn an approaching
train on one track. Then run along the other track on which train is expected
first and place the detonators as in Sub-Para (a) (1)
(2) Run back and protect with detonators the line on which the lamp/flag was
prominently placed earlier.
(ii) Reporting the damage to the Station Master – the Patrolman will return to the
site of obstruction after protecting the line in both the directions and shall remain
at the place of obstruction and send word about the danger through the first
railway employee or other persons he is able to contact at the spot itself.
(9) Responsibility of Engineering Officials in the Matter of Patrolling –
(a) Inspection of Patrol Books – JE/SSE/P.Way must examine the patrol books, initial
the entries each time he inspects and take corrective measures for irregularities
noticed. The ADEN should examine the patrol books during his inspection.
(b) Supply of Equipment to Patrolmen and Watchmen – JE/SSE/P.Way will be
responsible for ensuring that each Patrolman is provided with the equipment
specified, and for periodical distribution of consumable stores like kerosene oil,
match box etc. The Gang Mate will be responsible for seeing that the Patrolman
and stationary watchman possesses the correct equipment specified.
(c) The JE/SSE/P.Way will be responsible for instructing the patrolmen in their duties
about the rules for the protection of the lines and in acquainting them with all
vulnerable points on their beats. In addition to oral instructions, the JE/SSE/P.Way
shall by practical demonstrations, drill the patrolmen in their detailed duties and
responsibilities.
(d) Inspection of Equipment – JE/SSE/P.Way should check the equipment of all
patrolmen and watchmen once a month, record the results in patrol book and take
steps to recoup deficiencies.
(e) Check over Patrolling at Nights –
(i) By JE/SSE/P.Way – The following are the schedule of inspection of night
patrolling for JE/SSE/P.Way (Sectional) and the SSE/P.Way (In-charge) by
train:
Official By train
JE/SSE/P.Way(Sectional) Once a fortnight
SSE/P.Way (In-charge) Once a month
(ii) ADEN shall cover his entire sub-division once in a month by Train in the night
and check the patrolmen.
(10) Action by ADEN and JE/SSE/P.Way on Receipt of Information Regarding
Damage to the Line –
On the receipt of information of any damage to the line, ADEN and SSE/P.Way (In-
charge) and JE/SSE/P.Way concerned should proceed to site by the quickest
possible means and take necessary action for restoration.
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1005 Hot and Cold Weather Patrolling for LWR/CWR – (Back to Para 117(4)(a),
353)
(1) Hot Weather Patrolling: Period for hot weather patrolling shall be laid down by the
Chief Track Engineer for each section and patrol charts prepared where necessary.
Patrolling shall be organised by JE/SSE/P.Way accordingly. In addition, the
JE/SSE/P.Way and the Gang Mate shall be vigilant during summer and on hot days.
Patrolling will be introduced when the rail temperature rises above:
(a) td + 25° C on PSC sleeper track with sleeper density 1540 nos. / km and above.
(b) td + 20° C on PSC sleeper track with sleeper density less than 1540 nos. / km
Patrol beat for Hot weather patrolling will be as follows:-
(i) On single line or where only one road in a double line section is having
LWR/CWR- One patrolman for 2 km.
(ii) On double line section when LWR/CWR exist on both roads - One patrolman
for 1 km length of UP and DN road. The beats of each hot weather patrolman
will thus be restricted to 2 km.
(iii) Changes in beat length and man power deployment as given above, if found
necessary, may be decided by the Sr. DEN (Co) of the division depending on
prevailing local conditions, frequency of train service, weather conditions etc.,
The hot weather patrolman should always carry the following equipment:-
HS Flags - Red 2
Staff for Flags 1
Detonators 10
Canne-a-boule fitted with rubber ball 1
(2) Hot Weather Patrolman:
He shall patrol the track during the hottest part of the day, to look for prominent kinks,
incipient buckles or tendency towards buckling. He shall protect the track at the site of
the prominent kinks, incipient or actual buckles and report the same to nearest Station
Master and JE/SSE/P.Way immediately. The patrolman shall preferably be provided
with a GPS tracking device, to monitor his movements so as to ensure effective
patrolling.
He will walk over his beat slowly over one rail/on sleeper non gauge side of rail in one
direction and on the other rail/on sleeper non gauge side of rail in the return direction.
On double lines, he will repeat this procedure alternately on UP and DN tracks. He
will be vigilant and look out for kinks in the rail especially during the hottest part of the
day. When a kink is observed, he shall immediately examine at least 100 sleepers
ahead and in the rear of the kink for any floating condition of track. He should
meticulously sound each and every sleeper, 100 sleepers on either side of the kink,
to determine any floating condition. The amount of rebound will be noted by dropping
a Canne-a-boule on each end of the sleeper to determine the extent of void under the
sleeper. Should the amount of rebound reveal a floating condition, under which a
buckle may be anticipated or the patrolman has detected actual buckling of track, he
will take immediate steps to protect the affected portion by display of hand signals as
per rules in force. After protecting the track, the patrolman will arrange to advise the
Gang Mate, JE/SSE/P.Way of his apprehension of a buckle/actual buckle.
The Gang Mate on receipt of advice of a danger of buckle will proceed to the site
quickly with all available men. On arrival at site, he will first ensure protection of
affected portion. He should then inspect the condition of track 100 m on either side of
this suspected zone and commence heaping of surplus ballast, if available, on the
shoulders and upto the rail head and keep on compacting the ballast with available
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means. No attempt should be made to slew or align the track or disturb the existing
ballast section. The Gang Mate should continue to remain at site till the arrival of
JE/SSE/P.Way. The rail temperature will also be noted by one of these officials at the
place of apprehended/actual buckle. The rail facing the sun will be covered up to the
level of rail head on the outside by ballast or leaves etc. to bring down the temperature
of the rail.
(3) Cold Weather Patrolling: Period and section where cold weather patrolling is to be
done shall be laid down by Sr. DEN (Co) of the division based on rail/weld fracture
analysis, extent of rail corrosion ,overdue rail renewals and traffic density. Cold
weather patrolling shall compulsorily be started when rail temperature goes below (td-
300 C). Patrol charts will be prepared where necessary. Patrolling shall be organized
by JE/SSE/P.Way (In-charge) accordingly. Following guidelines may be followed for
issuing detailed instructions. (Back to Para 337, 346)
Patrol Beat for Cold Weather Patrolling shall be as follows:
(a) On single line or where only one road in a double section is having LWR/CWR -
One patrolman for four kilometre.
(b) On double line section when LWR/CWR are on both roads - One patrolman for
Two kilometre length of UP and DN road.
(c) Changes in beat length and man power deployment as given above, if found
necessary, may be decided by the Sr. DEN (Co) of the division depending on
prevailing local conditions, frequency of train service, weather conditions etc.
Cold Weather Patrolman should carry the following equipment:
(i) 10 fog signals in a tin case
(ii) Two tri-colour hand signal lamps/Rechargeable LED torch
(iii) One match box
(iv) Two red flags and one green flag
(v) One three-cell electric torch
(vi) One staff
(vii) Number plate
(viii) Spanner
(ix) Protective clothing according to local dress regulations including industrial
safety shoe / Gum boots, Safety jacket, Rain coat, Helmet with Head light.
(x) Patrol Charts shall be prepared as per Para 1004 (2).
(4) Cold Weather Patrolman:
He shall patrol the track during the coldest part of the night and lookout for weld/rail
fractures and excessive gaps at SEJ. He shall protect the track at the site of weld/rail
fractures or excessive gaps at SEJ and report the same to nearest Station
Master/JE/SSE/P.Way. The patrolman shall preferably be provided with a GPS
tracking device, to monitor his movements so as to ensure effective patrolling.
He will walk over his beat slowly along one rail in one direction and on the other rail
in the return direction. On double line, he will repeat this procedure alternately on UP
and DN tracks. He will be vigilant and look out for rail/weld failure. He will also notice
the gaps at SEJs if they fall in his beat. In case he notices a rail/weld failure or gap at
SEJ becomes more than the designed maximum gap, he will take immediate action
to suspend the traffic and protect the line as per Para 812. After protecting the track,
the patrolman will arrange to report to Keyman/Gang Mate, JE/SSE/P.Way who shall
arrange for making emergency repairs to pass the traffic.
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1006 Watchmen at vulnerable locations – In addition to patrolmen, stationary
watchmen are posted at known or likely locations of danger or trouble.
(1) Definition – Vulnerable Locations (Points) are those, where conditions unsafe for the
passage of trains are apprehended and there is need for stopping of trains in time in
case such conditions develop e.g.
(a) Bridges, having inadequate water-way, liable to scour in foundations, oblique/
Parallel flow of water to the approaches, rise of flood above danger level frequently.
(b) Bad banks liable to slips and subsidence.
(c) Bridges located across river courses fed by Railway affecting tanks.
(d) Cuttings and Hill designated as vulnerable by DEN/Sr. DEN.
(e) Water over-flowing over the track, and
(f) Any other condition likely to affect the safety of the track.
(2) List of Vulnerable Locations – A list of Vulnerable Locations should be maintained
by each Assistant Divisional Engineer/Divisional Engineer in a register form and
should be reviewed and brought up-to-date.
(3) Guarding of Vulnerable Locations –
(a) Stationary Watchman should be posted round the clock at every nominated
location during the monsoon period, as required.
(b) He should keep a watch on vulnerable location and in case he apprehends danger
he should take action to protect the line in accordance with Para 1004(8).
(c) The equipment for the watchman should be on the same scale as Patrolman
except that a watch man will not be provided with –
(i) Number plate.
(ii) Haversack.
(iii) Patrol book in tin case.
A notebook should however be provided to the watchman.
1007 Security Patrolling during Civil Disturbance and on Special occasions:
(1) On apprehension of a Civil Disturbance, the Divisional authorities should contact the
local Civil authority and arrange, as circumstances may warrant for security patrolling
of the railway line. This may be arranged on the pattern of the monsoon patrolling with
modifications, as deemed necessary, in consultation with Civil authorities.
(2) Security patrolling on special occasions should be carried out according to the special
instructions issued by the administration.
(3) The primary duty of the Patrolman employed on Security patrolling shall be to protect
trains against any condition of danger, such as tampering with track or obstruction
placed on line.
Page 359 of 417

SPECIMEN PATROLLING CHART

MAIN LINE AND BRANCH LINE LOW DENSITY TRAFFIC
2 BEATS LENGTH 8.45 km
JODHPUR – MARWAR SECTION
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Page 361 of 417

