Important Achievements of Track Design …rdso.indianrailways.gov.in/works/uploads/File/...Important...
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Important Achievements of Track Design Directorate during last five years
Sl
No.
Financia
l Year
Broad Area of
Achievement
Title of Achievement Description of Achievement Likely Benefit Current Status of
Implementation
1 2007-08 Safety Development of Design
and Drawings for
Movable Switch Diamond
RDSO developed design and drawings for 1:8.5 and 1:10
movable switch diamond crossing (without slip, with single
slip and with double slip) on PSC sleepers. Drawings were issued to Northern Railway and North Central Railway for
trial.
The concept will
eliminate the derailments
on diamonds due to unguided length at elbow
of obtuse crossing.
Prototype sets of 1
in 10 - one each for
single slip and double slip have
been developed.
2 2007-08 Safety Development of
specification for
outsourcing of
ultrasonic testing of
rail.
RDSO developed technical specifications for ultrasonic testing
of rails to be used by zonal Railways for outsourcing the USFD
testing to mitigate workload increase on account of operation
of heavier axle loads.
Introduction of state-of-
the Art USFD testing
m/c on Indian Railways.
Implemented
3 2007-08 Safety Development of AT
welding technology
with Compressed air
petrol preheating and
three piece moulds
RDSO successfully developed AT welding techniques with
three piece mould and compressed air petrol preheating for 52
kg/90UTS and higher rail sections in association with approved
portion manufacturing firms.
To improve quality and
in service performance
of AT welds.
Implemented
4 2008-09 Safety &
Reliability
Development of Design
and Specification of
Improved Switch expansion Joint (SEJ)
Drawings and specification for Improved SEJ for 80mm gap
(max.) and 65 mm gap (max.) for BG (1673mm) for 52kg &
60kg (UIC) on PSC sleepers were issued to all Zonal Railways for use.
The existing design of
SEJ has been improved
upon for more service life, better riding quality
and lesser maintenance
efforts.
Implemented
5 2008-09 Safety &
Reliability
Development of
specification of
Improved Rail Pad.
Specification of “Improved Rail Pad” for service life of 300
GMT or 8 years has been framed by M&C Dte in consultation
with Track Design Dte.
To improve the service
life of rail pad.
These pad are being
procured by the
railways for field
trial.
6 2009-10 Economy Field Trial of 22.5T
optimized Sleeper
RDSO had optimized existing design of PSC sleeper for 22.5T
axle load (Drg. No. RT- 7013) with M 60 grade of concrete
and 16 no. prestress strands.
Saving in cost of sleeper Under Trial
7 2009-10 Safety &
Reliability
Development of Nylon
cord reinforced GRSP
The specification of Nylon cord reinforced GRSP have been
developed and sent to zonal railways for trial for using under
CMS crossing to judge the performance.
To increase the life of
pad under CMC
crossing.
Under Trial
8 2009-10 Safety Development of digital ultrasonic rail testers.
RDSO successfully developed digital single and double rail testers and dedicated AT weld testers with digital technology
in association with industry. This will facilitate recording of A-
scan and monitoring of growth pattern of flaw.
Reliability of USFD testing of Rails/Welds
Implemented
9 2010-11 Safety Development of
specification for
ultrasonic rail testing
using vehicular system .
On account of increase in traffic and introducing of heavier
axle load, the work load of USFD testing has increased
considerably. The USFD testing is required to be undertaken
more frequently, as frequency of USFD testing is dependent on GMT of the section. RDSO developed technical specifications
for ultrasonic testing of rails/welds using vehicular system in
order to mitigate the increased work load of USFD testing and
to bring in state–of-the-Art vehicular systems of USFD testing
on Indian Railways
Introduction of state-of-
the Art Vehicular USFD
testing system on Indian
Railways. These will also help in effective
monitoring of flaw
growth pattern.
Tenders invited by
NR.
10 2010-11 Safety Development of Forged
Junction Rail
At locations of change of Rail Section in track, the junction
fish plate were used. It was not fisible to continue LWR at such
locations. RDSO developed the drawing and provisional
specification of 52kg and 60kg forged junction rail. This will
reduce instances of failure of junction fish plate and facilitate
continuance of LWR.
