Important Achievements of Track Design Directorate during ...

Important Achievements of Track Design Directorate during last five years(As on April 2021)

Sl No.

FinancialYear

Broad Area of Achievemen t

Title of Achievement

Description of Achievement Likely Benefit Current Status of Implementation

1. 2020-21 Safety and Throughput

Development of R260 rails

RDSO has developed specification for rail grade R260.This high carbon steel rail will have cleaner steel as compared to the presently used 880 grade (90 UTS) rail. It will have better mechanical properties, including higher yield strength. This is likely to result in reduced number of rail failures under the operating conditions prevailing on the Indian Railways. BSP/SAIL has started rolling of this grade rails and first rake of R260 grade rail panels (260m length) has been dispatched to IR in June-2020. Further, RDSO has inspected the rail manufacturing capability and the process of manufacturing of R260 grade of M/s JSPL rail plant in Raigarh. Satisfactory result of the Inspection has been communicated to M/S JSPL on 14.01.2021, with the approval of Railway Board.

Better quality rails for IR.

Approved Guidelines for Handling, stacking and maintenance of R260 grade rails has been sent to all Zonal railways vide letter dated 07.08.2020.

2. 2020-2021

Safety Guidelines for FB welding of R260

grade rails

Interim Guidelines for FB welding of R260 grade rails was prepared and sent to Railway Board for

approval vide letter no. CT/Welding/R260 dated 17.07.2020.Interim guidelines approved by Railway Board have been circulated to Zonal Railways and all stakeholders vide RDSO letter no. CT/Welding/R260 dated 05.08.2020 for compliance.

To improve quality and in service

performance of FB welds.

Implemented on 05.08.2020

3. 2020-2021

Safety Guidelines for AT welding of R260 grade rails

Final Interim Guide lines for AT welding of R260 grade rails had been sent to Railway Board for approval vide letter no. CT/Welding /R260 dated 21.8.2020 till regular vendors for R260 grade rails are developed.Railway Board has approved the Interim Guidelines for AT welding of R260 grade rails vide letter 2020/Track-I(P)/R-260 Grade Rails

dated 27.08.2020. Interim guidelines approved by Railway Board have been circulated to Zonal Railways and all stakeholders.

For AT welding of R260 grade rails during interim period till development of regular vendors is completed.

Implemented w.e.f. 27.08.2020 and withdrawn w.e.f 29.04.2021 after adequate vendors are developed.

4. 2020-2021

Safety

Revision of “Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds”,

Revised-2020.Document No.: T-53

Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised-2020,Document No.: T-53 had been revised for introduction of USFD testing by B-Scan SRT and DRT

This specification is being revised due to introduction of B-Scan facility in SRT/DRT, therefore

Features like continuous B-Scan recording, location stamping by digital encoder, time stamping, GPS coordinate

longitude and latitude) have been included in this specification for SRT/DRT.


5. 2020-21 Safety Modification in End Unloading Rake (EUR) Drawings

To avoid the problem of Rail tilting in the field while unloading the 260m long rail panel modification is done in drawings of Threader Wagon and Ramp Wagon in RDSO Drg. No. RDSO/T-8409 and RDSO/T-8410 and other related drawings

Avoid the Rail tilting while unloading 260m long rail panel

Modified EUR drawings issued in January,2021

6. 2020-2021

Safety

Revision of “Indian Railway Standard Specification for

Fusion Welding of Rails by Alumino Thermic Process”, Serial No. IRST-19-2020

Indian Railway Standard Specification for Fusion Welding of Rails by Alumino Thermic Process, Serial No. IRST-19-2020, had been revised for

introduction of Technological improvements in the AT Welding process.

Provisions for implementation of upgraded AT

welding technology with superior weld performance on Indian Railways and Inclusion of AT welding technique for R260 and1175

HT grade Rail.


7. 2020-2021

Safety

Revision of “Item specific guidelines for hard facing electrodes for reconditioning of

crossings, switches and SEJs” (Document No. TDG 0026)

Item specific guidelines for hard facing electrodes for reconditioning of crossings, switches and SEJs (Document No. TDG 0026, had been revised.

To improve quality and in service performance of rails


8. 2020-2021

Safety

Revision of “Item specific guidelines for vendor approval / extension of

approval for manufacture of AT welding portions and execution of AT rail joints”, Document No.: TDG 0017

Item specific guidelines for vendor approval / extension of approval for manufacture of AT welding portions and execution of AT rail joints, Document No.: TDG 0017, had been revised due to revision of Indian Railway Standard

Specification for Fusion Welding of Rails by Alumino Thermic Process Serial No. IRST-19-2020

To improve quality and in service performance of AT welds.


9. 2020-2021

Economy EOI for items having less than 3 Vendors (Vendor Directory Items)

An open-ended Expression of Interest (EOI) is floated since 23.07.2015 (re-uploaded on 14.11.2017) for increasing the vendor base of items given at i) & ii). Very feeble response was received from firms against this EOI, which could not be materialized and case was closed in

February, 2019. Fresh Open ended EOI Notice no. CT/Welding/EO/200 dated 17.07.2020 has again been called for both items. Observing no response from firms, all portion manufacturing firms and electrode manufacturing firms have been invited to register themselves in these two items vide this office letter no. CT/Welding/Reconditioning dated

10/02/2021.