Page 362 of 417

CHAPTER 11
AND PRE-MONSOON PRECAUTIONARY MEASURES
*********************
PART - ‘A’
1101 Observance of Rules –
(1) Any occurrence within or outside the Railway limits, which does or may affect the
safety of the Railways, its Engines, Rolling Stock, Permanent Way, Works,
Passengers or Railway Servants or which does or may cause unusual delays to trains
or physical and financial loss to the Railway, is termed an accident. For instance, a
flood outside Railway limits may seriously threaten the safety of the line and should
be treated as an accident.
(2) Rules for reporting and joint enquiries into the accidents are contained in the Accident
Manual issued by Railways and in the Railway (Notices of and Enquiries into
Accident) Rules,1998, issued under Section 122 of The RailwaysAct,1989 (24 of
1989).
(3) The Indian Railways (Open Lines) Rule 2.11 of General Rules, 1976 Edition enjoins
that –
(a) Every Railway Servant shall –
(i) See that every exertion effort is made for ensuring the safety of the public;
(ii) Promptly report to his superior any occurrence affecting the safe or proper
working of the railway which may come to his notice; and
(iii) Render on demand all possible assistance in the case of an accident or
obstruction.
(b) Every Railway servant who observes –
(i) that any signal is defective;
(ii) any obstruction, failure, or threatened failure of any part of the way or works;
(iii) anything wrong with a train; or
(iv) any unusual circumstance likely to interfere with the safe running of trains or the
safety of the public;
(v) shall take immediate steps, such as the circumstances of the case may demand
to prevent accident; and where necessary, advise the nearest Station Master
by the quickest possible means,
(vi) provided that in the case of a train having parted, he shall not show a stop hand
signal but shall endeavour to attract the attention of the Driver or Guard by
shouting, gesticulating, or other means.
1102 Report of Accident to the Station Master / Railway Servant In-charge
of Block Hut – Following actions to be taken by Engineering official:
(1) Soon after noticing the occurrence of an accident, Engineering official (if he is the first
to reach the site of the accident) shall report the accident to the nearest Station
Master through quickest possible means including electronic communication covering
the following information; to issue an all concerned message:
(a) Name of the station at or stations between which the accident has occurred
(b) Kilometer of the accident.
(c) Number and description of the train or trains involved.
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(d) Date and time of the accident.
(e) Particulars of loss of life and injuries to passengers and staff.
(f) Nature and cause, if known, of accident.
(g) Damage to Permanent Way, Works, Bridges, Overhead equipment (in case of
electrified section), signal and interlocking gear, engines or vehicles.
(h) Probable duration the line may be blocked.
(i) Whether transhipment is required and if so whether it is feasible.
(j) Assistance (if any required) such as Medical assistance, break-down train etc.
(2) Acknowledgment of the receipt of message should preferably be taken from the
Station Master.
1103 Accidents Impairing Through Traffic –
(1) Engineers to proceed to site –
(a) On receipt of intimation of the occurrence of an accident resulting in damage to
any part of the Way/Works/Bridges and affecting the free passage of trains, the
concerned JE/SSE/P.Way or (Works) or (Bridge) and the ADEN shall proceed to
the site of accident, by the quickest available means. On their way, they should
collect information about the extent of damage to Permanent Way/Works/Bridges
and arrange for movement of Materials required for restoration. They should also
collect additional staff and tools as required, the engineering tool van should be
sent to the site, if so considered necessary, by the quickest means.
(b) On receipt of intimation of an accident, the DEN shall contact the section control
and the ADEN and get the information regarding the extent of damage to
Permanent Way and Works, check on the arrangements made for labour and
Materials, etc., supplement them if necessary and proceed to the site of the
accident by the quickest available means, if the seriousness of the accident
requires his personal supervision and direction.
(2) Accident in an adjacent Division – In the event of an accident taking place on a
division, where assistance could be more expeditiously rendered by officials of an
adjacent division, such officials and the ADEN / DEN of the concerned adjacent
division should be advised; these officials should proceed at once to the site of
accident with necessary resources and render every possible assistance.
1104 Action at Site –
(1) By Engineering Supervisory Officials –
(a) Protect Train – Any Engineering staff available at the site of the accident shall
assist the Guard and Driver to protect the train in accordance with The General
Rules 6.03 and 9.10 (1976). The JE/SSE/P.Way should ensure that protection has
been afforded to the train in front and in the rear, in accordance with the rules. In
the case of double line, if the other line is also affected by the accident, steps shall
be taken to protect both the lines. If no infringement exists, trains must be
controlled and passed cautiously on the unaffected track.
(b) First aid and Rescue – The JE/SSE should render assistance to give medical relief
/ treatment to injured passengers and assist in rescue of trapped passengers.
(c) Advice to nearest Station Master – After a rapid survey of the position, particulars
should be sent to the nearest Station Master as in Para 1102 above. In case of
controlled sections, a field telephone should be got commissioned at once.
(d) Line Clear examination – If the Engineering official has reached the site and no
traffic official is available, he should carefully secure the line clear token or ticket
and any caution order, where necessary. If the accident has occurred in a station
yard, the train register book must be seized and if necessary, statement of staff
concerned recorded; if line badges are in use, it should be recorded as to in whose
possession each line badge was. The position of station control panel, block
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instruments, signals, points, point levers, indicators, keys, etc. should be noted and
recorded, jointly with the JE/SSE of the other concerned departments, available at
site. Item listed in Para 1108 may also be referred for further guidance.
(e) Preliminary clearing operation –
(i) In all instances in which the means taken for the restoration of communication
are likely to obliterate marks on the road and other evidence needed at a joint
enquiry, the senior official who arrives first on the spot should carefully examine
the track, train or vehicle and as soon as possible make notes, sketches etc.
and hand over the same to his superior or produce them at the enquiry. He will,
when the nature of the accident is such as will involve the question of eye-sight
of any of the staff, verify (in case of those permitted to wear glasses) that they
had worn glasses at the time of the accident and had carried a spare pair of
glasses with them.
(ii) In all cases of accidents, the cause of which might possibly due to sabotage, it
is essential that the clearance and restoration operations are not commenced
till the Police officials arrive at the site and intimate their agreement to the
commencement of clearance and restoration work, after, making thorough
investigations.
A factual note of the conditions obtaining at the site prior to restoration work
should be prepared and signed jointly by the senior-most Police and Railway
officials at the site. In the event of any difference of opinion between the Police
and the Railway officials, such difference of opinion may be recorded on the
joint factual note.
This should not, however, be allowed to interfere with rendering of first aid to
the injured, which is the first essential in all accidents.
(iii) In other cases, clearance and restoration operations can commence even
before the arrival of the Police and it is not necessary that all the rails, sleepers
and fastenings involved in an accident should be preserved, but only those,
whether serviceable or otherwise, which bear wheel marks, etc., especially
between the points of mount and drop. In all cases of serious derailments, these
are essential for a later reconstruction of the scene and should be preserved
and/or recorded by the first responsible official to reach the site of the accident,
as these would be valuable evidence to ascertain the cause of the accident.
(iv) The senior most Railway Officers at the site of the accident should arrange to
record the preliminary statements of the staff concerned, immediately after the
injured persons have been attended to and arrangements made for the onward
journey of the stranded passengers, as any delay in recording statements, might
result in suppression of some facts or fabrication of some evidence during
subsequent enquiries.
(v) In case sabotage is suspected, the procedure as outlined in clause (ii) above
should be followed. In addition, it should be ascertained promptly from the CRS
if he would like to inspect the site etc., before the commencement of clearance
and restoration work and then action should be taken in accordance with his
wishes. Before clearance and restoration operations are commenced all
relevant clues, Materials and damages and the deficiencies on Rolling Stock
etc., must be noted and preserved. In other serious accidents, however, the
same procedure as outlined in Clause (iii) above should be strictly followed.
(f) Contacting higher officials – JE/SSE should get in touch with the ADEN or DEN,
explain the position on telephone, wherever possible; if not, he should himself
organise the restoration of through running including ordering of ballast trains,
requisitioning of required Materials and tools and send information to ADEN and
DEN of the preliminary measures undertaken, by the quickest possible means.
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(g) Recording of details and advice regarding restoration time – He should arrange to
record the details of the accident and prepare notes on any special features
bearing on its cause, which may be of help in the enquiry.
(h) Preservation of clues –
(i) Nominated ART staff shall be responsible for taking photograph or recording
video.
(ii) Photographs /Videos showing the details of damage to Permanent Way and
Rolling Stock at the site of accident should be taken wherever necessary; in
case of suspected sabotage, the photographs of the site of the accident showing
the damage and possible clues should invariably be taken.
(iii) While taking photograph /video the principle of ‘whole to part’ must be followed;
i.e. the first shot (long shot) should cover the entire site along with OHE Mast
No. /Hectometre Post No. and the entire coach /wagon with coach /wagon
number. The 2nd shot (medium shot) should cover closer view showing
particular bogie and track structure. The 3rd /4th shot (close shot) and so on
should cover further closer view with finer details and specific components.
(iv) Photography /Videography should cover all the important locations on track and
affected parts of rolling stock. It should show inside view of driver and guards’
cabin and position of various switches, knobs, brakes, handles etc.
(v) At station photograph /video should cover Panel and Block instrument, sealing
of Relay room, various signalling and interlocking instruments.
(vi) Engineering officials should advise in writing or through electronic
communication to divisional safety officials for preserving evidences or clues
identified at site.
(vii) In case of a suspected sabotage, Tell-tale sign must be preserved and
recorded.
(viii) In case of rail/weld failure WILD data for preceding few trains must be collected
and analysed.
(ix) Record of data logger should be preserved and analysed in all accident cases.
(x) Speed recorder and event recorder of locomotive shall be frozen by the
concerned controlling/ safety officials.
(2) By ADEN –
(a) He should ensure that action specified under sub-Para (1) above has been taken
by JE/SSE/P.Way. If he is the first to arrive at site, the Assistant Divisional Engineer
should take action as specified for JE/SSE/P.Way.
(b) He should get in touch with the Divisional Engineer and the Controller/Chief
Controller and furnish complete information advising the details of action being
taken and the probable time for restoring through running.
(c) He should arrange to organise the measure for expeditious restoration of through
traffic and ensure incessant working until through running is achieved.
(d) A preliminary report should be prepared.
(3) By DEN –
(a) He should examine the adequacy of measures taken for restoration of through
running lines and ensure expeditious work.
(b) He should assess and advise the position to the DRM and PCE, with brief
particulars (over the field telephones on Controlled Sections) and probable time of
restoration. The Principal Chief Engineer/ Chief Track Engineer or HOD nominated
by PCE may proceed to site in case of very serious accidents.
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(c) A report should be prepared and submitted to the PCE and DRM.
(d) The DEN shall ensure that the fractured pieces of rail/weld are preserved and sent
to RDSO for detailed investigations, at the earliest possible, in all cases of
accidents, where rail/weld is a prima facie cause of the train accident.
(4) The senior-most Railway Officer at the scene of accident shall be responsible for the
general appraisal of the situation and co-ordination of all works.
1105 Report to the Principal Chief Engineer –
(1) Report on Accident –
(a) The Senior most Engineering Official at the site of the accident shall after initiating
measures for restoring traffic, submit a brief report to the PCE with a copy to the
DRM which will include the following particulars:
(i) Nature of the accident,
(ii) Cause, if known.
(iii) Particulars of loss of life and injuries to passengers and staff.
(iv) Extent of damage to Way, Works and Bridges.
(v) Particulars of rainfall and patrolling, in the case of damage by floods.
(vi) Steps taken for resumption of traffic.
(vii) Probable time, when normal working is likely to be resumed.
(viii) Whether transhipment is necessary and if so, for how long.
(ix) Whether a diversion is necessary and if so, when it is likely to be opened.
(x) Details of any assistance required, such as additional staff, labour, ballast trains
and other Permanent Way and Bridging Materials.
(b) A sketch showing important dimensions, positions of vehicles, tracks made by
derailed vehicles, marks on rails, particulars of condition of track for an adequate
distance in the rear of the point of derailment and any other information likely to be
of use in elucidating the cause of accident should accompany the report.
(2) Reports on Breaches – In the case of damages caused by floods, the Divisional
Engineer should initiate necessary investigation and submit a Technical Report with
drawings, to the Principal Chief Engineer, detailing the remedial measures required,
with the past history, if any, of the kilometrages affected, within a month of the
occurrence.
1106 Attendance of Police at Site –
Arrangements should be made for the police to attend the scene of accident in the
case of derailment of a train carrying passengers (or of any other train when it is
considered necessary) in order that they may observe the extent of disturbances
caused to the line, keeping guard over loose Materials lying about and over any
evidence affecting the cause of the accident and safeguard passengers’ luggage
and mail as required.
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1107 Examination of Site and Preparation of Sketches – (Back to Para 1121)
The first Engineering representative to arrive at site shall attend to the following –
(1) He should examine the entire site inclusive of track over which the train has passed
immediately before derailing, noting down any unusual features observed, especially
any parts of vehicles or other Material lying on or near the track.
(2) A dimensioned sketch should be prepared covering the entire site of accident,
showing all relevant features inclusive of track leading upto point of derailment,
showing position of derailed vehicles, point of mount and drop and other relevant
details. All the details given in Annexure - 11/1A should be incorporated in the sketch.
(3) He should take note of the particulars as detailed in Para 1108.
(4) An examination of the derailed vehicle/vehicles for defects not caused by the
derailment but which may have been the cause of the derailment should be made. He
should make out notes for inclusion in the joint report.
(5) He should examine the gang-charts/diary books to ascertain the date when track was
last attended.
(6) Details of engineering works in progress, if any, at the site of accident, caution orders
in force and nature of protection should be noted.
1108 Recording Particulars at Site of Accident (Back to Para 1104, 1121)
(1) Permanent Way particulars – Permanent Way particulars shall be recorded jointly with
the SSEs/Officials of the other concerned departments as per Annexure - 11/1B.
These records will inter alia include particulars of the track structures, the condition of
the track components, track geometry and other relevant details.
(2) Particulars with respect to Rolling Stock and Signalling – Engineering representative
should associate himself with the concerned representative of the other departments
in recording measurements of –
(a) The locomotive as per Annexure - 11/1C;
(b) Carriages and Wagons as pre Annexure - 11/1E and Annexure - 11/1D,
respectively; and
(c) Signalling, Interlocking and Telecommunication equipment-
(i) Position and condition of stretcher bars, its type, whether it is hugging the stock
rail.
(ii) Last movement done over the points just before the accident and whether
signalled or un-signalled.
(iii) How the points are being worked, method of locking of points, its connection
with signal. Position, setting and locking condition of points and condition of
switches.
(iv) Condition of motor point.
(v) Whether the crank handle is sealed, when was it last used and for what purpose.
(vi) Emergency operation of points, emergency route release etc.
(vii) TRS (Train Signal Register)/log book should be taken into custody to verify
entries of last three movements in either direction.
(viii) SM’s Control panel shall be frozen till the time position of the knobs, switches,
points & crossings etc. are jointly recorded.
(ix) Whether Panel was sealed and relevant record for last operation was made and
what were the indications shown on panel.
(x) Whether the relay room is in double locked condition.
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(xi) Any S&T gear is under disconnection.
(xii) Data logger- Analysis of event recorded in the data loggers.
(xiii) Position of block instrument in details including its handle, commutator, dial
indication, locking tec. In the case of electrified section, the block filter unit
attached to the block instrument is checked.
(xiv) If any manipulation in any signalling and interlocking gear.
(xv) Locking of cabin basement
(xvi) Date of last overhaul of block instruments, date of last overhaul of lever frame,
SM’s control frame.
(xvii) Date of testing the block instruments and other interlocking gears by Inspectors
/officers prior to the accident. Results of their test and action taken.
(xviii) Any interference with any signalling and interlocking gears.
(xix) Details of unsafe failures during last three months.
Note: As a precautionary measure, the relay room, cabin basement, block instrument, device for
crank handle/emergency operation of points/emergency route release, etc. should be locked
immediately after the accident and the key kept in the safe custody of the Station master/
responsible officials at site till joint observation and functional test of S& T gears are completed.
(3) Operating particulars – The following operating particulars should also be recorded
wherever relevant –
(a) Speed – The actual speed at the time of derailment, from the speedometer graph
or if the locomotive is not provided with the speedometer graph, by referring to
inter-station timings.
(b) The direction of the locomotive i.e., Short-hood or Long-hood leading.
(c) The brake power of the train.
(d) The marshalling of the train with reference to orders applicable on the section.
(e) Whether there has been sudden application of brakes.
(f) Whether there was sudden opening of regulators.
(g) Condition of loading in wagons, especially unequal loading, light loading, empties
between loaded vehicles, over loading, moving loads and any infringement to
standard dimensions.
(h) Particulars of Caution Orders issued to the Driver/Guard.
(i) Caution order Register.
(j) Block ticket.
(k) Authority to proceed without line clear.
(l) Use of lever collars and slide collars
(m) Shunting Authority
(n) Station diary
(o) Private Number Book
(p) Securing of vehicle.
(4) In Case of level crossings:
(a) Km of Level Crossing and station in between.
(b) Class of level crossing
(c) Manned /unmanned and number of GKs posted.
(d) Location within station limits/outside station limits.
(e) Whether interlocked.
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(f) Availability of telecom facilities and their working order.
(g) Availability of speed breakers, Road signs
(h) Visibility of gate from road and from Rail line.
(i) Whether on curve, cutting and gradient of Rail line and as also for road.
(j) Normal position of gate and status at the time of accident.
(k) Position of gate signal, lever, panel at the time of Accident.
(l) Bio data of GK and whether as per roster.
(m) Number and type of road vehicle, its loading condition, Driver’s name, registration
details, licence etc.
(n) Numbers of trains and road vehicles passing through the level crossing on an
average per day and last census taken.
(o) Weather condition at the time of accident.
1109 Use of Recorded Data – (Back to Para 1121) The object of recording all
available data at site and of evidence is to ascertain the cause of the accident with
a view to prevent its recurrence, and where the cause is due to negligence, to fix
responsibility.
(1) The joint measurement as per annexed proforma submitted by senior supervisors
shall not be complete till all the measurement of rolling stock and track have been
recorded. Only completed joint measurement w.r.t. rolling stock and track shall
become a document to be relied upon by the enquiry committee for drawing
conclusion regarding cause of accident.
(2) No enquiry shall be completed before the complete measurement of rolling stock and
track is available and made part of the enquiry report. Enquiry Committee may get
additional measurements done as per requirement of the derailment case.
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PART - ‘B’
RESTORATION OF THROUGH RUNNING
1110 Repairs to Damaged Track – Repairs to the track should in the first instance,
be kept to the minimum necessary to restore traffic with the least possible delay,
the required Materials being expeditiously arranged for. Soon after, the track
should be brought to its proper standard.
1111 Procurement and Arrangement of Labour –
(1) Adequate labour is the very first essential for restoration of through running. Engineers
should acquaint themselves with all possible sources from which labour could be
readily arranged in the event of a breach or a serious derailment on their section.
Labour should, as far as practicable, be conveyed to the site of accident by train or
any other faster mode depending upon availability.
(2) Labour should be arranged in one or more of the following ways:
(a) By ordering departmental labour within a reasonable distance to proceed to the
site.
(b) By ordering two or more men from each permanent gangs to proceed to the site.
(c) By obtaining labour from adjoining divisions, if considered necessary and possible.
(d) By calling on the Revenue Authorities to supply labour.
(e) By hiring temporary labour locally or from known sources.
(f) By arranging labour through reliable Contractors (wages should be fixed prior to
their engagement).
(3) In case contractor’s labour is engaged, it is preferable to allot work in such a way that
the departmental labour and contractor’s labour do not get mixed up. Settlement of
claims should be prompt. Labour should be organised in batches under the charge of
JE/SSE. Proper muster sheets should be maintained.
(4) In emergencies, ADEN/JE/SSE/P.Way may authorise Station Masters by
memo/electronically to issue proceed order for the journey of Track Maintainer/Labour
required for the work along with their tools and equipment from specified station to
the nearest station from the site of accident. As far as possible, all departmental labour
shall move with complete tools and equipment.
(5) Adequate arrangements should be made for food, shelter, water and lighting.
1112 Diversion –
(1) General – Should a diversion be decided upon, the work should be commenced as
quickly as possible.
(2) Classification of diversions – These may be classified as –
(a) Temporary
A temporary diversion is one which is not likely to be in use, for more than 10 days.
All trains must “Stop-dead” before entering a temporary diversion and proceed at
10 Kmph speed.
(b) Semi-permanent
A semi-permanent diversion, is one constructed for the special purpose of
facilitating the reconstruction of the line and/or bridges likely to be in use for a
period of more than 10 days. On a semi-permanent diversion, trains may proceed
at a non-stop reduced speed after adequate period of consolidation.
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(3) Curvature and Gradients – As far as possible the radius of curve should not be less
than 450 metres. Gradient should not be steeper than 1 in 100 and compensated for
curvature.
In difficult terrain it may be necessary to lay curves of radius not less than 225 metres
and adopt grades upto the ruling gradient on the section.
There should be no super elevation, in case of temporary diversions.
(4) Calculation for setting out diversion –
While setting out diversion, the following formula will be found handy –
S
L = √C 2 + 4RD − D2 +
2
RD
T= S
L−2+C
All measurements to be taken in same units, where,
AB= Portion of existing line to be diverted.
L= Length of half the diversion, measured along the original alignment.