Reduction in junction
weld failure
Implemented
11 2010-11 Safety &
reliability
Revision of
Specification of Retro-
Reflective Engineering Indicators as per
ASTM-D-4956-09.
Specification for retro –reflective Engineering Indicators has
been revised after conducting literature survey & studying IRC
and International Specification. The provisional specification for retro –reflective May -2011 was approved by Railway
Board and issued to zonal railways for implementation.
Revised specification includes both Type III (encapsulated lens
type) and type IV (micro-prismatic type) of retro-reflective
boards.
Improved visibility of
engineering indicators
specially during night.
Implemented.
12 2010-11 Safety &
Reliability
Design of 1:16 thick
web switch with ZU-1-
60 asymmetric tongue
rail
The design of 1:16 thick web switch on PSC sleepers was
developed by modifying the existing 1:16 turnout to suit the
ZU-1-60 asymmetrical thick-web tongue rail.
Improvement of service
life, better riding quality,
lesser maintenance effort
Prototype set is
being developed.
13 2010-11 Safety Development of
Drawings for modified
Special Bearing plates
for 1 in 12 PSC fan shaped layout
Drawings for modified special bearing plate to be used on
sleeper No.24,25, 26 & 27 in 1:12 BG 52 kg turnout were
issued to all Zonal Railways for trial. The performance of
above modified plates was found to be satisfactory as indicated by CTE/SWR in TSC meeting in Dec 2010.
Improved safety Implemented
14 2010-11 Throughput Development of
Drawings for 1 :8.5
Symmetrical split
derailing switch
Drawings for 1:8.5 derailing switch (symmetrical split layout)
for both 52 kg and 60 kg rail sections were issued to Zonal
Railways.
This layout shall help in
increasing speed up to
30 Kmph in loop lines
Implemented
15 2010-11 Throughput Development of
Drawings for 1 :12
derailing switch
Drawing for 1:12 derailing switch BG 60 kg (UIC) and BG 52
kg on PSC sleepers were issued to Zonal Railways.
This design will help in
increasing speed of loop
lines.
Implemented
16 2010-11 Economy Development of
technology for in-situ
reconditioning of CMS
Crossing
In-situ reconditioning of CMS Crossing by Translamatic
Robotic Welder was adopted for regular use in October, 2010.
Another technology of Inweld Canada has been approved for
extended field trial. Expression of Interest (EOI) was called for development of more technoloies. The offers received are
under technical evaluation.
Improved service life of
CMS crossing and
elimination of
requirement of traffic block for removal and
insertion of CMS
crossing
Implemented. More
technologies are
under development.
17 2010-11 Safety &
Reliability
Field Trial of Under
Sleeper Pads
Field trial is to be carried out on sleepers fitted with Under
Sleeper Pad(USP) to study its effectiveness in ballast
protection, reduction in ballast pressure, reduction in overall
track maintenance & vibration control etc. RDSO has
formulated trial scheme for field trial of the same in NR &
SCR.
Ballast protection,
reduction in ballast
pressure, reduction in
overall track
maintenance & vibration
control
The trial of this
item is in progress
in NR & SCR.
18 2010-11 Safety &
Reliability
Development of ERC
Mk-V
ERC MK-V with toe load of 1200-1500 has been designed &
developed by RDSO and same has been approved for adoption
in Indian Railways for regular use.
Increase in toe-load. This item has been
adopted on Indian
Railways.
19 2010-11 Safety & Reliability
Development of Composite GRSP
To improve the life and performance of existing 6mm GRSP, RDSO has developed Composite GRSP. After successful lab
tests and satisfactory field performance, composite GRSP has
been approved by Railway Board for regular adoption.
This pad is expected to have minimum service
life of 8 years / 300
GMT.
This item has been adopted on Indian
Railways.
20 2010-11 Throughput Technical scrutiny and
inputs for Operation of
AC Double Decker
Coach on Howrah –
Dhanbad section
The operation of first rake of AC double decker coaches was
planned on Howrah-Dhanbad section. Necessary technical
scrutiny was done on aspects related to track and SOD for
Operation of AC Double Decker Coach on Howrah – Dhanbad
section and further inputs were provided for regular operation.