For developing more vendors.

Under process.

10 2020-2021

Safety A&C Slip No. 5 of “Manual for Ultrasonic testing of rails and welds”, Revised-2012.

The frequency of USFD testing of tongue rails of points and crossings had not been clearly defined in the A&C Slip No. 5 of Manual for Ultrasonic testing of rails and welds, Revised-2012

To address issues related to safety andenhancedcapacityandmobility.


11. 2020-21 Consultancy Scrutiny of Annexure C-1 (Technical Standards of

Track Structure)of Mumbai Metro Line-3

Scrutinized Annexure C-1 (Technical Standards of Track structure) of Mumbai Metro Line-3.

Fast and economical Publictransportsystemin metrocity

Implemented

12. 2020-21 Safety Identification of Routes for Rail Grinding Machines

Identification of route for newly procurement of RGMs with covering Golden Quadrilateral, Golden Diagonal, 25T, DFC feeder route, CC+8+2T, CC+6+2T and other important routes is under

process.

For better utilization of Rail Grinding Machines for Indian Railways.

In process

13. 2020-2021

Throughput Revised Proforma for Rail Grinding data collection

Revised Proforma for data collection from RG Sites has been prepared and got finalized by steering group of RGM.

For evaluation the efficacy of Rail Grinding in Indian Railways

Finalized

14 2020-21 Throughput Specification revision details

In compliance to DG’s directives, dated 10.6.2020, the all the IRS Specifications of the Directorate has been revised as per ISO procedure.

To give opportunity to all stakeholders to make recommendations / suggestions for modifications / improvements in these documents. to make the specification at par with the international standards.

(i) IRS/T-39: The IRS specification for Pre-tensioned pre-stressed concrete sleepers for BG and MG

Railway Board has approved the IRS/T-39 (6th revision) vide letter dated 04.03.2021.

(ii) IRS/T-45: The IRS specification for pre-tensioned prestressed concrete sleepers for turnouts B.G. and M.G

Railway Board has approved the IRS/T-45 (4th revision) vide letter dated 04.03.2021.

(iii) IRS/T-42:

The IRS specification for Single coil spring steel washers,

Railway Board has approved the IRS/T-42 (1st revision)) vide letter dated 26.04.2021.

(iv) IRS/T-31: The IRS specification for Elastic Rail Clips, T-31

Railway Board has approved the IRS/T-31 (Fivth revision)) vide letter dated 04.03.2021

(v) IRS/T-56:

The IRS specification for Metal liner for use with elastic rail clips

Railway Board has approved the IRS/T-56 vide letter dated 29.12.2020

(vi) IRS/T-47: The IRS specification for 6mm thick Grooved Rubber Sole Plate no

Railway Board has approved the IRS/T-47 (Revision 1) vide letter dated 29.12.2020

(vii) IRS/T-44:

The IRS Specification for Glass filled Nylon-66 Insulating Liners

Railway Board has approved the IRS/T-44 (Revision 1) vide letter dated 29.12.2020

(viii) IRS/T-57:

The IRS specification for Polyethylene Dowels for concrete sleepers


(ix) IRS/T-58: The IRS specification for spring steel Circlip for use with Anti-theft ERC


15 2019-20 Safety and Throughput

ACS No. 1 to Technical Specification for Track Based Gauge Face Lubricators, IRS:T-48, June-2013

To incorporate the field experience of field officials, modification in technical specification was required. Based upon the observations during the joint

inspection and interactions with Zonal Railways and recommendations made by the Track standard committee, some modifications in the technical specification for track based gauge face lubricators, IRS:T-48, June-2013 has been done as ACS No. 1.

Increase in service life of rail by lubrication and efficient friction management.

Final Draft ACS No. 1 to IRS:T-48, June-2013 duly approved by Railway Board has been issued to Zonal Railways for further necessary action, vide letter dated 26.02.2020.

16 2019-20 Safety Technical Specification for Zinc Aluminium Metallisation of Rail

To make rail corrosion resistant , a sacrificial layer

of Zn-Al (85%-15%) is coated on 260m long Rail panel in the Rail manufacturing process.

Improvementinservicelife of Rail due to corrosion resistant coating

Specification approved by Railway Board in Feb,2020. Infrastructure setup for Zn-Al

metallization will be carried out by Rail manufacturer (SAIL and JSPL) in their premises.

17 2019-2020

Safety Problems with Thick Web Switches provided with Clamp type point machine and Spring Setting Device (SSD) for Thick web switches

The issues related to problem of Gauge variation in the Thick Web Switches resulting in frequent failure of points were raised during visit of DG/RDSO to Mumbai on 20.09.2019, and communicated to RDSO through Secy. to GM / WR’s note dt. 20.09.2019.