D=Maximum distance of diversion from original alignment.
S= Straight portion of diversion.
C= Length of straight between reverse curves.
R= Radius of curves.
T= Length of tangent.
(5) Opening for traffic – The diversion track should be adequately consolidated and tested
by locomotive/ loaded wagons before opening for traffic. The most vulnerable portion
of the diversion is at the junction of the old bank with the new bank. Care should,
therefore, be taken to provide benching of slopes at the junction. Cross-levels should
be checked after passage of every train and rectified till the track gets stabilised.
(6) Issue of safety certificate – The opening of line on temporary diversion shall be done
in accordance with the Para 1209 of this manual.
1113 Transhipment – The decision as to whether transhipment is to be done, is taken
by Transportation/Commercial Department. If it is decided to provide gangways,
footpath etc., purely for the purpose of transhipment, these should, as far as
possible, be laid away from the site of repairs, so that the progress of restoration
is not interfered with.
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1114 Funds Required During Emergencies –
(1) The DEN or the ADEN on his behalf may draw upon the station earnings for
expenditure necessitated by floods, accidents or earthquakes vide Para 1405 of
Indian Railway Code for Engineering Department for the following purposes –
(a)Payment to daily labour hired at the site of breach or accident.
(b)Purchase of tools or Materials required in connection with accident which cannot
be supplied in time by the Store Department.
(c) To provide food to engineering labour at the site of breach or accident with the
assistance of Station Master or Inspectors of the Commercial Department.
Supply of food free of charge is permitted in special circumstances at the discretion
of the administration to facilitate expeditious restoration of traffic. When food is
supplied free at the site of an accident to engineering and other labour, the
expenditure per head per day shall not exceed the prescribed limit.
(2) The Accounts Officer should be advised immediately by memo/electronically of each
sum taken from station earnings.
In all cases, Engineers obtaining advances from Station earnings should do so under
a clear receipt. The purpose for which the money has been drawn should be clearly
stated on the receipt. A complete account should be submitted at the earliest possible
date to the Accounts Department supported by pay sheets and vouchers.
(3) All payment to labour should be witnessed by the ADEN at site.
(4) Works, which are considered to be urgently necessary to safeguard life or property or
to repair damage to the line caused by flood, accident or other unforeseen
contingency, so as to restore or maintain through communication may be started on
Urgency Certificate in accordance with Para 1103 of Indian Railway Code for
1115 Obstructions Found on Track – When obstructions are found on the track
those should be cleared after protecting the line and informing the nearest Station
Master. Where sabotage is suspected, the Police should be advised immediately. The
JE/SSE/P.Way should, if so required, arrange to meet the Police Official at the place
of occurrence. A detailed report should be submitted by JE/SSE/P.Way to the
ADEN/DEN. The DEN should in turn report such occurrences whether or not sabotage
is suspected to the DRM and PCE.
1116 Flooded Causeways / Dips – (Back to Para 1117)
(1) Permissible depth of water for passage of trains – In the case of causeways that are
flooded and the velocity of current is insignificant, trains may be permitted to pass
when the depth of water above rail-level does not exceed 300 mm for passenger and
mixed trains and 450 mm for goods train, provided in each case JE/SSE/P.Way has
satisfied himself by walking over and probing that Permanent Way is intact and in a
fit condition.
(2) (a) Indication posts – Indication posts about 1200 mm in height shall be fixed at each
dip, one at each end of the level portion, with flat bar attached to them to indicate level
mentioned in sub Para (1)above.
(b) The posts should be painted black and white in 300 mm length so arranged that
the flat bars which shall be painted white, show up against 300 mm length of
black colour.
(c) The posts shall be fixed 3 m from the centre of the track in the case of Broad
Gauge
(d) The details for fixing Indication Posts have been shown in Annexure - 11/2.
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(3) In the section where Electric Locos/Stock and or Diesel Locos ply, special gauges
may be provided by the administration at the place liable to flooding, indicating the
depth at which these Locos/Stock have to be stopped from the operation. These
depths should be specified for each type of Locos/Stock by the administration.
1117 Special Precautions when Track is Submerged –
(1) The following precautions shall be observed when the track is submerged:
(a) In all cases train shall be stopped dead and allowed to proceed at a speed not
exceeding 10 Kmph.
(b) If water rises over the top of the ballast but is below rail level, the track should be
checked before each train, by two men walking abreast one at either end of the
sleepers, and only if the track has not been disturbed, should the train be allowed
over the track.
(c) When water overtops the rails, the JE/SSE/P.Way shall pilot the train, after
ensuring that the track is safe, by walking over the track and checking by means
of probing, subject to depths specified in Para 1116 not being exceeded.
(2) Advice should be sent by the JE/SSE/P.Way to the ADEN and DEN, DRM and PCE
when water rises above ballast level and again when it subsides. This should be
followed up by special reports to the ADEN and DEN. Records of such occurrences
should be entered in the SSE/P.Way in-charge's Section Register.
1118 Driver’s Report on Defects in Track –
(1) Intimation of Defects –
(a) The Indian Railways (Open Lines) General Rules, 1976 (rule 6.07), on report of
conditions likely to affect running of trains, stipulates that-
(i) ‘Loco Pilots, Guards and Station Masters shall advise the Controller or the
Centralized Traffic Control Operator of any known conditions or unusual
circumstances likely to affect the safe and proper working of trains.
(ii) The Controller or the Centralized traffic Control Operator, on becoming aware
of such defect or failure shall inform the same to the railway servant responsible
for the maintenance of the equipment and other railway servants concerned.’
(b) In this regard detailed procedure mentioned by Railways in Subsidiary Rules
should be followed.
(2) Action on receipt of reports of defective track –
(a) By JE/SSE/P.Way – The JE/SSE/P.Way shall –
(i) Arrange to collect the requisite details and take necessary action for quick
restoration of traffic. He will also proceed to site, if necessary, and inspect the
length of track reported on and record particulars in detail. Then arrange to
rectify the track and remove or modify the restriction imposed, as found
necessary.
(ii) Submit a detailed report to the Assistant Divisional Engineer and copy the same
to the Divisional Engineer.
(b) By Assistant Divisional Engineer – Whenever possible, the Assistant Divisional
Engineer should personally examine the track reported on for defects and make a
detailed report to the Divisional Engineer.
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1119 Abnormal Occurrences Attributable to Locomotives and other Rolling
Stock –
(1) Whenever distortion of track or any other abnormal occurrence attributable to
locomotives or any other rolling-stock is noticed, the JE/SSE/P.Way shall –
(a) Immediately impose speed restriction as necessary and arrange protection of the
line as per rules.
(b) Report the occurrence to the SSE (Loco) concerned copying the message to the
ADEN / DEN and Divisional Mechanical Engineer, Control and Station Master on
either side of the block section. Whenever possible, the number of engine/rolling-
stock considered to be responsible for distorting the track should be given.
(c) Make a careful examination of the affected track with a view to finding out if any
inherent weakness or defect in the track has contributed in bringing about the
“abnormal occurrences”, Particulars of defects should be noted in detail.
(d) Attend to defects as necessary and having done this, remove or modify the
restriction as necessary.
(e) Submit a detailed report to the ADEN and copy the same to the DEN.
(2) On receipt of intimation of any abnormal occurrence attributable to locomotive/Rolling-
stock, ADEN should proceed to the site, examine the track minutely with reference to
the report made by JE/SSE/P.Way and submit a special report to the DEN on the
possible cause of damage with suggestion to prevent recurrence.
1120 Accident not affecting through traffic –
(1) The JE/SSE/P.Way should immediately proceed to the site of the accident and take
such measures, as necessary, to clear the obstruction and restore the line.
(2) The accident report in the prescribed form together with a sketch and statements of
track particulars taken over sufficient length should be submitted in duplicate by the
SSE/P.Way in-charge to the ADEN who will forward one copy of the report to the DEN
with remarks.
Accident reports should be scrutinised by the DEN in all respects with particular
reference to the time taken in restoring the line. Such instructions may be issued by
the DEN to the ADEN and SSE/P.Way in-charge and to other departments, as may
be deemed necessary.
The accident report form shall include particulars of date and time, Kilometer,
description of accident, cause if known, number and type of train, engine, vehicles
involved, names of Drivers and Guards, extent and cost of damage to the permanent
way and rolling stock, time of restoration and the SSE/P.Way in-charge's special
remarks. Accidents such as damage to the Gate Leaves/Barriers by road vehicles,
cattle run over and fire in which track is not affected, should be reported separately.
(3) As far as possible the ADEN should proceed to the site of accident of sufficient
importance, such as derailments on running lines, gathering lines and of locomotives.
1121 Conducting Accident Enquiry-
(1) Stability of train against derailment depends on several factors such as track
geometry, vehicle characteristics, the state of their maintenance, loading pattern of
freight trains, engine-manship and speed of the particular vehicle at relevant point of
time etc. Rail wheel interaction is a complex phenomenon and thus each derailment
case therefore needs careful examination of all relevant available evidences in
respect of rolling stock, track, speed of train and vehicle at the Material time etc. to
arrive at the cause.
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(2) Careful observation of clues and a comprehensive record thereof is vital for accident
enquiry. A comprehensive record of track and rolling stock Parameters; signalling,
interlocking and operating features are required for investigation of derailments.
(3) There are two broad categories of derailment, viz. sudden derailment caused by
wheel set jumping of the rails and Derailment by flange climbing, caused by wheel
mounting the rail in a relatively gradual manner.
(4) Derailment proneness increases with increased Lateral wheel force, reduced Vertical
wheel load (Offloading) and increased Positive Angularity of wheel. Derailment
proneness becomes substantially higher in case of axle moving with a persistently
positive angularity. Track and rolling stock Parameters and operating features should
be critically analysed for their contribution towards these causes.
(5) While analysing the mechanism of derailment, relative contribution of track and rolling
stock Parameters to the rail-wheel interaction forces needs a comprehensive
analysis. Reference should be made to the safety limits/ Maintenance limits specified
in this manual IRCA Rules/ other Manuals.
(6) It is of vital importance to analyse whether any damage to track components is an
after effect of the accident or otherwise.
(7) The track Parameters stipulated in this manual shall be considered keeping the
following view point-
(a) Various Para of this manual clarifies that the provisions and tolerances mentioned
therein are not safety tolerance but with a view to maintain track geometry for good
riding comfort.
(b) The maintenance tolerances given in different Paras of this manual are for mainline
track unless otherwise specified.
(c) The maintenance tolerances for yard lines, other lines and work spots on mainline
having low speed potentials should be suitably considered.
(8) Items mentioned in Para 1107, Para 1108 and Para 1109 shall be fully complied
particularly Annexure - 11/1 (A to E) shall be used for recording the details.
(9) Photography & videography of accident site shall be with great care & precision,
similar to a crime scene photography/videography.
(10) M&C report from RDSO must also be part of accident enquiry report in case
accident is attributed to breakage of any component of track or rolling stock.
1122 Records of Accidents –
(1) Apart from individual files, all important accidents, breaches, washouts and
subsidence of track should be carefully recorded with complete particulars in the
Section Register by SSE/P.Way.
(2) In the case of damage by flood at important bridges, detailed particulars with remedial
measures adopted should be entered by ADEN in the Rivers and Floods Register and
reference made thereto in the Bridge Inspection Register.
(3) Records of all the accidents should be maintained systematically in the offices of
SSE/P.Way (In-charge), ADEN and DEN so as to facilitate supply of statistical and
other information as may be required.
1123 Accident Statements to the Railway Board –
(1) Returns of the accidents under specified categories are compiled by the Operating
Departments for submission to the Railway Board. Relevant particulars should be
promptly furnished by the DEN and Works Manager/Deputy Chief Engineer of
Engineering Workshops to the proper authority on such forms as may be prescribed.
(2) Workshop accident fall under Factories Act and should be reported according to the
rules in force and to such local authority as may be specified.
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PART - ‘C’
PRE-MONSOON PRECAUTIONARY MEASURES
1124 General precautions to be taken before monsoon –
It is necessary to take certain precautions and carry out certain essential works before
the commencement of monsoon, such as
(1) All catch water drains and side drains must be cleared of silt, vegetation and other
obstructions to ensure free flow and quick drainage of storm water.
(2) The waterways of bridges must be cleared of vegetation and other obstructions. If
silting is noticed in some spans, it should be removed to ensure that the full waterways
is available for the discharge of flood water. During de-silting, care should be taken to
remove the silt only upto the bed level.
Protective and River Training Works must be maintained in good condition and repairs
carried out wherever necessary. Scour holes should be filled with boulders. [Ref:
Chapter VIII of IRBM]
(3) The High Flood Level (HFL), Full Supply Level (FSL) in the case of canals with year
of occurrence and Danger Level (DL) must be painted. The Danger Level Mark shall
be painted with bright red band across each pier adjacent to the abutment so as to be
clearly visible to the Patrolmen, Special Watchmen and Drivers. Flood Gauges shall
be painted on important bridges as specified.
(4) Water shall not be allowed to stagnate on the track. For this purpose, cross drains
should be provided at regular intervals. In yards, cross drains and longitudinal drains
should be cleared/provided to proper grades.
(5) In hilly areas, where there is incidence of falling boulders, a survey should be carried
out to locate loose boulders. Such loose boulders should be dropped in a systematic
manner.
(6) Selection of Patrolman and Watchman should be made in accordance with Para
1004(6) and they must be trained and tested for their knowledge of rules. The duties
to be performed by them should be clearly explained to them. The equipment of
Patrolmen and other watchman shall be complete in all respects.
(7) Spare trollies should be kept in readiness at the headquarters of the JE/SSE/P.Way
and at other stations in the proximity of vulnerable locations. Motor Trollies must be
overhauled and kept in fit condition.
(8) Rivers in the upstream reaches should be inspected for guarding against possible
change in water course.
(9) The prescribed reserve stock of boulders, empty cement bags, wire netting and sand/
quarry dust should be kept at specified locations for rushing to site, in case of
emergency and should be made good, in case of deficiency.
(10) Action should be taken as envisaged in Para 1127(3) in the case of Railway Affecting
Works.
(11) The temporary Engineering Indicators must be painted and kept ready for use.
(12) The rain gauges should be inspected before the monsoon and it should be ensured
that they are in perfect working condition.
(13) Use of modern technological advancements such as drone videography etc., can be
deployed to assess the condition of specific assets/locations and water course etc.,
which are difficult to access.[Ref: RDSO Report No.BS-129 entitled as “Guidelines for
Inspection of Railway Bridges using Unmanned Aerial System (Drone)”]
(14) Trees which are likely to fall on running lines during heavy wind/storms should be
identified and cut in advance.
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(15) Vulnerable Locations/kilometrages should be reviewed jointly by the Assistant
Divisional Engineers and Divisional Engineers and on the basis of past history and
pre-monsoon inspections and the register of vulnerable locations should be brought
up-to-date.
1125 Materials for Emergencies –
(1) Arrangements should be made to stock sufficient quantities of rails, sleepers,
Materials for cribs, ballast, sand/quarry dust/cinder and boulders at suitable points
near Vulnerable Locations, so that the Materials may be rushed to site as required.
(2) Before the onset of monsoon, specified number of wagons loaded with sand/quarry
dust/cinder, ballast and boulders should be kept at appropriate stations for quick
movement to Vulnerable Locations.
(3) During monsoon, as far as possible, Ballast Train should be programmed to work in
the vicinity of the Vulnerable Zones so that they may be utilised without delay in
emergency.
(4) Locations and quantities of reserve stocks should be made known to all DENs and
ADENs by the PCE. Reserve stock should not be used except in an emergency. When
it is used, it should be recouped.
DEN should send a certificate to the PCE to the effect that monsoon reserve stock is
in order and to the scale laid down, by the prescribed date.
(5) Bridge Engineer/ DEN should arrange to keep equipment like Service Spans,
Trestles, Cribs, Derricks, Compressor, Equipment and Materials required for blasting,
rock breakers, welding sets etc., ready for use in emergencies. These should be
stocked in working order at convenient places so that they can be despatched to the
site of breaches without delay.
1126 Service Spans and Rail Clusters – Details of temporary service spans and rail
clusters available on each railway should be listed and circulated for the guidance of
ADENs and DENs before the monsoon. The detailed drawings of the same shall be
circulated by the PCE of the railway for the guidance of JE/SSE/P.Way and ADENs,
who should be in the possession of the same.
1127 Railway Affecting Works (Including Railway Affecting Tanks) –
(1) Definition – The term “Railway Affecting Work” may broadly be taken to mean any
work which if not constructed and maintained properly, or not operated properly may
result in danger to Railway Line (Bridge/ embankment). This may include tanks,
storage works, canals, bunds, etc.
(2) Register of Railway Affecting Works – The DEN/ADEN will maintain an up-to-date list
of Railway Affecting Works as jointly approved by the Railway and the state
Government. The list shall invariably show the particulars of state Authority
responsible for maintenance of each Railway Affecting Work.
(3) Inspection of Railway Affecting Tanks – Where, as per current practice the Public
Works or Revenue Department forwards to the Divisional Engineer every year, their
inspection reports on the condition of these tanks which are classified as Railway
affecting, action should be taken as follows – (Back to Para 1124, 1128)
(a) The DEN should peruse the reports carefully and mark those tanks which he
considers are not in satisfactory state of repair. He should then forward the reports to
the Assistant Divisional Engineer with instructions that the tanks so marked should be
inspected and reported on.
(b) ADEN shall jointly inspect with civil authorities, all R.A.W / R.A.T. before the monsoon
every year and arrange for their safe maintenance to avoid any danger to nearby
tracks and structures. Records of the annual inspections should be kept in registers
as prescribed. ADEN should report to the DEN details of the action being taken by
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the Public Works or Revenue Department. The DEN should timely prevail on the
authorities concerned to carry out all necessary repairs before the ensuing monsoon
and take other actions to ensure safety of Railway assets. A typical sketch of RAW
tablet is shown below –
(c) Copies of the inspection notes of ‘Railway Affecting Tanks’ as received from the State
Authorities with particulars of date of inspection and notes of action taken or proposed
by him should be included in the Register of Railway Affecting Works maintained by
the ADEN.
1128 Vigilance over Railway Affecting Tanks during Heavy Rains –
(1) The Divisional Engineer and the ADEN should arrange with the Local
Authorities/Village Headman in whose jurisdiction ‘Railway Affecting Tanks’ are
situated to watch them during periods of heavy rain and give timely intimation to the
nearest Station Master, if there is likelihood of any tank failing. The Station Master will
telephone/convey reports received from Village Headman/State Government
authorities to the SSE/P.Way (In-charge), ADEN and Divisional Engineer.
(2) When the railway line is threatened, ADEN and SSE/P.Way (In-charge) shall take
adequate steps to ensure the safety of Railway property and staff and arrange
patrolling of the line and or post watchmen with necessary equipment at the place or
places threatened and advise the DEN accordingly.
(3) All the Bridges which are likely to be affected by ‘Railway Affecting Tanks’ or other
storage works should be provided with a tablet on top of one of the Parapets, with the
letters R.A.W. engraved on it, followed by an arrow mark pointing in the direction of
the railway affecting storage work in question.
(4) If the bridge in whose catchment a Railway Affecting Tank is located is classified as
a Vulnerable Location, Stationary Watchmen should be posted during monsoon, as
necessary. If for any reason, repairs as envisaged during the inspection, as per Para
1127(3) is not carried out, the section of the Railway line likely to be affected should
be considered as vulnerable and Watchman as considered necessary posted.
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1129 Weather Warnings and Action to be Taken – (Back to Para 1003)
(1) General –
(a) Arrangement should be made with the concerned Meteorological Centre for receipt
of bad weather warnings.
(b) The bad weather warnings to be received should cover both high velocity winds
and cyclones as well as heavy rainfall and arrangement should be made for receipt
of the same throughout the year.
(c) The list of officials who should receive the bad weather warnings and their
addresses should be advised to the Meteorological Department by the Division.
The list should be reviewed and updated every year.
(d) Detailed instructions and fool-proof arrangement should exist for prompt
communication of bad weather warnings on receipt to the line staff.
(e) Anemometer should be installed at one of the adjacent stations of specially
selected bridges where very high velocity winds are experienced and where there
is a danger of vehicles capsizing (Para 717 of IRBM may be referred).
(f) Suitable working rules should be framed prescribing for each location the danger
level of wind velocity and enjoining upon the Station Master to control (stop) the
traffic on the section concerned when the wind velocity exceeds the Danger Level
and also to inform the Station Master on the other side and the Section Controller
of the need to control the traffic.
(2) Precautions to be taken by Station Master, Driver and Guard – Regarding controlling
of trains –
(a) When a weather warning message has been received forecasting heavy or
cyclonic storm and there is reasonable doubt that a severe storm and high winds
are going to break through, that may endanger the safety of Passengers/Train, the
Station Master may, in consultation with the Guard and Driver, detain the train until
the storm and high winds abate and it is considered safe to allow the train to
proceed from his station.
(b) In spite of the action outlined above should the Driver be still caught on run in a
storm and high winds of an intensity which in his opinion are likely to endanger the
safety of Passengers/Train, he should bring his train with the least delay to a halt,
avoiding such stoppage at places like sharp curves, high embankments, cuttings
and bridges. The train could be restarted in consultation with the Guard only after
the storm and high winds abate and it is considered safe to proceed.
(3) Action by the SSE/P.Way (In-charge) –
(a) The SSE/P.Way (In-charge) on receipt of weather/cyclone warning, should arrange
to advise monsoon Patrolmen/Watchmen and Gang Mates to be extra vigilant.
During the fair season, he should introduce monsoon patrolling as soon as possible
and also post watchman as required at all vulnerable locations and bridges by day
as well as by night, for a period extending upto 48 hours beyond the period
specified in the weather/ cyclone warning message.
(b) The JE/SSE/P.Way should be out in his section, as far as possible by trolley, during
the period of warning and 48 hours beyond, if the trains are in operation.
(4) Action by the Gang Mates – On receipt of advice from the Station Master, the Gang
Mate should take the following action –
(a) During the fair season, the Gang Mate of station yard gang should depute two
reliable Track Maintainer provided with patrolmen’s equipment for patrolling the
block sections on either side and for alerting the intermediate Gang Mates.
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(b) During monsoon period also, the Gang Mate of the station yard gang should send
two Track Maintainer in opposite directions to alert intermediate Gang Mates,
Patrolmen and Watchmen.
(c) Should there be very heavy rain or a severe storm weather during the monsoon or
fair season, the Gang Mate and Track Maintainer of all gangs on their own initiative
should commence monsoon patrolling by day as well as night. Similar action to
carry out patrolling should be taken on receipt of bad weather warning for the
duration of warning and 48 hours beyond.
(5) The individual Railway may issue instructions in the form of joint circular to suit the
local requirements.
(6) Inspecting officials should test the knowledge of Gang Mates and Track Maintainer
about these instructions issued.
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Details of Recording to be done at Accident Site and Indication Posts for