Increased throughput Implemented.
Running
successfully
21 2010-11 Consultancy Scrutiny and
finalization of Standard
Gauge SOD of Air port express Metro Line of
DMRC and operation
of trains.
The Standard Gauge Schedule of Dimension for AEML was
scrutinized in consultation with all concerned directorates. This
facilitated Operation of trains on Standard Gauge first time in India.
Fast and economical
public transport in Metro
city.
Implemented.
22 2011-12 Safety &
reliability
Revision of Manual for
Flash Butt Welding of
Rails Revised-2012)
Taking into consideration latest developments in the field of
flash butt welding world over, the flash butt welding manual
1972 has been updated and revised.
The Manual for Flash Butt Welding of Rails Revised-2012 has
been approved by Railway Board and issued for
implementation by FBWP.
Production of flash butt
welds of greater quality
& reliability by both
fixed and mobile plants
Revised manual
circulated to all
zonal railways for
implementation.
23 2011-12 Safety &
reliability
Development of track
based gauge face
lubricating system.
The gauge face lubrication is required to enhance service life
of rails particularly on sharp curves.
In order to assess suitability of mechanized lubricators, 12
imported & 8 indigenous lubricators were installed in CR, WCR and ECoR in 2008 with trial of two years. Based upon
the experience gained, Final specification No. IRST-48 of 2013
has been approved by Railway Board on 7/6/13.
Reduction in wear of rail
gauge face specially at
curved locations.
Implemented
24 2011-12 Safety &
reliability
Revision to
specification of fish
plates (IRST-1-2012)
The IRS specifications for fish plates needed revision due to
deletion of approved sources of raw material by QA/Mech Dte,
inclusion of dimensional tolerances etc. The existing
Specifications IRS-T-1:2012 & T-6 were reviewed and
comprehensive specification has been issued.
Comprehensive
specification issued.
Implemented
25 2011-12 Safety &
Reliability
Design of 1:12 Scissor
Cross over with 60 Kg
UIC rail with PSC
sleepers
Design and drawings for 1:12 Scissor Cross over with 60 Kg
(UIC) rail with PSC sleeper layout with 4.725 m c/c spacing of
track have been developed with new concepts having curved
CMS crossings up to tangent point and hollow CI block. Drawings have been issued for trial.
Improved service life,
better riding quality and
lesser maintenance effort
Under trial
26 2011-12 Economy Development of
Weldable CMS
Crossing
Drawings and Specification for 1:12 & 1:8.5 Weldable CMS
Xing BG 60 kg were developed by RDSO to bridge the
technological gap between IR and world railways• Field trial of
1 in 12 and 1 in 8.5 60 Kg weldable CMS crossings of RDSO
design has been ordered in N.Rly and C.Rly respectively
manufactured by firm M/s VAE VKN Sonepat.
Improved service life of
track components at
crossing , better riding
quality , lesser
maintenance effort and
feasibility of
continuation of LWR
through turnouts
Under trial
27 2011-12 Economy Development of
technology for
repair/reconditioning of rail top defects
Technical evaluation of technology has been done by RDSO
for repair of rail top defect by Translamatic Robotic Welder
has been done by RDSO. Field trial of technology has been ordered in two zonal railways under supervision of RDSO
Improved service life of
rail/weld, lesser
maintenance effort
Under trial
28 2011-12 Economy Improved SEJ for
curves up to 4 degree
Technical evaluation of Design and drawings for Improved
SEJ to be laid at curve up to 4 degree was done by RDSO.
Field trial has been ordered in three zonal railways for
validation of design and drawing.
Elimination of fish
plated joints resulting in
better ride quality and
lesser maintenance effort
Under trial
29 2011-12 Economy Development of
Composite Sleepers
Extended field trial of composite sleepers of M/s Tietek, USA
design and limited field trial of Composite FFU (Fibre
reinforced foamed urathane) sleepers of M/s Sekisui, Japan's
design were started for development of composite sleepers for
bridges. Composite Sleepers of two more technologies have
been approved for limited field trial.