Drawing of P-Bracket and modified Ground connections will resolve the problem of holes in switch rail getting oblong with time and track circuit failures due to crushing of insulation. Modified drawings of SSDwill take care of failure of insulation of Spring Setting Device (SSD). The joint maintenance schedule for signalling and track maintenance of TWS shall ensure regular maintenance of TWS & SSD.

Signal Dte. has issued drawing of P-Bracket and modified Ground connections vide letter No. STS/E/PM/220mm Vol.-I dated 23.05.2019 to resolve the problem of holes in switch rail getting oblong with time and track circuit failures due to crushing of insulation. To take care of failure of insulation of Spring Setting Device (SSD), modified drawings of SSD have been issued vide letter dated 04/10.10.2019 for adoption & implementation. A joint maintenance schedule for signalling and

track maintenance of TWS has been issued to all Zonal Railways vide Signal Dte. letter No. STS/E/HS/Turnouts/Vol.-IV dated 14.02.2019

18 2019-

2020

Safety Technical

Specification for Stationary Flash Butt Welding Plant and Connected Machines &Accessories:

Railway Board vide letter dated 30.10.2018

directed to prepare technical specification to replace/upgrade with most modern technology to these existing old Flash Butt Welding Plants. Technical Specification was prepared in association with M&C Dte., as per RDSO ISO procedure and issued to concerned Railways for necessary action vide letter dated 07.05.2019.

Salient features of specification are as under: (i) Automated: Pre-

straightening, rail grinding/brushing, Alignment of rail ends before welding, Post weld straightening, grinding of joint and cooling device

(ii) New features added: Smoke trapping device, particulate matter collection trolley and post weld heat treatment.

(iii) Striping unit made inbuilt with machine and synchronized with welding operation.

Technical Specification was prepared in association with M&C Dte., as per RDSO ISO procedure and issued to concerned Railways for necessary action vide letter dated 07.05.2019.

19 2019- 2021

Safety Economy

Adoption of technology, of Translamatic, for Robotic Welder using Plux-cored wire for

Railway Board vide letter No. 2017/Track-I(P)/RW-F Vol. VI dated 04.04.2019, have approved adoption of technology of Translamatic Robotic Welder using Plux-cored wire brand Translarail of M/s CTF, France, for reconditioning of cupped AT welding joints and wheel burn/scabs of rails for

To introduce one more technique, for Reconditioning of Cupped AT welding joints and wheel burn/scabs of rails.

Three firms have been approved so far.

Reconditioning of Cupped AT welding joints and wheel burn/scabs of rails

regular use on Indian Railways network.

20 2019-2021

Safety Trial of Vehicular system for ultrasonic testing of rails/welds (High Speed Vehicular USFD testing

between NDLS- Ratlam and NDLS-DDU route of IR )

Railway Board vide letter no. Track/21/2004/0903/7 dated 31.03.2009 directed NCR to invite tenders for work. Subsequently, vide letter no. Track/21/2004/ 0903/7 dated 18.06.2010 NR was nominated for invitation of tenders. Work for Vehicular USFD testing has been awarded on

19.05.2017 by Northern Railway. Two complete rounds of testing have been done so far. RDSO is monitoring the performance of the vehicular USFD system.

High Speed Vehicular USFD testing is carrying out between NDLS- Ratlam and NDLS-DDU route of IR

Under Progress

21 2019-20 Safety Finalized Drg. No. RDSO/T-5848 (Alt-1) & RDSO/T-5849(Alt-1

Finalised drawing of Joggled Fish Plate RDSO/T-5848 (Alt-1) & RDSO/T-5849(Alt-1) on the basis of satisfactory performance received from Zonal Railways

To improve performance of joggled fish plate

Issued

22 2019-21 Safety Interim Report on rail grinding

Interim Report on Rail Grinding is under preparation on the basis of rail grinding Pre/Post data for SCR,

NCR and NR Railways.

To improve the rail/wheel life, removal of RCF defects, favorable rail/wheel contact etc.

Under preparation

23 2019-20 Safety Preparation of Functional Specification for Rubberised Surface at Level Crossings.

To maintain the road surface in good condition to minimize the road accidents on level crossings. .

To improve the road condition to minimize road accidents and minimizing frequent renewals

Issued, July 2019

24 2019-2020

Safety Technical Specification for Re-Furbishing of Existing Glued Insulated Rail Joints and In-situ Fabrication of Glued Insulated

This specification covers the working methodology, performance parameters and testing regime for in-situ re-furbished glued insulated rail joints & in-situ fabricated glued insulated rail joints.

Economical and Feasibility of in-situ fabrication of Glued Insulated Rail Joints.

Issued June-2020

Rail Joints (Provisional)

25 2019-2020

Throughput Procurement of Rail Profile Measuring equipment (MiniProf)

Rail profile measuring equipment is to be used to measure the rail profile before and after grinding of rail profile by Rail Grinding Machine.

Measure the rail profile data Pre/Post grinding.