Flooded Causeways/Dips
Railway Board vide Letter No. 2018/Safety(A&R)/1/8 Dated 25.01.2019 issued revised
Observation/ Measurement Proforma for various Parameters related to track and rolling stock
for Accident Investigation /Inquiry. The same may be referred. These Proforma are incorporated
herein as Annexure - 11/1A to E, however, latest Railway Board instructions as applicable may be
referred-
(a) A sketch showing the accident site is to be prepared as per Annexure - 11/1A.
(b) The track Parameters are to be recorded vide Annexure - 11/1B.
(c) The Parameter of Locomotive are to be recorded in Annexure - 11/1C.
(d) The Parameter of Wagon are to be recorded in Annexure - 11/1D.
(e) The Parameter of Coaches are to be recorded in Annexure - 11/1E.
Annexure - 11/1A Para 1107
Site Sketch- The following details are to be shown on the dimensioned sketch to be prepared in
the case of accidents –
1. The train number, the date and Kilometerage of site of accident should be furnished.
2. The North point should be indicated.
3. It should indicate prominently the direction of movement, and also the names of stations in rear
and advance of the accident site.
4. It should a show a length of about 300 metres behind the point of mount and almost an equal
distance in front. However, track measurement should be limited as per proforma for track
measurement.
5. Each track of the Permanent Way must be denoted by a pair of lines.
6. The position of level crossings, Telegraph Posts/ Electrical Posts, Bridges, Tunnels, Gradient
Posts with Gradient Symbols, Curves- demarcating the beginning and end, giving details of
degree of curvature, prescribed super elevation and length of transitions should be indicated.
7. It should also indicate the position –
(a) of all derailed vehicles and the marks left by them either on sleepers, rails or ballast,
(b) of the point of mount with position of rail joint on either side,
(c) of the point of drop,
(d) of the pair of wheels of the first derailed vehicle,
(e) in which every displaced rail/wagon or part of a rail/wagon and detachable components
were found.
Note – In all cases, dimension from nearest Kilometre post and center line of track should be
given.
8. In case of accidents within station limits, sufficient details about the station layout should be
shown in order to fully explain the movement of the affected train in relation to the topography of
the place. The signal aspects at the time of accident should be correctly depicted.
9. The distance of the site of accident from a permanent structure to fix the site of accident precisely
should be indicated.
10. The distance should be indicated to show the extent of the disturbance caused in the Permanent
Way or train composition on account of the accident.
11. Any marks on sleepers or other track fittings should be clearly indicated in their exact position in
relation to the track or vehicles.
12. Locating and examining the wheel mounting mark(s) at the initial point of derailment is very
important for identifying the category of derailment. Precise measurements and critical and
detailed examination of the wheel mounting marks should be made e.g. their length, strong or
faint, broken or continuous, single or multiple, etc. Photographs should be taken of such marks,
not only on the rail, but also on the fastenings, sleepers and ballast.
13. Broken parts of other extraneous Material, if found on the site of accident, should be shown in
the sketch, with details giving their precise position in relation to track.
14. If necessary, more than one sketch should be enclosed one clarifying the yard layout and the
system of working it and the other giving details, such as, position of wheels, wheel marks etc. In
the former, one line should be used to represent both rails of track and such position of the station
yard (in case of accidents within station limits) should be covered as may be necessary. All
necessary details relevant to the issue must be embodied in the sketch. The terminal station on
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the down side should be mentioned on the right extremity of the sketch, the terminal station on
the up side being mentioned on the left extremity. If the accidents take place within station limits
the shorter sketch should be based on the Station Working Diagram.
15. Details of track structure should be shown in the sketch.
16. Details of damages to bridges involved, span wise should be shown.
17. In the case of accidents to and near level crossings, full details of the level crossings should be
furnished.
18. Any other details as may be considered necessary to reconstruct the scene of the accident
should also be shown.
TO BE JOINTLY SIGNED BY
SUPERVISOR (C&W) SUPERVISOR (TRAFFIC) SUPERVISOR (P.WAY)
Page 383 of 417

Annexure - 11/1B (Para 1108)
Proforma for Track Measurement (Part – A)

(Proforma showing the detailed particulars to be collected in the case of Permanent Way
during an Accident)
Soil Ballast
Condition Depth below
Type e.g. sandy, Type of Rain Type/stone,
- firm, sleeper bottom in
SI. loamy clay, Formation Fall Moorum,
Wet, cms Stating Drainage
No Moorum, Black Sand,
slushy whether clean or
cotton etc. Ash etc.
etc. caked
1 2 3 4 5 6 7 8
Width of shoulders in cm.