Composite Sleeper,
made of recycled
materials is eco friendly
and ideal solution to
bridge timbers. It will
also reduce maintenance
effort.
Under Trial
30 2011-12 Consultancy Scrutiny and
finalization of Standard
Gauge SOD of BMRC.
The Standard Gauge Schedule of Dimension for Bangalore,
Chennai, Jaipur & Gurgaon Metros was scrutinized in
consultation with all concerned directorates and forwarded to
Railway Board for approval. This facilitated Operation of metro trains on Standard Gauge.
Fast and economical
Public transport system
in metro city.
Implemented.
31 2011-12 Throughput
enhancement
Schedule of Dimension
for Eastern and Western
Corridor
The Schedule of Dimension for Eastern and Western Corridor
for DFC was finalized. The same has been approved & issued
by Railway Board in Jan.-2013.
Enhanced freight
operation capacity.
Implemented.
32 2012-13 Economy Development of
Explosive Depth
Hardened (EDH) CMS
Crossing
EDH CMS crossings developed by a firm were put in limited
field trial in NR and SCR after inspection by RDSO. The
performance of above crossings were found to be satisfactory
and extended field trial has been ordered in six zonal railways
Improvement in service
life and reduction in the
requirement for
reconditioning
Under Trial
33 2012-13 Safety Revision of
‘Specification for
fusion welding of rails
by Alumino-thermic
process, IRST-19’.
Specification for fusion welding of rails by Alumino-thermic
process, IRST-19 has been revised incorporating all 16 nos. of
A&C slips issued. Theses A&C slips were issued for various
improvements made in quality of AT welding and
advancements made in this area.
Improvement in quality
& reliability of AT
welds.
Implemented.
34 2012-13 Safety Revision of ‘Manual
for fusion welding of
rails by Alumino-
thermic process, 1998’
‘Manual for fusion welding of rails by Alumino-thermic
process, 1998’ has been revised and issued as ‘Manual for
fusion welding of rails by Alumino-thermic process, 2012. All
13 nos. of A&C slips have been incorporated which deal with
various improvements made in quality of AT welding and advancements made in this area.
Improvement in quality
& reliability of AT
welds.
Implemented.
35 2012-13 Safety Revision & printing of
‘USFD Manual’
‘Manual for Ultrasonic testing of rails & welds, 2006’ has
been revised and issued as ‘‘Manual for Ultrasonic testing of
rails & welds, 2012’. All 09 nos. of A&C slips have been
incorporated which deal with various improvements made in
area of USFD testing.
Improvement in
reliability of USFD
testing
Implemented.
36 2012-13 Safety Development of AT
welding technology
with Compressed air
petrol preheating, three
piece moulds and
Automatic tapping
thimble.
In order to reduce human element in AT weld to improve
reliability. As welding techniques with Auto tapping thimble
was developed by RDSO in association with approved vendors
for AT portions. RDSO has successfully developed vendors for
the AT welding technique with Compressed air petrol
preheating, three piece moulds and Automatic tapping thimble.
To improve quality and
in service performance
of AT welds.
Implemented w.e.f.
01.02.2013
37 2012-13 Safety Revision of specification for
ultrasonic rail testing on
outsourcing basis
‘Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds (Provisional) Revised, 2007’ has been revised
so as to incorporate the provisions for outsourcing of welds and
issued as ‘Indian Railway Standard Specification for
Ultrasonic testing of rails/welds (Provisional) - Revised, 2012.
Introduction of state-of-the Art USFD rail and
weld testing m/c on
Indian Railways.
38 2012-13 Consultancy Scrutiny and
finalization of Standard
Gauge SOD of Chennai
Metro(CMRL)
The Standard Gauge Schedule of Dimension for CMRL was
scrutinized in consultation with all concerned directorates and
forwarded to Railway Boar for approval. This facilitated
Operation of metro trains on Standard Gauge.
Fast and economical
Public transport system
in metro city.
Under
consideration of
Railway Board.
39 2008-13 Safety Amendments in
IRSOD, BG- 2004
07 No. Amendment and corrigendum slips proposed to address
issues related to safety and enhanced capacity and mobility.