Received

26 2019-2020

Throughput Electro-Mechanical Gate System for Ballast

Hopper Wagon

Technical evaluation of E Global tender no. TM-1904 for procurement of Electro Mechanical Gate System of Ballast Hopper Wagon for IR

For better utilization of Ballast Hopper Wagon

Finalized

27 2019-2020

Safety Development of B-Scan SRT and

DRT for Ultrasonic testing of Rail.

RDSO has framed the specification for B-Scan SRT and DRT. Three vendors each for B-Scan SRT and B-Scan DRT has been developed by the RDSO. Railway Board vide letter no 2020/Track-I(P)/SRT-DRT dated 01.03.2021 has fixed the target for commencement of USFD testing of Rails by B-Scan SRT/DRT as 01.03.2021 in “A” routes.

USFD testing of rails by pedestrian SRT or DRT with continuous B-Scan recording is required to be introduced on IR. Recorded B-Scan data can be audited to know the defects which have not been recorded by the USFD operator and to perform run over run analysis.

Three vendorshave been approved by RDSO for SRT & DRT on 22.10.2019 & 14.11.2019 respectively.

28 2019-2020

Safety

Revision of “Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds using Vehicular

Systems”, Revised – 2020, Document No.: T-52.

Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds using Vehicular Systems Revised – 2020, Document No.: T-52 Vehicular USFD specification had been revised due to Revision in Under reporting and Over reporting criteria and deletion of Border line OBS and developed OBS defect. Rail Cum Road Vehicle is included in Type of Vehicle

On Indian Railway, classification of defect is in OBS and IMR category and there is no Borderline/Develop

ed OBS categorization. So, this categorization is deleted and performance parameters is specified in OBS

and IMR


categorization. Under reporting level is modified, so that reliability of vehicular USFD

system is nearly matching with the pedestrian testing and there is no need to specify the separate testing frequency of

vehicular USFD system and pedestrian USFD system.

29 2019-2020

Safety

Report for operation of 22.9t

axle load:

A report has been prepared by Track Design Dte. of RDSO for operation of 22.9t axleload and sent to Railway Board by this office letter no.CT/DG/LW/HAW dated14.08.2019 by Director General/RDSO.

For operation of 22.9t axle load.

Railway Board vide letter no. 2020/CE-II/TS/22.9 dated 20.08.2020 approved the operation of 22.9t axle load at 75 kmph on 60 kg 90 UTS rail, with certain stipulations.

30 2019-20 Safety Improvisation in insulating liners.

Global RFP for HVN Liners was uploaded on 07.03.2019 on RDSO’s website with last date of RFP submission as 08.04.19.

More durable fastening components.

On recommendation of RDSO on 27.12.19, Railway Board vide letter dated 04.02.20 approved the trial of 2 km length on 04 Zonal Railways.

31 2019-20 Safety Improvisation in rubber pad

A Global RFP for High Performance Rail pad using rubber based was uploaded on RDSO’s website on 30.07.2018 with last date of submission upto 25.03.2019 A Global RFP for High Performance Rail pad using TPE based has also been uploaded on website on 05.04.2019 with last date of RFP submission upto 28.06.2019

More durable fastening components.

No firm has qualified the requirement of both category of RFP.

32 2018-19 Safety Development of 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Single Slip to Drg. No. RDSO/T-6493 and 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Double Slip to Drg. No. RDSO/T-6494.

The development of 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Single Slip to Drg. No. RDSO/T-6493 and 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Double Slip to Drg. No. RDSO/T-6494 has been carried out for the first time on Indian Railways which will facilitate Zonal Railways to switch over to diamond crossing of higher rail section on sections where rail renewal to higher rail section is being carried out.

The development will facilitate Zonal Railways to switch over to diamond crossing of higher rail section on sections where rail renewal to higher rail section is being carried out.

Prototype developed & found satisfactory.

33 2018-19 Safety & Passenger comfort

ISEJ for curved track upto 2°

The issue of ‘Improved SEJ for curved track upto 2 degrees was deliberated under item no. 1307 in 86th meeting of Track Standards Committee (TSC). Further, the item was deliberated in 9th Extra-ordinary meeting of TSC held at IRICEN/Pune from 18.01.2018 to 19.01.2018 and vide pending item no. 40 in 87th TSC meeting held in January, 2019. Railway Board vide letter no. 2016/CE-II/TSC/1 dated 04.07.2019 approved the recommendations of 87th TSC on the above item. In compliance to Railway Board’s orders on the 87th TSC item, recommendations to adopt Improved SEJs of SG80 design to Drawing No. RDSO/T-6902, RDSO/T-6914 and DG65 design to RDSO/T-6922 & RDSO/T-6930 for straight track, on curved track up to 2 degrees on IR with certain precautions were sent to Railway Board vide letter dated 20.08.2019 & 19.11.2019.

For use in curved track

Necessary action as regards to changes/modifications required to be done in Para 4.5.5 of “Manual of instructions of long welded rails, 1996”, is being done by RDSO.

34 2018-19 Safety Continuation of Long Welded Rails on sharp curves and steep gradients.