Sleepers
from outside of rail
Packing
Condition - New/ second hand/ Square
Left Right Left Right Type Density loose or
damaged/ unserviceable etc. or not
sound
9 10 11 12 13 14 15 16 17
Rails Rail fastenings Rail joints
Condition
Weight 60 Condition:
of wear Number Condition:
kg, 52 Kg Tight or loose Creep-Direction
(attach rail GMT per Hogged, Staggered
(Year of or missing and extent of
profile. if Carried sleeper battered, or square
manufacturin (in each creep
wear is seat low etc.
g) sleeper)
heavy)
18 19 20 21 22 23 24 25
General
Location of point of mount Location of points of derailment
remarks about
cracks or Whether on a Whether on a
Description of
fracture of Whether on falling falling
anti- sabotage Whether on
fishplates, straight, grade, level or grade, level or
measures straight, curve
fish bolts and curve or rising rising
other or transition
transition grade and or grade and or
components on sag on sag
26 27 28 29 30 31
Note-
(1)Left and right are with respect to direction of Train movement.
(2)The data in Col. 2 to 26 need not be collected when the defect is obviously and
indisputably on account of sabotage and/or obstruction on track.
(3)Only broken track Material which is not indisputably to be broken after the accident
should be included in Col. 26 and should be preserved.
(4)Col. 27 need be filled in only when there is a suspicion about sabotage being the
cause of derailment.
(5)Sag extends 90 metres on either side of theoretical junction of the grade lines Col. 29
and 31.
To be Jointly Signed By
Supervisor(C&W) Supervisor(Traffic) Supervisor(P.Way)
Page 384 of 417

Proforma for Track Measurement (Part – B)
Gauge slack or tight from Cross Level

Distance Marks on Grinding or
Station the Exact in loaded under loaded
apart sleepers or rubbing
No. condition condition
(metres) rail top marks on rails
(mm) (mm)
1 2 3 4 5 6
Versine in mm in loaded conditions Remarks

Examination
regarding
of alignment
On 20 M. or 10 M. On 10 M. or such length of
for perceptible
chord depending on shorter chords as transition,
kinds of track Subsidence of
practice prevalent considered degree of curve
distortion in track
on the Railway for necessary for sharp and specified
the vicinity of
flat curves more curves less than super elevation
the point of
than 600 M. radius 600M. radius general
derailment
alignment etc.
7 8 9 10 11
Note-
(i) The point of mount should be marked station No. 0 and the stations numbered serially
as (+) for measurements ahead of site of derailment and (-) for measurements in rear.
(ii) The cross level will be measured on the left rail only as determined from the direction of
movement.
(iii) Normally measurement will be taken at station 3 M. apart for a distance of 45 meters on
either side of 0 station if the cause of derailment is indisputably known, otherwise they
will be taken for a distance of 100 meters in rear and 45 meters ahead of zero station.
(iv) Where necessary measurements for Col. 3, 4 and 5 may in addition be taken at individual
sleepers.
(v) This proforma need not be filled when the cause of derailment is obviously established
as due to sabotage, obstruction on track, broken axle, and/or spring having fallen off
prior to point of derailment.
(vi) Longitudinal levels should be recorded for 300 meters on rear and 100 meters in front,
in case of straights at the middle of each rail and at versine recording points on curves
@ 20/10M intervals.
To be Jointly Signed By
Supervisor(C&W) Supervisor(Traffic) Supervisor(P.Way)
Page 385 of 417

Annexure - 11/1C(Para 1108)
Proforma for Motive Power/ Locomotive (Diesel &Electric)
Proforma to be filled in case of accident /derailment when loco is involved in accident.
1. Basic information:
(a) Date of Accident:
(b) Train No. :
(c) Loco Class:
(d) Loco Number:
(e) Loco manufacture year and place:
(f) Base Shed of Loco:
(g) Date & Place last POH:
(h) Kilometres earned after last POH:
(i) Date & place of last major inspection:
(j) Date & place of last schedule inspection:
(k) Whether any schedule is overdue?
2. Give brief particulars of the safety items not provided or provided but missing/not
working-
Whether Loco is provided with:
Safety fittings Provided Working
Headlight
Speedometer
Speed Recorder
Flasher light
Horn
Brake System
VCD
3. Check & record the observations as follows:
(a) Position of control handles, cutout cocks etc. after the accident.
(b) Functioning of brake synchronizing valve-whether working or not.
(c) Position of brake blocks after the accident-whether applied or not.
(d) Condition of cattle guard.
(e) Any sign of seizure of roller bearing in Axle box including condition of its
components
(f) Condition of Pivot and Side Bearer arrangement of bogie including
obstruction to Bogie rotation.
(g) Condition of Friction Damper components/ Hydraulic Dampers
(h) Condition of Traction Rod/ Guide Rod including its connection.
(i) Condition of Traction Link including its connection.
(j) Condition of Lateral Stop components between Bogie and Loco body underframe
(k) Any other observation in respect to mechanical defect of the
locomotive, which might have any bearing on safe running of loco.
Note: Defective or broken Material should be sent to CMT for testing, if necessary.
Page 386 of 417

4.0. Measurement for Wheels for All Classes of Locomotives with wheel gauge
(04 locations applicable for Bo-Bo Locos)
S. Description Observed Value (in mm) Remarks

No.
1. Particulars-of axle (ID No.)
1
2
3
4
5
6
LH RH
1
2
Diameter of wheel at tread
2. 3
4
5
6
LH RH
1
2
Wheel Flange thickness
3. 3
4
5
6
LH RH
1
2
Wheel Root wear
4. 3
4
5
6
LH RH Tread wear should be
1 measured from tread at
63.5mm from wheel gauge
2
Tread wear face (from the back face of
5. 3 flange)
4
5
6
UST of axle: Axle Observation Information is relevant in case
Give the date of last UST of axle breakage
test done 1
6. 2
3
4
5
6
Page 387 of 417

Observed Value
S. No. Description Remarks
(in mm)
1 All measurements shall be

Wheel gauge: taken on a level tangent un-
For checking wheel gauge, 2 canted track. Information is
three measurements at 3 relevant in case of wheel disc
equal spacing on the inner shifting/bent axle only.
7. 4
periphery of the two wheels
on the same axle is to be 5 For safety, similar limits as
recorded. Check for bent 6 applicable for track gauge
axle, if any. are relevant for wheel gauge
also.
Notes:
1. Wheel number one is the outer end axle of truck under the short hood and wheel count
increases towards the Long hood on diesel loco, whereas for Electric Loco, wheel number one
is the outer end axle under Cab-I (Cab- 1 is that side of the loco which has the compressors
and Cab-2 is that side of the loco which has the ARNO convertor) and wheel count increases
towards theCab-2
2. The measurements of wheels are to be done using wheel gauges to ROSO drawing No.SKDL-
3592 for all locomotives except WAP5 locos. For WAP5 locos RDSO's drawing No. SKDL-
4446 and SKDL-4447 may be followed.
3. All measurements are to be taken on a level, un-canted track at the nearest yard.
4. Service limits given in the Maintenance Manual are for good maintenance practice and these
are not safety limits. However, the measured values shall be compared with the service limits
and degradation in values shall be discussed while finalizing the findings.
Page 388 of 417

5. Measurement of other relevant items:
S. Observed
Description Remarks
No. Value (in mm)
1 Buffer /coupler height All measurement shall be
Measurement of Parameters such as taken on a level tangent un-
buffer length etc. may also be done to canted track. This
check possibility of buffer measurement is required to
entanglement. be taken only in case of
trailing stock iswith buffers.
End Axles
(1,3,4 &6)
2 Lateral clearances
Middle Axles
(2&5)
End Axles Applicable for Bo-Bo
3 Lateral clearances
(1,2,3 &4) Locomotives only.
Longitudinal clearances, between axle Except WDP3A, WDG4,
4 box &bogie. Pedestal liner (for all WDP4, WDP4B, WAP5,
axles) WAP7, WAG9 Locomotives
Longitudinal clearances between axle
Applicable to WDP3A
5 box &bogie pedestal liner (for middle
locomotive only.
axles)
6 Height of Rail Guard from rail level
Condition of suspension Springs i.e.

normal/ broken fresh and old fracture
7
or deformities occurred after
derailment due to sudden impact.
Deflected height of coil spring after re-
8
railing on level, uncanted track
Condition of Rubber/ Elastomeric
9 Spring Assembly at the Secondary
stage
Note - Measurement of items (e) to (i j) in Para 3 & item 8 & 9 in Para 5 will be done as per site
condition.
Supervisor (C&W/ LOCO) Supervisor (Traffic) Supervisor (P.WAY)
Page 389 of 417

Annexure - 11/1D(Para 1108)
Proforma for Wagon
Note: Details regarding all derailed vehicles should be given except:-

1. (i) Where vehicles have derailed due to locomotive derailment
(ii) When the obvious and indisputable cause is sabotage or an obstruction on track
2. Front and rear and left (L) and right (R) are with respect to direction of movement.
3. For an obvious cause of derailment such as a broken axle, spring dropping off the run,
and/or some part of under gear hanging loose and causing obstruction only relevant
particulars need be filled.
4. Particulars for each derailing vehicle should be given in one sheet. Information against
columns (5), (6), (8), (16), (17), (21), (22) should invariably be given for adjacent
wagons on the same sheet.
5. Relevant details of adjacent vehicles should also be given if cause of derailment is not
apparent.
Details of BPC along

with the name of Carrying
Date of
S. Train station from where it Wagon Mech. Tare in capacity Built Return
Incident Type
No No. is issued and of No. Code Tonnes and Axle Date Date
&Time
engineer (C&W) load
who issued
1 2 3 4 5 6 7 8 9 10 11
POH ROH Commodity loaded and

Payload in Tonnes remarks regarding Station
Particulars Particulars Position
uneven loading
from
From From Actual (give sketch for details Engine
Date Shop Date Depot of uneven From To
Labels Weighment
loading)
12 13 14 15 16 17 18 19 20 21
Wheel and axle

face Particulars (in
Buffer/Coupler Height
case of breakage
of wheel /axle)
(i) Measure Buffer/Coupler Axle face Ultrasonic Stamping particulars
height after uncoupling &re- particulars particulars on on wheel disc
railing on uncanted level track the hub of the regarding
(ii) Record whether there is buffer disc Manufacturer/RA/RD
entanglement (Yes/No)
22 23 24 25
1L 1L 1L
End 1L
1R 1R 1R
End 1R 2L 2L 2L
2R 2R 2R
End 2L 3L 3L 3L
3R 3R 3R
End 2R 4L 4L 4L
4R 4R 4R
Page 390 of 417

Wheel and Axle
Observation after measuring the profile with tyre defect gauge
Wheel diameter Wheel (Good/ Rejectable) **
(i) Measurement gauge
(ii) Record whether in mm
Worn-
below *(taken Thin Sharp Deep Hollow Flat
out
condemning at three flange flange flange tyre tyre
root
size (Yes/No) places)
26 27 28
1L
1
1R
2 2L
2R
3 3L
3R
4 4L
4R
*The wheel gauge is to be measured at the horizontal plane passing through the center of
the axle
** The wheel profile is to be checked with tyre defect gauge only (Ref: IRCA Pt. III Rule No.3.2.2
(d) and 4.18.1 Plate No.-57 to 66)
Roller Bearing
(To be recorded in case of any abnormalities observed in Roller bearing / Axle Box )
Condition of face Condition of locking plates Condition of Roller Bearing and its
cover plate & studs components
29 30 31
Axle Box (for IRS Stock/UIC)

(To be recorded only when failure of plain bearing is involved as a cause)
Clearance between
Brass thickness Condition of box Condition of sole Condition of
brass and collar of
mm and brass plates journals
journal in(mm)
32 33 34 35 36
Lateral clearance Whether axle guard Are the axle guard bent or Remark
between axle box and can work clear of otherwise damaged to prevent regarding
axle guard in (mm) axle box free movement of axle box bridle bar
37 38 39 40
Clearances for CASNUB Bogie ( Corresponding measurements to be taken for IRS/UIC

Bogie)
Lateral clearance
Lateral clearance
Type of between side Longitudinal clearance between side
between side frame
Bogie frame &bolster in frame &axle box adopter in mm
&axle box adopter in mm
mm
41 42 43 44
Page 391 of 417

Spring and Spring Gear
Remarks Condition of
Camber of Deflected
Any Broken / whether suspension Condition
Thickness spring in height of
cracked/missing/ any spring springs i.e. of
of packing mm after coil spring
clearance of eye normal, broken elastomeri
plate re-railing after re-
shackle and touches /fresh and old c pad
under on a level railing on
shackle pin and sole bar fractured or above
spring uncanted level,
general (for deformities adaptor
seat in track (for uncanted
condition (for laminated occurred after (for
mm laminated track (for
UIC/IRS) spring derailment due to CASNUB)
spring only) CASNUB)
only) sudden impact
45 46 47 48 49 50 51
Bogie
Condition of Center Condition of Friction
Condition of Side Bearer including Vertical
Pivot including Snubber Wedge
clearance at side bearers (for stock having
lubrication and wear Assembly (for
clearance type side bearers only)
(for CASNUB) CASNUB)
52 53 54
Any other defect in

Whether a load Details of broken
vehicle which may List of damages to
is placed on parts giving Other
have contributed to or the wagon due to
more than one location w.r.t. point observations*
caused the accident
wagon of mount and drop
derailment
55 56 57 58 59
Note - Measurement of item 3, 4 & 5 of opening note, item 42, 43, 44, 46, 47, 49, 50, 56& 59will
be done as per site condition.
Supervisor (C&W) Supervisor (Traffic) Supervisor (P.WAY)
Page 392 of 417

Annexure - 11/1E(Para 1108)
Proforma for Carriage
Proforma to be filled in case of Derailments
Note: Details regarding all derailed vehicles should be given except:

1. (i) Where vehicles have derailed due to locomotive derailment.
(ii) When the obvious or indisputable cause is sabotage or an obstruction on the track or
broken axle or wheel.
2. Particulars for each derailed vehicle should be given in one sheet. Information against
columns nos. (5), (6), (7), (14), (50) and (51) should invariably be given for adjacent
coaches on the same sheet.
3. Front and Rear, left (L) and Right (R) are with respect to direction of movement.
4. For an obvious case of derailment such as a broken axle, spring dropping off on run, and/or
some part of under gear hanging loose and causing obstruction, only relevant particulars
need to be filled.
5. Relevant details of adjacent vehicles should also be given if cause of derailment is not
apparent.
Details of BPC
along with name
Date of of the station Carrying
S. Train Vehicle Tare in Built Return POH
Incident where issued Type capacity in
No No. no. tones date date details
&Time and Engineer tones
(C&W) who
issued it
1 2 3 4 5 6 7 8 9 10 11
Wheel gauge in mm (to be Wheel diameter

Station Any indication of
Position measured at three locations) (i) Measurement
bent axle or
from measured in empty condition (ii) Record whether
wheel having
engine at the horizontal plane passing below condemning
shifted on axle
through the center of the axle size (Yes/No)
From To
12 13 14 15 16(i) 16(ii) 17
Observations after
measuring the profile
Wheel and axle face particulars (in Stamping particulars on
with wheel defect
case of breakage of any wheel / axle) wheel discs regarding
gauge(Good I
manufacturer/ RA/RD (in
Rejectable)
case of breakage of any
Ultrasonic
Axle Face wheel/axle)
particulars on the L R
particulars
hub of the disc
18 19 20 21 22
1L 1L 1L
1R 1R 1R
2L 2L 2L
2R 2R 2R
3L 3L 3L
3R 3R 3R
4L 4L 4L
4R 4R 4R
Page 393 of 417

ROLLER BEARING
(To be recorded in case of any abnormalities observed in Roller bearing/ Axle Box)
Condition of axle box, Condition of bearing Condition of Roller
Condition of face
rear and front seal & studs/ locking Bearing and its
cover plate
covers/end cap (FIAT) plate and bolts (FIAT) components
23 24 25 26
Spring and Spring Gear

Condition
Deflected Vertical clearances(for ICF)
Condition of Rubber Condition of Height of
Conditio height of
of spring i.e. Rubber Bogie
n of Air Coil spring Bogie Body- Disc and
suspensio Normal Bolster
Spring after re- frame- Bogie Bump Stop base plate
n spring /Cracked
including railing on a Crown Bolster frame of Primary from rail
i.e. Normal including clearance
leakage level clearanc clearan Suspension level (for
/Fractured length of
in piping uncanted e ce
(old/fresh) crack(for (for LHB) LHB)
track
LHB only)
27 28 29 30 31 32 33 34 35
Condition of Bogie Components

Condition of Condition of Control Arm,
Condition of Equalizing Condition of Anchor Link
Hanger Rubber element and Bore
Stay (for ICF) (for ICF)
(for ICF) (for LHB)
36 37 38 39
Damping System
Condition of Axle Guide Cum Dash Condition of Hydraulic Condition of Anti Roll Bar
Pot including Oil level (for ICF) Dampers (for LHB)
40 41 42
System of Bogie Rotation and Clearances Condition of