After detailed deliberations, literature study and field visit, a study report no. CT-30 (Modified) on Continuation of Long Welded Rails on sharp curves and steep gradients duly approved by Railway Board has been issued on 25.08.2018 for

continuation of LWR on sharp curves and steep gradients on trial basis.

Improvement in safety and riding comfort and reduction in maintenance effort.

LWR on sharp curves and steep gradients are being permitted on trial basis by Zonal Railways in consultation with RDSO on case to case basis and performance is being monitored by Zonal Railways. Performance of LWR on trial basis is almost satisfactory as reported by Zonal Railways.

35 2018-19 Safety Development of 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Single Slip to Drg. No. RDSO/T-6493 and 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Double Slip to Drg. No. RDSO/T-6494.

The development of 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Single Slip to Drg. No. RDSO/T-6493 and 1 in 8.5 Diamond Crossing, 60 Kg, BG on PSC sleepers with Double Slip to Drg. No. RDSO/T-6494 has been carried out for the first time on Indian Railways which will facilitate Zonal Railways to switch over to diamond crossing of higher rail section on sections where rail renewal to higher rail section is being carried out.

The development will facilitate Zonal Railways to switch over to diamond crossing of higher rail section on sections where rail renewal to higher rail section is being carried out.

Prototype developed & found satisfactory.

36 2018-19 Safety & Passenger comfort

ISEJ for curved track upto 2°

The issue of ‘Improved SEJ for curved track upto 2 degrees was deliberated under item no. 1307 in 86th meeting of Track Standards Committee (TSC). Further, the item was deliberated in 9th Extra-ordinary meeting of TSC held at IRICEN/Pune from 18.01.2018 to 19.01.2018 and vide pending item no. 40 in 87th TSC meeting held in January, 2019. Railway Board vide letter no. 2016/CE-II/TSC/1 dated 04.07.2019 approved

For use in curved track

Necessary action as regards to changes/modifications required to be done in Para 4.5.5 of “Manual of

the recommendations of 87th TSC on the above item. In compliance to Railway Board’s orders on the 87th TSC item, recommendations to adopt Improved SEJs of SG80 design to Drawing No. RDSO/T-6902, RDSO/T-6914 and DG65 design to RDSO/T-6922 & RDSO/T-6930 for straight track, on curved track up to 2 degrees on IR with certain precautions were sent to Railway Board vide letter dated 20.08.2019 & 19.11.2019.

instructions of long welded rails, 1996”, is being done by RDSO.

37 2018-2019

Safety Issuance of A&C Slip No. 4 of “Manual for Ultrasonic testing of rails and welds”, Revised-2012

To include the reduced testing frequency period for rails and welds to reduce the number of rail failures and weld failure in initial period, A&C Slip No. 4 of Manual for Ultrasonic testing of rails and welds,

Revised-2012 had been issued.



38 2018-2019 &

2019-2020

Safety Benchmarking of Vehicular USFD

system.

RDSO has carried out the Benchmarking of two vehicular USFD system capable of doing ultrasonic

testing of Rails at maximum speed of 40KMPH. RBMV (Rail Borne Maintenance Vehicle) based Vehicular USFD system of M/s PE-NIA JV, Hyderabad (under Northern Railway Contract) had been benchmarked in Nov-Dec 2018. RCRV (Rail Cum Road Vehicle) based Vehicular USFD system of M/s Rail Technology International,

Australia had been benchmarked in Sept-Oct 2019. Both the vehicular USFD system has capability of displaying results in A-Scan and B-Scan along with inbuilt GPS tagging for the USFD testing.

High Speed USFD testing of Rails at maximum speed of 40KMPH.

Out of two benchmarked vehicular USFD system, presently M/s PENIA JV, Hyderabad (under Northern Contract) Vehicular USFD System is in use on IR network.

39 2018-2019

Consultancy Scrutiny

andfinalization of SODof Kolkata Metro Rail Corpn.

Scheduleofdimensions(SOD)for Kolkata Metro has been scrutinized & commented and further approved by Railway Board.


Implemented

40 2018-19 Consultancy Interim Speed Certificate-Noida Metro

Draft Interim speed certificate of Noida Metro has been scrutinized and vetted from Track point of view.

Fast and economicalPublic transportsysteminmetrocity

Implemented

41 2018-21 Mobility &Through put enhancement

Scrutiny and vetting of speed certificates and oscillation trial reports.

More than 350 nos. speed certificates and 109 nos. oscillation trial reports were vetted from track point of view.

Increased Mobility and Throughput.

Implemented.

42 2018-21 Throughput Development of modern fastening system suitable for ballasted track on Indian Railways.

A global RFP for “Modern Fastening System” suitable for ballasted track fit for 25t axle load on IR was uploaded on 26.07.2018 on RDSO’s website with last date of submission up to 31.01.2019.

To select global fastening system suitable for Indian Railways.

The status of various proposals has been sent to Railway Board on 29.1.2021 for approval of trial on IR. Decisions of trial is awaited from Railway Board

43 2017-2018

Safety Prototype development of CMS crossings for 1 in 12, 60Kg (UIC) Scissor crossover

At present, no design of 1 in 12 Scissors Cross-over BG (1673) over PSC sleeper is available with Railways. Due to scarcity of wooden sleepers and insufficient traffic blocks, railways are facing problems in maintenance of such cross-over on wooden sleeper.

The development of CMS crossings for 1 in 12, 60Kg (UIC) Scissor crossover on PSC sleeper will improve the track safety with lesser track maintenance efforts.

Accordingly, development of 1 in 12, 60Kg (UIC) Scissor crossover to Drg. No. RDSO/T- 8109 has been undertaken by various CMS manufacturers and two firms have been approved for its bulk manufacturing.

44 2017-2018

Safety Development of 1 in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1

Development of 1 in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1 was taken up In reference to Northern Railway’s PO dt.15.03.2016 (for 3nos.) and Western Railway’s PO dated 02.01.2017 (for 8nos.) placed on one of the CMS crossing manufacturing firm.

The 1 in 20 60 Kg layout consisting of 1 in 20 CMS crossings will facilitate upgradation of speed on Indian Railways.

One firm has been permitted for undertaking bulk production of 1 in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1

as per PO / tender conditions vide letter dt. 11.05.2018.

45 2017-

2018 Safety Development of 1

in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1

Development of 1 in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1 was taken up In reference to Northern Railway’s PO dt.15.03.2016 (for 3nos.) and Western Railway’s PO dated 02.01.2017 (for 8nos.) placed on one of the CMS crossing manufacturing firm.

The 1 in 20 60 Kg layout consisting of 1 in 20 CMS crossings will facilitate upgradation of speed on Indian Railways.

One firm has been permitted for undertaking bulk production of 1 in 20 Acute CMS crossing for BG 60Kg on PSC sleeper to Drawing No. RDSO/T-5860/1 as per PO / tender conditions vide letter dt. 11.05.2018.

46 2017-18 Consultancy Scrutiny

andfinalization of SODofNoida Metro

Schedule of dimensions (SOD) of Noida Metrofor Standard Gauge has been scrutinized from TrackPointofview.

Fast and economicalPublictransportsysteminmetrocity

Implemented

47 2017-18 Consultancy Scrutiny andfinalization of SODofMumbai Metro Line-3

Schedule of dimensions (SOD) of Mumbai Metro Line-3 for Standard Gauge has been scrutinized from TrackPointofview.

Fast and economicalPublictransportsysteminmetrocity

Implemented

48 2017-18 Consultancy Interim Speed Certificate-Hyderabad Metro

Draft Interim speed certificate for Mettuguda-Begumpet Corridor-3 of Hyderabad Metro has been scrutinized and vetted from Track point of view.

Fast and economicalPublic transportsysteminmetrocity

Implemented

49 2017-18 Consultancy Scrutiny andfinalizationofSOD of Navi MumbaiMetro

Schedule of dimensions (SOD) Rev. 5, February2017 of Navi Mumbai Metro for Standard Gauge has been has been vetted from Track Point of view.

Fast and economical Public transport system in metro city

Implemented

50 2017-18 Consultancy Scrutiny andfinalization of SODofNagpurMetro

Schedule of dimensions(SOD)version-G (June2017) of Nagpur Metro for Standard Gauge has been vetted from Track Point of view.


Implemented

51 2017-2018

Consultancy Scrutiny andfinalization of Annexure C-1 (Technical

Standards of Track Structure)of Kolkata Metro Rail Corpn

Scrutinized Annexure C-1 (Technical Standards of Track structure) and further approved by Railway Board.


Implemented

52 2016-2017

Safety Issuance of A&C Slip No. 3 of “Manual for Ultrasonic testing of rails and welds”, Revised-2012.

To include the Guidelines for USFD testing of tongue rail of point & crossing in service A&C Slip No. 3 of Manual for Ultrasonic testing of rails and welds, Revised-2012 had been issued



53 2016-2017

Safety Development of Design and Drawings for special layout of 1 in 8.5 Scissors Cross-over at SECR over PSC Sleepers with centre to centre distance of track as 7100 mm

South East Central Railway (SECR) requested RDSO for development of design and drawings for special layout of 60 Kg 1 in 8.5 scissors cross-over over PSC Sleepers with centre to centre distance of track as 7100 mm for replacement of such layout over wooden sleeper at Bhilai Yard. The same also figured in the inspection note of Member Engineering (ME) during the visit of Bhilai Steel Plant in Dec 2016 with the direction to develop drawings early

The design of 1 in 8.5 Scissors Cross-over on PSC Sleepers with centre to centre distance of track as 7100 mm will facilitate Zonal Railways to lay the crossover wherever such field requirements exist.

Design and Drawings for Scissors Cross-over Assembly (RDSO/T-8539), CMS Crossings (RDSO/T-8540 , 8540/1 &8549), PSC Sleepers(RDSO/T-8554 to 8573 & RDSO/T-8615), Check rail (RDSO/T-8548), CI blocks (RDSO/T-8607 & 8608), Grooved Rubber sole Plate (RDSO/T-8541 to 8546), Angle tie (RDSO/T-8605)have been completed.