Clearance Remarks Grounding
Condition Condition of cables,
between regarding Condition
Condition of of Side Longitudinal/ Wheel Slip
Traction free of Brake
Center Pivot Bearer Lateral
Center and movement Protection Gear
including including flexibility of
Longitudinal/ of bolster (WSP), and Assembly
verticality of Pivot Oil level Secondary Speed
Lateral Bump and pivot
Pin (for ICF) and Wear Spring (for
Stop (for and their sensor (for
(for ICF) LHB) LHB)
LHB) condition
43 44 45 46 47 48 49
Page 394 of 417

Details of
Buffer/Coupler broken parts Any other defect in the
height (to be taken Condition of giving location vehicles which may List of
on a level Other
Side Buffers w.r.t. point of have contributed to or Damages
uncanted track Observations
Working, mount and caused the derailment to the
after uncoupling considered
dead, derailment and such as condition of Coach
and re- railing) relevant to
drooping, whether coupler, draft gear due to
(in mm) derailment
entanglement breakage pocket, shearing plates accident
considered due etc.
Front Rear to accident
50 51 52 53 54 55 56
Note - Measurement of item 5 of opening note, item 24, item 28 to 49, item 54 & item 56will be
done as per site condition.
Supervisor (C&W) Supervisor (Traffic) Supervisor (P.WAY)
Page 395 of 417

Page 396 of 417

CHAPTER 12
CRS SANCTION FOR WORKS AFFECTING PASSENGER
RUNNING LINES
*********************
1201 References to Act/Rules –
(1) The safety of the travelling public is governed (ensured) by the Rules laid down in –
(a) The Railways Act, 1989 (24 of 1989) (as amended from time-to-time),
(b) The Indian Railways (Open Lines) General Rules, 1976 (as amended from time-
to-time),
(c) The Railways (Opening for Public Carriage of Passengers) Rules, 2000 (as
amended from time-to-time), and
(d) Indian Railways Schedule of Dimensions (as amended from time-to-time).
(2) The above documents specify the authority competent to sanction and specify the
procedure for obtaining sanction for any work which affects a running line, before the
work is started or brought into use or before a new section of line is opened for traffic
operations.
1202 Works Requiring the Sanction of Commissioner of Railway Safety and
Notice thereof –
(1) Under Section 23 of The Railways Act, 1989 (24 of 1989) and Chapter VII of the “The
Railways (Opening for Public Carriage of Passengers) Rules, 2000”, the sanction of
Commissioner of Railway Safety is required for the execution of any work on the open
line, which will affect the running of trains carrying passengers and for any temporary
arrangement necessary for carrying it out, except in cases of emergency.
(2) For the commencement and opening of the following works, when they are connected
with or form part of Railway already opened, the sanction of Commissioner of Railway
Safety shall be obtained –
(a) Additions, extensions or alternations to running lines
(b) Alterations to points and crossings in running lines, (shifting of points and crossings
is not included in alteration)
(c) New signaling and interlocking installations or alterations to existing installations
(d) New stations, temporary or permanent
(e) The construction (but not the removal) of an ash pit on a running line
(f) Heavy re-grading of running lines involving lowering/raising of track in excess of
500 mm
(g) New bridges including road over and under bridges, foot over bridges,
strengthening, raising, reconstruction, dismantling or extension of existing bridges,
addition or replacement of existing girders, including the provision of temporary
girders, etc. affecting running lines.
(h) Provision of new level crossing, shifting of existing level crossing on passenger
running lines. De-manning and downgrading of a level crossing, manning of
unmanned level crossings, upgrading of level crossing involving changes in the
method of working or operation (such as interlocking) and closing down of manned
level crossings on passenger running lines. However, sanction of CRS shall not be
required for providing lifting barriers in place of leaf/swing gates at interlocked/non-
interlocked level crossing or closing of unmanned level/canal/cattle crossing.
Page 397 of 417

(i) Permanent diversion (deviation) more than 2 km in length without any station
in-between or irrespective of length when a new station is involved, is to be treated
as new line.
(j) Temporary diversion irrespective of length, except those laid for the restoration of
through communication after an accident.
(k) Additions or alterations to the electrical installations for electrical traction.
(l) Any work covered in Section 21 to 23 of The Railways Act, 1989 (24 of 1989).
(3) New works would include altogether new constructions, additions of new lines/new
structures, gauge conversion and doubling. However, it does not include the works of
alteration such as shifting of points and crossings, extension of siding, extension of
loop line, alteration in buildings, etc.
(4) Application for any alterations, reconstruction, or additions that require the sanction
of Commissioner of Railway Safety should ordinarily be made 30 days in advance of
the expected commencement of such work.
If for any reason a work for which sanction of CRS is obtained but work is not taken
in hand within 12 months from the date of sanction, the Commissioner of Railway
Safety should be approached for renewal of the sanction.
1203 Application for Sanction of Works –
(1) Application to Commissioner of Railway Safety for sanction for carrying out works
affecting the passenger running lines should be submitted in the manner specified
below –
(a) In the case of the Divisional Works, the application should be made by Senior
Divisional Engineer and/or Senior Divisional Signal and Telecommunication
Engineer for track, bridges, and signaling and interlocking works as the case may
be. When a Junior Administrative Grade Officer does not exist on the Division in
any department the Divisional Railway Manager/Additional Divisional Railway
Manager should sign the application.
In case of works executed by Construction Organisation whether for Civil
Engineering or Signal and Interlocking, applications will be signed by the Junior
Administrative Grade Officer for Chief Engineer (Construction) and/or Chief Signal
and Telecommunication Engineer (Construction) as the case may be.
(b) For Divisional works which involve both Civil Engineering and Signal and
Interlocking, the application shall be signed jointly by the Junior Administrative
Grade Officers of both Civil Engineering and Signal and Telecommunication
Departments of the Division. In the absence of a Junior Administrative Grade
Officer, the application will be signed by Divisional Railway Manager/Additional
Divisional Railway Manager.
In the case of works executed by Construction Organisation, which involve both
Civil Engineering and Signal and Interlocking, the application shall be signed jointly
by Junior Administrative Grade officers representing Chief Engineer (Construction)
and Chief Signal and Telecommunication Engineer (Construction).
(c) (i) Signaling and Interlocking works on Open Line undertaken by Railway
Electrification Organisation shall be carried out as per instructions for Signaling
works included in the Indian Railways Signal Engineering Manual (IRSEM).
Applications to CRS for such signaling works shall be prepared, signed, and
submitted by an officer, not below the rank of Senior Divisional Signal and
Telecommunication Engineer or Deputy Chief Signal & Telecom Engineer.
Dy.CSTE/ RE shall also countersign.
(ii) While such Signaling and Interlocking works are executed by Railway
Electrification Organisation, Dy.CSTE/RE and Sr.DSTE Open Line of Division shall
Page 398 of 417

sign a joint certificate indicating that all Safety precautions and necessary checks
as per extant instructions have been carried out for commissioning the Signaling
and Telecom works.
(2) In all cases, the name and designation of the signatory should invariably be given.
1204 Documents to Accompany Applications –
(1) Documents to accompany the application are detailed in Form (Annexure - 12/1) and
they should be complete in every respect.
(2) The officer should furnish along with his application a Track Certificate, where
applicable, on Form (Annexure - 12/2) signed by Deputy Chief Engineer (Track) and
in his absence by Chief Engineer (Track) to the effect that the track is suitable for the
maximum axle loads stated therein. The certificate will be countersigned by the Chief
Track Engineer/Principal Chief Engineer.
(3) For a major bridge or when special spans (designed and constructed by Zonal
Railways based on site requirement) are used, a certificate on Form(Annexure - 12/3)
issued by Deputy Chief Engineer (Bridges) to the effect that the bridge or bridges are
designed to carry the axle loads proposed to be run, should accompany the
application. The bridge certificate will be countersigned by the Chief Bridge
Engineer/Principal Chief Engineer.
(4) For the purpose of Forms (Annexure - 12/2 and 12/3),the Principal Chief Operating
Manager should be consulted in regard to the types of locomotives and rolling stock
to be used, their axle loads, and speeds. The rules for traffic working obtained from
the Operating Department and particulars of electric block- signaling work, if any from
the Signal and Telecommunication Department should accompany the application. In
the case of electrified section, suitable certificate should be given by Electrical
Department.
1205 Submission of Safety Certificate –
(1) The Commissioner of Railway Safety in according his sanction may or may not
propose to inspect the works.
(2) If the Commissioner of Railway Safety decides to inspect the work prior to opening,
he will, after inspection in the company of the officers concerned, communicate in
writing his sanction to open the work.
(3) Should the Commissioner of Railway Safety decide not to inspect the work prior to
opening, the Safety Certificate in Form (Annexure - 12/4), together with the
certificates referred to therein shall be completed and submitted before the work is
opened, e-mail to be sent to the Commissioner of Railway Safety, by the Engineer(s)-
in-charge. Copies of Safety Certificate should be sent to the Divisional Railway
Manager and Principal Chief Engineer and/or Principal Chief Signal and
Telecommunication Engineer.
(4) The Safety Certificate for engineering works should be signed by the Assistant
Divisional Engineer concerned and countersigned by the Divisional Engineer. If any
conditional sanction is given by CRS, it should be specifically certified that the
conditions as stipulated are fulfilled. If the signaling and interlocking work are involved,
the Safety Certificate should be signed jointly by the officers of the Signal and
Telecommunication Department also.
(5) Safety Certificate shall be dispatched to the Commissioner of Railway Safety
expeditiously.
(6) When phase working is involved, a separate Safety Certificate should be issued,
whenever each phase of work is completed.
Page 399 of 417

1206 Deviations from Plans Approved by Commissioner of Railway Safety
–
If any deviations from the plans approved by the Commissioner of Railway
Safety which affect the layout of lines or the arrangement of signals or the
working rules, are found necessary, his prior approval to such deviations
should be obtained with reference to his sanction.
1207 Applications for Running of New Types of Locomotives and/or Rolling
Stock or for Increasing Speed of Existing Locomotives and/or Rolling
Stock –
Application to the Commissioner of Railway Safety for sanctioning the running of
new types of locomotives or rolling stock or increasing the maximum permissible
speed of existing locomotives or rolling stock on a specified section or sections, or
for Double Heading/ Multiple Heading should ordinarily be made by following the
procedure prescribed in Policy Circular No. 6 as amended from time to time.
1208 Notification to Railway Officials When Opening Works –
Except as described in Para 1209, no new work affecting the running of trains or the
traffic working at stations should be brought into use until the staff of all departments
has been notified by means of a circular notice issued by the Divisional Safety
Officer/Divisional Operating Manager. Timely intimation of the date of opening of
works should be sent to the Divisional Operating Manager/Divisional Safety Officer,
wherever any new or revised working rules are to be brought into operation, to
enable him to give the running staff due notice.
1209 Works Arising Out of Accidents Including Breaches – (Back to Para
1112)
(1) An abbreviated procedure to be adopted in the case of accidents as laid down in
Section 24 of The Railways Act, 1989 (24 of 1989) as reproduced below:
“Temporary suspension of traffic - When an accident has occurred on a railway
resulting in a temporary suspension of traffic, and either the original lines of rails and
works have been restored to their original standard or a temporary diversion has been
laid, for the purpose of restoring communication, the original lines of rails and works
so restored, or the temporary diversion, as the case may be, may, without prior
inspection by the Commissioner, be opened for the public carriage of passengers,
subject to the following conditions, namely:
(a) The railway servant in charge of the works undertaken by reason of the accident
has certified in writing that he opening of the restored lines of rails and works, or
the temporary diversion will not in his opinion be attended with danger to the public;
and
(b) A notice of the opening of the lines of rails and works or the diversion shall be sent
immediately to the Commissioner.”
(2) A certificate on Form (Annexure - 12/5) which is worded in accordance with Section
24 of The Railways Act, 1989 (24 of 1989), must be written out and signed by
representative of Engineering Department in charge of the work before opening it.
This certificate shall be dispatched by quickest means to the Officers concerned
followed by confirmatory copies by letter. The Engineering representative should hand
over a copy of the certificate to the representative of the Operating Department at the
site of accident; the latter will not permit the passage of traffic over the restored road
or the diversion until he is in possession of the certificate.
(3) Diversions should, wherever possible, be tested by running a Material train, or light
engine over them, before opening for public traffic.
(4) The Certificate to Commissioner of Railway Safety need not be sent when the line is
Page 400 of 417

restored through communication within 24 hours.
(5) Where the use of temporary diversion is likely to be extended for more than three
days, the Commissioner of Railway Safety may if, he considers necessary take the
earliest opportunity of inspecting it.
1210 Opening of New Lines –
Whenever it is proposed to open a new line for traffic, or to initiate the use of Electric
Motive Power on a line already opened, or to commission a line where gauge
conversion has been done- rules and procedure contained in the relevant Chapters
of “The Railways (Opening for Public Carriage of Passengers) Rule 2000 (as
amended from time to time)” shall be strictly followed.
Page 401 of 417

Annexure - 12/1 (sheet 1) - Para 1204
............................. RAILWAY
Application for Sanction
No. ............................................. Dated: …………..
From: ........................................
To,
Sir,
The Commissioner of Railway Safety,

............................................... Circle.
I hereby apply for your sanction to $

..............................................................................................................................................................
............................................................................................................being commenced and opened
for the public carriage of passengers, when ready.
(2) With reference to Chapter VII of the Railways (Opening for Public Carriage of Passengers)
Rules, 2000, I beg to enquire whether you wish to inspect the work prior to its opening for the public
carriage of passengers, in which case intimation will be given of the date of completion.
(3) In the event of your deciding not to inspect the work prior to opening, the Engineer-in-charge
will, on completion of the work, submit the Safety Certificate duly signed by him, prior to the opening
of the work for the public carriage of passengers and when required, also dispatch an e-mail** to
your address intimating that the work has been opened and the Safety Certificate has been signed
by him.
(4) The application for the use of locomotives and rolling-stock to be drawn or propelled thereby
on the proposed line, in accordance with Section 22(a) of the Railways Act, 1989 (24 of 1989), is
sent herewith/not required.
(5)The following documents+ are appended: –
(1) Temporary works –
(a) Description of proposed works.
(b) Drawing of temporary works.
(c) List of infringements to Schedule of Dimensions.
(d) List of deviations from the Manuals of Instructions for Signaling and
Interlocking and Block Signaling.
(e) List of deviations from General and Subsidiary Rules.
(f) Restrictions.
(g) Rules for Traffic Working.
(h) Documents for bridges as Chapter VII of the Railways (Opening for Public
Carriage of Passengers) Rules, 2000.
(2) Permanent works –
(a) Description of proposed works.
(b) Drawing of permanent works.
(c) List of infringements to Schedule of Dimensions.
(d) List of deviations from the Manuals of Instructions for Signaling and
Interlocking and Block Signaling.
(e) List of deviations from General and Subsidiary Rules.
(f) Restrictions.
(g) Rules for Traffic Working.
(h) Documents for bridges as per Chapter VII of the Railways (Opening for
Public Carriage of Passengers) Rules, 2000.
(6) Certified that a detailed examination of the strength and arrangement of the Materials to be used
in the temporary/permanent works in above connection has been made and that the design and the
Materials to be used are up to the loads, which will be required to carry and that their opening for the
public carriage of passengers will not be attended with any danger.
(Delete temporary or permanent work, as the case may be).
Yours faithfully,
Page 402 of 417

Annexure - 12/1 (sheet 2) - Para 1204
No. ..............................................................Dated ..........................................................

From,
The Commissioner of Railway Safety,
................................................. Circle.
To,
The ............................................................
................................................. Railway.
Sir,
Your No. .............................................................................
A sanction is accorded to the above work being carried out.
* I do not propose to inspect the work prior to its opening for the carriage of passengers. When
ready, it may be opened on a Safety Certificate (vide Paragraph 3 of your letter), which should be
submitted to me directly without any delay.
* I propose to inspect the work prior to its opening for the public carriage of passengers. The
advice of the date when the work will be ready for inspection should be intimated at least 14 days
before it is proposed to open it.
Commissioner of Railway Safety.
Note- * Strike out Paragraph not applicable.

$ Here enter the name of work and mention whether permanent or temporary.
** Form e-mail – “Reference sanction No. ......................................... dated ................... Work opened
for public traffic on ..................................... The first train to pass ………………... No danger to the
Public. Certificate signed".
+ If any of the documents are not sent, “NIL” to be written against such items.
Working rules for extensive remodeling schemes may be sent in not later than one month before the
date on which the work is to be brought into use and in such cases 'will follow' should be written
instead of 'NIL'.
Page 403 of 417

Annexure - 12/2 - Para 1204
Track Certificate
(To accompany application)
I do hereby certify that the track on section................................ (Station ……………….. to Station
.............................) from ...................................km ………………… to ......................... km, the * weakest portion
of which consists of ............................ kg rails ………………. meters long each with maximum wear of
.....................................% on..................................sleepers of density ............................. and minimum depth of
ballast cushion below sleepers out of which ........................... minimum of clean ballast exists under sleepers
on consolidated and stable formation is to the required strength which can safely take. …………… rolling stock
(brief description)** up to ............................. tonnes axle load at a maximum speed of …………………………..
Kmph subject of the local speed restrictions noted below –
Sl. No. From Km To Km Between Nature of Brief reason for

Stations restriction the restriction
....................................................
Deputy Chief Engineer (Track)
Countersigned by
......................................................
Chief Track Engineer/Chief Engineer
Note – * The weakest portion on which no speed restriction has been imposed only needs to be given.
** The maximum number of locomotives proposed to be coupled together for multiple operations shall be
specifically mentioned.
Page 404 of 417

Bridge Certificate
(To accompany application)
1. Certified that the bridges on Section............................ (station .................................. to station

..........................) from ............................ km to ............................. km the minimum strength of
superstructure being .......................... % of RBG/BGML/MBG/………….. standard as per Bridge Rules
1941/1964 Revised corrected up to and inclusive of ............................... Correction slip No.
............................. dated .................................. are safe to carry ………… (Rolling stock) not exceeding
.......... units (in the case of the locomotive) coupled together, at a maximum speed of ……. Kmph subject
to the following restriction:-
Sl. No. Bridge No. Location Km Spans and Nature of Brief reasons
description restriction
2. Sub-structures of all the bridges are in satisfactory condition and safe to carry the above rolling stock at the
speed proposed, conforming to the provisions of the I.R.S. Sub-structure Code ……., corrected up to
Correction Slip No. ………, except those that are weak and distressed which will be kept under observation
with adequate speed restrictions on the same as follows: –
Sl. No. Bridge No. Location Km Spans and Nature of Brief reasons
description restriction
……………………………………….
Dy. Chief Engineer (Bridge Design)
Countersigned by:
…………………………………………
Chief Engineer/Chief Bridge Engineer
Page 405 of 417

Safety Certificate
(When the Commissioner of Railway Safety does not inspect the work prior to opening, this
certificate must be signed before opening temporary or new works)
From,
The Divisional Railway Manager / Divisional Engineer/ Divisional Signal & Telecommunication
Engineer, ................................................................Division.
To,
The Commissioner of Railway Safety, ..........................................................Circle.
Description of work ........................................... ..................... .............................. .

Reference: Chief Engineer/Divisional Railway Manager....................... Application No.
....................................................................................... dated …………… . .. sanctioned under
Commissioner of Railway Safety No. ..................................... dated …… …… .. to commence and
open the above work.
Following Permanent / Temporary work has been done ................................
...................................................................................................................................
(1) I do hereby certify that, in the work above mentioned –
(i) The Schedule of Dimensions has not been infringed* except in regard to the items
sanctioned under.................................letter No. ...................................... dated..............
....................
(ii) Engineering work has been carried out in accordance with Plan No. ...............................
*except in regard to the alterations sanctioned under....................... letter no. ...............
dated...............
(iii) *The weight of rails, the strength of bridges and general structural character of the works are
such as have been prescribed under the rules.
(iv) The*Signaling/*Interlocking/*Block-signaling has been carried out in accordance with
Signaling Plan No………and the requirements laid down in the Manuals of Instructions for
the installation and maintenance of Signaling, Interlocking and *Block-signaling apparatus
have been fully complied with *except in regard to the items sanctioned under letter No.
........................................ dated...........................................
(v) The work has been carried out in accordance with the documents already supplied.
(2) A certificate from the Divisional Operating Manager/Divisional Safety Officer stating that the
necessary working rules have been issued and giving reference in regard to sanction to
deviation (if any) from General and Subsidiary Rules is attached/not required.
(3) I hereby certify that on the...................................................., I have carefully inspected (and
tested +) the above work and that I have satisfied myself that it has been properly completed
(and is in good working order +) and that the work can be opened for the public carriage of
passengers without endangering the safety of the travelling public or the employees of the
Railway, *subject to the following speed restrictions: –
Temporary.................................................. Kmph due to ................................................
Permanent.................................................. Kmph due to ...........................................
(4) The work is being opened on.......................................................................................
Assistant Divisional Engineer Countersigned by .......................................

Dated ................................ Dated....................................
Assistant Signal & Telecommunication Engineer Countersigned by …………………………….
Dated ................................ Dated....................................
Assistant Bridge Engineer Countersigned by .......................................

Dated ................................ Dated....................................
No.................................................. Dated.........................
Copy forwarded to .................................................................................. for information.
Note – * To be scored out if not applicable.

+ Necessary in case of Signaling and Interlocking work only.
Page 406 of 417

Annexure - 12/5 - Para 1209
Certificate in connection with Restoration of

Through Running after Accidents.
Commissioner of Railway Safety ............................................ ,

Copy - Chief Engineer, Chief Signal and Telecommunication Engineer, Chief
Operating Manager, Divisional Railway Manager, Divisional Engineer, Divisional Operating
Manager, Divisional Signal and Telecommunication Engineer, Station Masters.
Station Master’s .................................................................................................... All

concerned Message No. .................................................................... dated
..................................... line and works restored to working order/temporary Diversion laid.
Certificate signed. Work being opened to traffic without danger to public or goods, subject to
a speed restriction of ................................................................................................ Kmph.
....................................................
Engineer-in-charge.
Page 407 of 417

CHAPTER 13
TRACK MANAGEMENT SYSTEM
*********************
1301 General - Track Management System (TMS), is a web-based IT application, using
internet as the communication backbone for effective communication among the
various users, facilitating 24x7 availability of information such as track assets,
inspection records, testing and recording details, maintenance details and
managerial outputs etc.
1302 Modular Structure - TMS software has been developed in a modular fashion
in such a way that modules developed in future can be easily integrated into it.
Master data of section details, various components of track structure e.g. rail,
sleepers, fastenings, ballast, formation, gradient, special features like points and
crossings, level crossings, bridges, LWR etc. have been entered into the system.
Data on condition of various components are also stored and updated by various
manual and mechanized inspections, work data and asset change data. Data are
fed into TMS using various tabs in the portal. Some of the more common tabs are
discussed as under:
(1) Asset tab - allows the user to input track asset details which include rail, sleeper,
fastening, weld, joint, blanket/ballast, formation, catch water drain, longitudinal
drain, switches, switch expansion joint, long welded rail, bridge, level crossing etc.
The identification of left and right rail shall be in the direction of increasing kilometer
irrespective of direction of traffic.
(2) Inspection tab - permits user to record inspections of track geometry, track
components and track features. All manual (including USFD) and machine-based
inspections can be fed into TMS through this function.
(3) Planning tab: - permits the user to plan the inspection schedule and track
maintenance.
(4) Work tab - Locations needing inspection/attention provide a tool to the user to
assign resources (man & machine) and report compliance. Details of gang work,
special works and machine works, asset change details etc. are entered through
this module.
(5) Miscellaneous tab – Message centre, circulars, inspection notes etc. are entered
through this module.
(6) Store Module – This module facilitates the maintenance of ledgers for issue, receipt
and accountal of various types of P.Way Material.
(7) Report tab gives the user, opportunity to take out various standard as well as
analytical reports such as Track Diagram, TRC, OMS results, Track asset details,
USFD defects, welding performance analysis, inspection records, track component
condition details and track asset details. Results and various analysis of Track
Recording Cars and Oscillation Monitoring Systems are also available.
1303 Integration with TRC and OMS - TMS also facilitates uploading of
mechanised recording done by machines such as Track Recording Car (TRC),
Oscillation Monitoring System (OMS) and analysis thereof. TMS system provides
various alerts in the form of SMS, email, application home page alerts etc. to end
users for maintaining the track geometry and adhering to their inspection
schedules.
Page 408 of 417

1304 Security Features of TMS - It is pertinent to note that the access to the TMS
software is based on username and password-based authentication method. Thus,
the role of System Administrator in assigning the various roles to the individual user
is very vital. Further, the access to various modules is custom designed for the
various functionalities of different users. Thus, users such as Divisional
Engineering Control, JE/SSE/P.Way (USFD), Divisional Administrators (TMS),
Senior Officers of the Division, Headquarters and officers of track machine
organization have customized user interfaces to enable effective use of the TMS
modules. Accordingly, various analytical/managerial reports are available for
Divisional users, Head Quarter users and Railway Board for planning and decision-
making.
1305 Single Source of Information Management - TMS system is a single source
of information management pertaining to Permanent Way for various relevant
documents such as Railway Board Circulars, Zonal Circulars, Important
Instructions and letters etc. These are being uploaded by designated officials and
are being used by all concerned in the hierarchy.
1306 Utilization of TMS:
a) Elimination of manual record keeping.
b) Effective monitoring of inspections & follow-ups.
c) Improved transparency at every level.
d) Proactive maintenance actions possible using Data.
e) Better inventory management control.
f) Optimum resource utilization is possible.
g) Prioritization of works is feasible.
h) Holistic planning at Zonal/Divisional level for fixing priorities of maintenance
works.
i) Quick access to information.
j) Anywhere anytime access through web-based application.
k) Complete data is available through single window.
l) Automated alerts, e-mails & SMSs for inspection due/overdue etc.
1307 Withdrawal of Registers -
Due to the implementation of TMS, the following registers have been withdrawn
and replaced by the TMS module.
a) Curve Inspection Registers.
b) Points and Crossing Registers. (Joint P&C inspection register with S&T to
continue but inspection of this register to be entered in TMS by JE/SSE/P.Way.
c) Level Crossing Registers
d) LWR Registers.
e) Welding Registers.
f) Rail / Weld Failure Registers.
g) Toe Load Measuring Registers.
h) Push Trolley / Footplate / Rear window inspection Registers. (Footplate
inspection booklet of JE/SSE/P.Way/ ADEN / DEN / Sr. DEN is to be
maintained but entry to be made in TMS by respective officials.)
i) Rail/Sleeper / fastening / Ballast inspection Registers.
Page 409 of 417

j) Sand hump Registers
k) Gap Survey Registers.
l) USFD Registers.
m) TRC Registers.
n) OMS Registers.
o) Track Diagrams.
Note: - (i) The list extends to all the aforesaid P.Way Maintenance Registers excluding
Material handling and Bridge Registers. The old manual registers closed as above
should be preserved in ADEN’s office.
(ii) Section register, Gang chart and Gang diary shall continue to be maintained in
physical form.
1308 Administrators in TMS are users who are authorized to create, edit or delete
users and also to create jurisdictions for various users along with various other
works such as:
a) Railway Board TMS Administrator - Railway Board Administrator is authorized
to define sections, routes, stations, line and Material master, etc.
b) Railway Board Security Administrator - Security Administrator in Railway Board
is authorised to create new users (Board Level), update users’ profile, reset
password, upload circulars and important letters
c) Zonal Security Administrator - Security Administrator in Zonal Railways is
authorised to create new users (Zone Level), update users’ profile, reset
password, and upload circulars and important letters
d) Zonal TMS Administrator - TMS Administrator in Zonal Railways is authorised
to enter Engine Run Section, Traffic Control Section, Tamping Frequency,
Upload RAW Manual, System Map, define Special Routes (e.g. Golden
Quadrilateral & D route, major coal route, etc.).
e) Divisional Security Administrator - Divisional Security Administrator is
authorised to create role, new users, update users’ profile, reset password, role
transfer, provide jurisdiction and maintain details of gangs Departmental as well
as Pvt. Agency, creation of agency, Certification of USFD Machines, Flash butt
welding plants, etc.
f) Divisional TMS Administrator - Divisional Administrator is authorised to fill the
various details which are of the common interest such as details of Stations,
Sections, Loop Line, Supplier, Master Code, USFD Team, USFD Machine,
Special Works, GMT , Gradient, PSR, etc.
g) Store Administrator - Store Administrator performs verification of Scrap,
Assigning of ART, scale of Material for SSE/P.Way, etc.
h) TRC Administrator - TRC Administrator performs Uploading of TRC and OMS
recordings along with TRC Extraction, TRC Bifurcation, OMS Extraction, OMS
Bifurcation
j) TWTC: Various activities related to Certification of welders by the Thermit
Welding Training Centre (TWTC).
Page 410 of 417

CHAPTER – 14
TRAINING, COMPETENCY & REFERENCES
*********************
1401 Types of Training Courses – Permanent Way staff need to be trained for their
job both through theoretical class room training and practical work at site using the
tools and equipment of the particular trade. Use of audio video aides is desirable
for better understanding of the subject. Training is a continuous process right from
the time of recruitment. Following four types of training courses should be
organized in the Training Institutes run by the Railway Administration:
(1) Initial/Induction/Basic Courses.
(2) Promotional Courses.
(3) Refresher Courses.
(4) Special Courses.
The duration for various courses for above training is listed in Annexure - 14/1.
1402 Initial /Induction Courses –
(1) General – Initial and induction Courses are for new entrants. It is meant for directly
recruited categories such as Track Maintainers and Apprentice JE/SSE/P.Way.
The syllabi and the training program for the initial course should be drawn up by
the Railway Administration and circulated to all zonal/ divisional training institutes.
(2) Induction Course for Track Maintainers – This course will be held at the Divisional
Training Centre under the direction of a JE/SSE/P.Way. It should include
introduction to the working of the Department in general and to the gang work in
particular in a clear and simple manner.
(3) Initial/ Induction Course for Apprentice JE/SSE/P.Way –
(a) This course should be held at the Zonal Railway Training Institute. The course
content should include class room lectures, field demonstrations, and practical
training.
(b) The Class Room lectures should include –
(i) General working of the Railways and Organization of various Departments. All
establishment matters including extant rules and various Acts.
(ii) Permanent Way – Organization and distribution of Permanent Way staff,
Methods and systems, works incidental to maintenance, rails and rail joints,
sleepers and fastenings, ballast, formation, maintenance in electrified and track
circuited areas, permanent way renewals, maintenance and laying of curved
track, inspection systems and speed indicators, patrolling during monsoon and
emergency, pre- monsoon precautions, action to be taken during accidents and
breaches, level crossings, working of trollies, motor trollies and lorries, laying
and maintenance of SWR and LWR/CWR, maintenance of high speed routes,
points and crossings and layouts, maintenance of tools and other common
equipment in use and details of Track Structure.
(iii) Transportation – General Rules, fixed and detonating signals, various systems of
train working and signaling, Failure of communication on single, double and
multiple lines.
(iv) Office work – Accountal of stores and Permanent Way Materials, Imprest, Tools
and Plants, stock verification, classification and disposal of surplus Material
and Materials at site Account through TMS (store) Module.
Page 411 of 417