These drawings have been issued to SECR vide letter no. CT/PDS dated 16.05.2017

54 2016-17 Consultancy Interim Speed Certificate-

Lucknow Metro

Draft Interim speed certificate of Lucknow Metro has been scrutinized and vetted from Track point of view.

Fast and economical Public transport system in metro city

Implemented

55 2016-17 Reliability Drawingof1mlongcombinationFishPlate60Kg(UIC) &52 Kg (IRS)(Drawing no. RDSO/T-8533to8536)

The drawing no. RDSO/T-8533 to 8536 for 1 m long combination fish plate (52/60 Kg) has been developed. The drawing has been issued for trial on nominated Zonal Railways.

This will improve the alignment of the rail joint.

Under trial in Zonal Railways

56 2016-17 Safety Report No. CT-43 (Rail Grinding Progress Report No. 2)

This report covers Analysis of data of Rail Grinding on Indian Railways (SCR, NCR and NR). The report proves effectiveness of rail grinding.

To improve the rail life, removal of RCF defects, favorable rail/wheel contact etc.

Issued on June-2016

57 2016-17 Safety Trial of steam curing cycle at reduced temperature for manufacturing of PSC sleeper.

AS per literature study and various suggestions received from UIC study, it has been planned to reduce steam curing cycle below 60 degree Celsius from the p resent maximum curing temperature of 70 to 80°c to eliminate chance of Delayed Ettringite Formation (DEF) which may result in internal splitting in sleeper from 2 to 10 years.

More durable sleepers manufacturing.

Stem curing cycle with reduced temperature has been approved by Railway Board and incorporated in IRS T-39 for implementation.

58 2016-17 Throughput PSC sleeper for special location for 25 t axle loads.

Railway Board vide letter dated 27.12.16 asked ROSO, for development of PSC sleepers for special locations viz level crossing, SEJ, turnout sleepers for 25t axle load.

Development of special location sleepers.

Implemented on 20.02.2017.

59 2016-17 Throughput Reduction maximum cement content in concrete mix design of various sleeper

In view of reduction in cement content in latest version of IS code for prestressed concrete sleeper "1S: 1343-2012" from 530kg/~ for 450kg/m [ROSO has proposed the amendment in specification IRS/T- 39. Limits of concrete workability have also

More durable concrete sleeper.


60 2016-17 Safety Design and drawing for rerailing ramp for 60kg running rail and 52kg guard rail

ROSO had designed rerailing ramp for bridge approach on request of SCR in the year 2013- 14. On the basis of suggestions received from SCR vide their letter dated 17.11.15, ROSO has further updated all drawings.

Safety during derailment in bridge approach will improve.

Revised drawings have been sent to SCR on 04.04.2016 for tials.

61 2016-17 Throughput Revision of

specification of PSC turnout sleeper (IRS/T-45- 1996).

Previously IRS/T-39, the specification of PSC line sleeper for BG & MG and IRS/T-45 specification of PSC turnout sleeper for BG & MG were revised simultaneously in year 1996. Subsequently IRS/T- 39 was revised in year 2011 and 2016. However, IRS/T-45 has not been revised since 1996. In order to have uniformity of instruction the work of revision in IRSIT-45 was I taken in hand.

More durable PSC

turnout sleeper.

Final revised specification have been sent on 17.11.2016.

62 2015-16 Consultancy Interim speed Certificate-Kochi Metro

Draft Interim speed certificate for KMRL is received on 11.11.2016, and vetted from Track point of view on 07.12.2016

Fast and Economical Public transport system in Metro city

Implemented

63 2015-16 Consultancy Technical eligibility criteria and special condition for design and construction of ballastless washable apron

As per Railway Board's instructions vide letter dated 03.11.15, draft "Technical eligibility criteria and special conditions" for inviting tender by Zonal Railways for design' and construction of ballast less washable apron has been prepared in consultation with stakeholders

Uniformity of tender technical condition among all Zonal Railways.

Railway Board has approved it and issued instructions to Railways on 11.02.2016.

64 2015-16 Consultancy Design of mix gauge BG & NG sleeper for use in yard in SECR.

SECR vide letter dated 10/16.03.15 requested RDSO to design PSC sleeper for mix gauge BG & NG having three rail seats f p r 60 kg rail for use in Motibagh Yard of Nagpur Division

Design and mix gauge BG & MG Sleepers

RDSO work completed on 17.04.2015.

65 2015-16 Throughput Revision of specification and STR for PSC sleepers

Railway Board vide letter dated 15.10.15 instructed Track Design Dte and QA/Civil Dte to review STR and specification of PSC sleepers and propose modifications / amendments, if any. The SAG committee of ED/QA/Civil & ED/Track-ll. RDSO has examined existing STR & specification of PSC sleepers in details and proposed various suggestions for improvement in quality of PSC sleepers in Indian Railwavs.

Increased quality and durability of PSC sleepers.


66 2015-17 Economy Reduction ballast requirement using under sleeper pad.

Member Engineering in' meeting with RDSO official on 04.6.15, and 26.6.15 and during his visit to RDSO on 17.7.15 for GCM emphasized the need of reducing the requirement of ballast on Indian Railways track due to less availability of ballast in

Development of cost effective technology using under sleeper pads to achieve the reduction in ballast

Railway Board vide letter dated 14.6.19 has approved the field trial of USP

future from environmental consideration. thickness without compromising track performance.

in three zonal Railway viz. CR, SER & NCR and nominated CR for procurement of complete trial quantity.

67 2015-17 Safety Revision of IRS specification for 6mm thick GRSP and 6.2mm thick CGRSP.

Railway Board vide letter dated 05.05.15 has nominated a committee compromising of ED/Track- I, ED/Track-II & EO/QA/Civil to examine and review the STR, QAP and specification of various P.way fittings. The committee has suggested various changes in specification and STR of GRSP & CGRSP

More durable Rail Pads.

Implemented in 2017.

68 2015-21 Safety Amendments inIRSOD,BG-2004

15No. Amendment and corrigendum slips proposed to address issues related to safety and enhanced capacity and mobility.

Increased mobility with enhanced safety.

Implemented.

Achievements:DesignDevelopmentofTrackrelatedcomponents

Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds using Vehicular Systems Revised – 2020, Document No.: T-52 Implemented on 20.02.2020

Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds, Revised-2020.Document No.: T-53 Implemented on 11.06.2020

Revision of Indian Railway Standard Specification for Fusion Welding of Rails by Alumino Thermic Process Serial No. IRST-19-2020 Implemented on 27.08.2020

Revision of Item specific guidelines for hard facing electrodes for reconditioning of crossings, switches and SEJs (Document No. TDG 0026) Implemented on 01.11.2020

Revision of Item specific guidelines for vendor approval / extension of approval for manufacture of AT welding portions and execution of AT rail joints Document No.: TDG 0017 Implemented on 24.11.2020

Single Rail Tester (SRT) Single Rail Tester (SRT) developed by RDSO having B-Scan facility for ultrasonic testing of Rails and Welds

Double Rail Tester (DRT) Double Rail Tester (DRT) developed by RDSO having B-

Scan facility for ultrasonic testing of Rails and Welds

Self Propelled Rail Bound Vehiclebased Vehicular USFD System M/s PE-NIA JV, Hyderabad Vehicular USFD System

Rail Cum Road Vehicle (RCRV)based Vehicular USFD System Rail Technology International, Australia - 8000SX

Smartest automatedRail flaw detection system

ERC Mk-V:

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

6.2mm Composite GRSP:

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

32.5t Axle load PSC Sleeper:

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

Wider & heavier PSC sleeper: The design of Wider & heavier PSC sleeper to drawing no RT-8527 has been finalized by RDSO in Year 2016 and after field trials on recommendation of RDSO, Railway Board approved adoption of Wider sleeper on 09.07.18. The main advantages of Wider PSC sleeper over existing BG Line sleeper to Drawing no. RT-2496 are as under: i) Increased width and weight providing higher frame

resistance against buckling, chances of reducing de-stressing temperature with likely reduction in rail/weld failures

ii) Increased rail seat area resulting in higher rubber pad life

iii) Reduced ballast pressure leading to reduction in ballast pulverization, deep screening cycle & enhanced drainage

Development of fastening components for Wider PSC Sleeper

Drawings for compatible fastenings to Wider sleeper viz. 10mm CGRSP to drg. no. RT-8258, SGCI insert to RT-

6901, Metal liners (RT-8616 & 8617) and GFN Liners to drg. no. (RT-6938 & 6939) were also developed.

NCR-GRSP for Turnouts: Nylon cord reinforced GRSP pads has been designed and developed by RDSO with two layers of treated Nylon Cord (for proper adhesion with rubber) placed in the center of GRSP. The two layers of Nylon Cord reinforcement are placed crosswise to each other with a thin rubber layer between two layers of reinforcement. Since the service conditions of the turnouts are such that high levels of force and acceleration are encountered, these high level forces cause excess wear and tear of rubber pad beneath the rails on the turnouts, especially the crossing portion. This nylon cord reinforced pad is designed to withstand the excess wear and tear at the turnouts in the track structure due to its better properties than GRSP.

Modified GRSP-liners:

The modified fastening components (6.2mm & 10mm thick CGRSP, GFN Liner & Metal Liner) for use on sharp curve have been developed by RDSO.

The drawings of 6.2mm & 10mm thick CGSP, GFN Liner & Metal Liner were circulated to nominated Zonal Railways for trials on PSC curve sleeper to drawing no. RT-4183 to RT-4186 and RT-4170 to RT- 4173 or with wider PSC curve sleeper to RT-8621 to RT-8624.

Railway Board has approved adoption and procedure for procurement and inspection of modified 6.2mm/10mm thick Composite GRSP, Metal Liner & GFN Liner used on sharp

1:6

R6

1:6

R6

EXISTING LINERMODIFIED LINER

curves on IR.

RT

-8694

RT

-8694

RT

-3711

Existing Proposed by SWR Modified by RDSO

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