(c) Practical Training – Practical training shall include visits to various sites open
line and construction site where Permanent Way maintenance/Construction
work is being done.
(4) Training shall be given to permanent way staff as prescribed in Training Manual.
Gang Mate/Keyman shall be given competency certificate by Divisional Training
Centre before deputing them on LWR/CWR sections. The competency certificate
shall be valid for five years from the date of issue. In exceptional cases,
competency certificate can be given by ADEN by duly examining his level of
competence. Such a competency certificate will be valid for a period of one year.
1403 Promotional Courses – The course for promotional training will be necessary
in the case of staff promoted from a lower to a higher status by a process of
selection. The promotional training courses should undergo by the employees
immediately after the promotion at the first available opportunity and is applicable
in the following cases:
(1) Promotion from Track Maintainer/Gateman to work as Keymen/Gang Mates: This
Basic/Promotional Training should be held at the Divisional Training Centers.
(2) Promotion from Track Maintainer to JE/P.Way: This promotional course should be
held at the Zonal Railway Training Institute.
(3) Promotion from JE/P.Way to SSE/P.Way: This course should be held at the Zonal
Railway Training Institute.
1404 Refresher Courses – It will be necessary to conduct Refresher Courses to
enable the staff to keep themselves abreast with the latest rules and techniques.
Keymen, Gang Mates, and JE/SSE/P.Way should be sent for Refresher Courses
once in five years. In the Refresher Courses, all subjects pertaining to the
concerned categories shall be covered as enumerated under promotional courses
but the extent of coverage will be on a limited scale.
1405 Special Courses – In addition to the regular courses mentioned above, special
courses on any of the following subjects should also be arranged periodically to
increase a sense of awareness of the staff on these subjects – Rail Wheel
Interaction & derailment, Geotechnical Investigation, Survey, USFD, AT & FB
welding, Mechanized Maintenance, Points & Crossings, Curves, High Speed
Track, Track Recording, TMS including Store Modules.
It is desirable that the staff posted for the maintenance of welded track or posted
on sections maintained by Machines, should be given a special training on the
relevant subjects pertaining to their duties in a short course arranged before they
are posted in these areas.
Training Module for Non-Gazetted staff of Civil Engineering Department as
circulated by Railway Board shall be followed.
1406 Certificate of Competency – (Back to Para 822, 912) In order to ensure safe
working & proper output, a qualified person shall be appointed. Such qualified
person shall be responsible for supervising Track works and its proper protection.
The qualified person shall hold a certificate of competency, which shall be issued
according to prescribed instructions. Staff in whose favor a certificate is issued
should be literate, having knowledge of Hindi or other local language, should have
passed the prescribed Medical test. The certificate of competency will be issued
for a specified period, by an authorized officer, and renewed periodically.
Categories of staff competent to supervise and execute the works are listed in
Annexure - 14/2.
Page 412 of 417

1407 Training and Certification of welders-
(1) Certification of Welders of Approved portion manufacturing firms and labour
contracting firms shall be done by RDSO as per provisions of “Indian Railway
Standard Specification for Fusion Welding of Rails by the Alumino-Thermic
process”.
(2) Training and certification of Departmental welders and supervisors shall be done
by Thermit Portion Plant (TPP), Northern Railway, Lucknow and Thermit Welding
Centre (TWC), Vijayawada as per procedure for certification given in Annexure -
1 of “Manual for Fusion Welding of Rails by The Alumino-Thermic process”.
1408 Category of Medical Examination – In order to secure continuous effective
service and to ensure that one shall not possesses any disease, unfitting him or
likely to unfit him for that Service, Regular medical examination of railway staff
should be done.
Following different Medical category, based upon the nature of work and
responsibility for P.Way Non Gazetted staff as prescribed in Chapter V of Medical
Manual is reproduced as under -
(1) Group A: Vision tests required in the interest of public safety. Categorized as A-1
toA-3.
(2) Group B: Vision tests required in the interest of the employee himself or his fellow
workers or both. Categorized as B-1 & B-2.
(3) Group C: Vision tests required in the interest of administration only. Categorized
as C-1 & C-2.
Frequency and Standard of medical test shall be qualified by P.Way staff during
their service as listed in Annexure - 14/3. Authorized Medical Examiner for these
tests shall be DMO and above.
1409 Books of Reference – Books of reference listed in Annexure - 14/4 and other
publications from RDSO and IRICEN/Pune including Technical Monograms
considered essential, should be supplied to the officers and the JE/SSE/P.Way of
each Division.
The Chief Engineers’ and the Divisional Engineers’ Offices should make
arrangement to ensure circulars and instructions are available in TMS and/or at
Zonal web site as a separate tab on Engineering department page.
Page 413 of 417

Various Training and Duration

SN Type of Place of Training
Category Duration Frequency/Remarks
. Training Duration
Induction Training in Zonal

Once on joining Railway
(For new Training Institute
service /Promotion
1 recruits (Training Institute-6 1 year
JE/SSE/P.Way through LDCE from
posted in month in field- 6
P.Way category
Railway month)
Training in Zonal 17 days Once on Promotion from

2 SSE/P.Way Promotion
Training Institute (3 weeks) JE
Training in Zonal
Training Institute /
17 days
3 JE/SSE/P.Way Refresher Training in Once in five year
(3 weeks)
Centralized
Training Institute
4 Gang Mate Promotion Once on promotion from
Keyman to Gang Mate
18 days
5 Keyman Basic or from track maintainer
to key man
Gang
6 Refresher 6 Days Once in five year
Mate/Keyman
7 Gateman Induction 12 Days For new recruits
Training in
Divisional Training For gateman picked up
8 Gateman Induction Institute 6 days from track maintainer
capacity
9 Gateman Refresher 6 Days Once in five year
Track
10 Induction 30 Days Once on joining Railway
Maintainer
Track
11 Refresher 6 Days Once in five year
Maintainer
Once selected for USFD
12 JE/SSE/USFD Initial Training at RDSO 4 weeks
testing
First refresher after 3
Training at
13 JE/SSE/USFD Refresher 1 week year. Thereafter once in
RDSO/IRICEN
five year
Once on selection as
14 Welder (AT) Initial 2 weeks
Welder
15 Welder (AT) Refresher Training in 1 week Once in Two years
TPP/LKO &
JE/SSE TWC/Vijayawada
16 (Welding Initial 1 week One time in service
supervisor)
Page 414 of 417

LIST OF FUNCTIONARIES AUTHORISE TO ISSUE COMPETENCY CERTIFICATE FOR VARIOUS

TRACK ACTIVITIES.
Functionaries Authorized to Issue

Lowest Authorized
SN Nature of Activity /Work Competency / Permission for Work.
Level of Supervision
(Minimum Level)
To carry out Maintenance work
under their personal supervision in
LWR/CWR for following works Divisional Training centre.
1. Renewal of fastenings not (Valid for 5 years from the date of
requiring lifting. Keyman issue)
1
2. Emergency repairs to Rail fracture In exceptional cases, by ADEN for
3. Inspection and Checking of SEJ, one year as per Para 1402 (3) (c).
oiling and greasing and re-tightening
/renewal of fittings once a fortnight.
(a) Hot weather patrolling
(b) Cold weather patrolling
Protection of track and secure safety
SSE/P.Way (Overall In-charge)
of trains in case of buckling, rail Patrolman (Railway
(Experienced and trust worthy men
2 fractures, or any abnormal behavior Employee)
from the Permanent Gang to work as
of track.
patrolman/Watchman.)
(c) Any other Patrolling
(d) For passing of train in
emergency at rail/weld fracture site.
Carrying out various activities in
connection with maintenance of Subject to passing of Initial/Refresher/
3 JE/P.Way
track as given in relevant chapters Promotional courses
of this manual.
To use Trolley /Lorry/Dolly Gang Mate /
4 To Use Trolley/Lorry Head Trolleyman / ADEN (Valid for Two years)
To use Motor trolley Motor Trolley Driver
SSE/P.Way (In-charge)/
Gateman /
5 To work as Gateman Divisional Training Centre
Trackman
(Valid for 5 Years)
To use of trolley/ Motor Trolley/ Senior Scale officer,
6 JE/SSE/P.Way
Lorries (Valid for Two years)
TPP/Lucknow or TWC/ Vijayawada
7 To Supervise AT welding. JE/SSE/P.Way (after satisfactory completion of TW3
course)
TPP/Lucknow or TWC/ Vijayawada
To execute AT weld (Provisional
Departmental (TW1 competency valid for executing
Certificate)
8 AT Welder 100 joint or 6 months whichever is
earlier)
TPP/Lucknow or TWC/
Departmental
Vijayawada
To execute AT weld AT Welder
(after satisfactory completion of TW2
9 (Regular Competency Certificate for
course with validity up to 2 years and
departmental welding.
after two year reassessment valid for
next 2 year.)
Provisional Competency certificate Contractor/ Firm AT M&C Directorate of RDSO
10
for welder of private firm. Welder (Valid for 2 years)
Regular Competency Certificate for Contractor/ Firm M&C Directorate of RDSO
11
Welder of private firm. Welder (Valid for 5 years)
Supervision of FB Welding (Min
Diploma in Mech/Elect Engg. Or Departmental/Firm FB
CTE/CE(con)
12 BSc duly passing test as per Flash welding supervisor
Butt welding manual provision)
Page 415 of 417

Welder for FB welding (Min class X
or equivalent duly passing test as Departmental/Firm
13 CTE/CE(con)
per Flash Butt welding manual FB welders
provision)
Supervision of FB Welding of
Railway PSU / Metro (Min Diploma Railway PSU /
14 in Mech/Elect Engg. Or BSc duly Metro/Firm FB welding CTE
passing test as per Flash Butt supervisor
welding manual provision)
Welder for FB welding of Railway
PSU / Metro (Min class X or
Railway PSU /
15 equivalent duly passing test as per CTE
Metro/Firm FB welders
Flash Butt welding manual
provision)
USFD operator of departmental Departmental USFD M&C Directorate of RDSO
16 USFD machines (Initial certification) Operator (Valid for 3 years)
USFD operator of departmental

Departmental USFD M&C Directorate of RDSO
17 USFD machines (Subsequent
Operator (Valid for 5 years)
certification.)
USFD operator of contracted USFD USFD Testing by M&C Directorate of RDSO

18
machines (Provisional certificate) contractor operator (Valid for 6 months)
USFD operator of contracted USFD USFD Testing by M&C Directorate of RDSO

19
machines (Regular Certificate) contractor operator (Valid for 2 Years)
Quality Control in charge for Quality control In- M&C Directorate of RDSO
20 outsourcing of USFD charge by contractor (Valid for 3 Years)
Page 416 of 417

Medical Examination Standard
Category Visual Validity/ Periodical medical exam (PME)
SN. standards
1 JE/SSE/P.Way A-3
Every four years till 45 yrs. and then every two years till 55
2 Gateman
yrs. and thereafter annually till retirement.
3 Trolleyman
Gang Mate, B-1
4 Keyman, Track On attaining the age of 45 yrs. and there after every 5 yrs.
Maintainer.
Safaiwala, C-2 No PME
5
Watchman
Offices, which should be equipped with a copy of the

publication
For the
Item personal use of Assistant
Publications Divisional JE/SSE/
No. such officers Divisional
Engineer’s P.Way’s
and inspectors Engineer’s
office office
as may be office
prescribed
1 Act- Indian Railways ... 1 1 1
Code- Indian Railway for the
2 ... 1 1 1
Indian Railway Permanent Way
3 1
Manual 1 1 1
4 Indian Railway Works Manual 1 1 1 1
5 Indian Railway Bridge Manual 1 1 1 1
Manual- Accident & Circulars
6 1 1 1 1
pertaining to Accidents.
Rules for the opening of a
7 Railway for the public carriage of ... 1 ... ...
passengers.
Rules- General and Subsidiary,
8 1 1 1 1
Parts I & II
9 Schedule of Dimensions 1 1 1 1
Standing Orders-Engineering
10 1 1 1 1
Department
Working Time Table and
11 1 1 1 1
Appendix thereto
Manual of instructions for
fabrication, installation
12 1 1 1
and maintenance of glued
insulated rail joints.
Manual for Flash Butt Welding
13 1 1 1
of Rails
Manual for Fusion Welding of
14 Rails by the Alumino-Thermic 1 1 1
process
15 Small Track Machine Manual 1 1 1
16 Track Machine Manual 1 1 1
Manual for ultrasonic testing of
17 1 1 1
rails and welds
Guidelines for handling and
18 1 1 1
stacking of rails (No. CT-35)
Page 417 of 417

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GOVERNMENT OF INDIA

There was need to issue updated Manual in view of various technological

S. Faculty from IRICEN 2nd Member Chapter(s)

(Santosh Kumar Agrawal)

CHAPTER 1 - DUTIES OF PERMANENT WAY OFFICIALS

CHAPTER 2 - TRACK STRUCTURE AND COMPONENTS

CHAPTER 4 - CURVES & TURNOUTS

CHAPTER 5 - TRACK MONITORING& TOLERANCES

CHAPTER 6 - MAINTENANCE OF PERMANENT WAY

CHAPTER 7 - PERMANENT WAY RENEWALS

CHAPTER 9 - LEVEL CROSSINGS AND GATEMAN

CHAPTER 10 - PATROLLING OF THE RAILWAY LINE

CHAPTER 11 - ACTION DURING ACCIDENTS INCLUDING

CHAPTER 12 - CRS SANCTION

CHAPTER 13 - TRACK MANAGEMENT SYSTEM

CHAPTER 14 - TRAINING, COMPETENCY & REFERENCES

ABBREVIATIONS AND TERMINOLOGY

DUTIES OF JE/SSE/ P.WAY (OTHER THAN SECTIONAL OR IN-CHARGE)

Cross- Weight Dimensions in mm

60 Kg/m Rail (UIC 60)

Cross- Weight Dimensions in mm

Cross-Sectional Area - 76.70 cm2, Mass per metre - 60.21 Kg/m

Common lengthwise colour code

206 Rail Fastenings:

Quantity of Ballast per Meter

250 350 500 2785 2943 13160 707 5300

Sl. No PARTICULARS SKETCH REF Dimension (mm)

LIST OF COMMONLY USED TRACK FITTINGS FOR THE GUIDANCE OF FIELD

Annexure - 2/4 (B) (Para 206, 210, 223, 224, 225)

(d) Some of the commonly used Liners

(e) Commonly used SEJs

Annexure - 3/4 (Para 309)

Portion details Welding details

Test joint results Chainage Reference

Summary (at the end of the month)

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Fig. 3.7: Force Diagram in LWR / CWR

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