Increased mobility with
enhanced safety.
05 out of the 07
amendment/implem
ented. Remaining
02 are under
consideration of
Railway Board.
40 2008-13 Mobility &
Throughput
enhancement
Scrutiny and vetting of
speed certificates.
More than 500 No. speed certificates were vetted from track
point of view including some very important operations as
mentioned below:
1. Operation of 22.32t (CC+6t+2t) axle load wagons.
2. Operation of BG RS-2 and RS-3 DMRC Coaches.
3. Operation of 22.82t (CC+8+2t) axle load wagons. 4. WAP7 class of locomotive up to a maximum speed of
140kmph.
5. Multi-operation of 3WDG3A/3WCG2 locomotives and 59
BOXN wagons (loaded to CC+8+2t) over Lonavala-
Palasdhari Ghat Section.
6. Operation of MEMU Coaches fitted with pneumatic
suspension up to a maximum speed of 110kmph.
7. Operation of Shatabdi express and other similar trains with
18 numbers of LHB AC EOG coaches at 140kmph.
8. Operation of BG AC EOG Double Decker Chair Car
coaches (width 3050mm) at maximum speed of 160kmph. 9. Operation trials of long haul train-two freight trains
amalgamated into one train (python).
10. Operation of WDP4D twin cab class of locomotive up to
135kmph.
11. Operation of second class Non AC EOG LHB variant
coaches (LS2) up to a speed of 135kmph with pay loads
upto 16T maximum.
Increased Mobility and
Throughput.
Implemented.
41 2013-14 Economy Grooved Rubber sole
plates (GRSP) with
horn for turnouts
RDSO has developed new designs of GRSP with horn for lead
portion, under check rail at crossing, beyond crossing and for
approach and exit sleeper for 1 in 12 & 1 in 8.5 turnouts and
the same issued to all Zonal Railways for trial.
Solution for working out
of rubber pads leading to
increased service life of
sleepers and other track components.
Under Trial
42 2013-14 Consultancy Scrutiny and
finalization of SOD of
Gurgaon Metro
(RMGL)
The Standard Gauge Schedule of Dimension for RMGL was
scrutinized in consultation with all concerned directorates and
forwarded to Railway Boar for approval. This facilitated
Operation of metro trains on Standard Gauge.
Fast and economical
Public transport system
in metro city.
Under
consideration of
Railway Board
43 2013-14 Reliability,
Economy
Review of Design of
Spring Setting
Device(SSD)
The design of SSD was reviewed to address problems
experienced in field. As a consequence, Drawings for SSD
and their parts –RDSO/T-6216, RDSO/T-6945 and RDSO/T-
6217/1-32 have been altered and issued to Zonal Railways.
The revised ‘Laying and Maintenance Instructions’
incorporate frequency of inspection and oiling & greasing of
SSD has also been issued to ensure smooth operation of SSD.
Improved Reliability and
acceptibility of SSD in
field which in turn shall
enhance the service life
of switch.
Implemented
44 2013-14 Safety,
Economy
Finalization of Drawing
for Combination SEJ Drawings for Comination SEJ with 60 Kg tongue rail and 52
Kg stock rail have been finalized and issued to Zonal
Railways. Such SEJ can be used at the location of change in
rail section from 52 Kg to 60 Kg (or vice versa)
Improved safety due to
elimination of
Compound fish plate.
Cost reduction as only
one SEJ is required in place of two SEJs for
different rail sections.
Implemented
45 2013-14 Throughput &
Economy
Development of
Ballastless Track with
Indigenous Fastening
System (BLT-IFS)
including tunnels and
viaducts
BLT-IFS design has been completed including proto-type
development in a record time of 3 months and its drawings and
construction guidelines has been prepared which has been
approved by the Railway Board vide letter dt. 13.12.2013. The
drawing & construction guidelines have been sent to zonal
railways on 16.12.2013 for undertaking the trial. The BLT-IFS
design can also be used in tunnels & viaducts with suitable
modification in the pad stiffness.
The BLT design has
been developed using
indigenous fastening
system resulting in cost
saving and easy
availability of fastening
components. The
proposed BLT-IFS can
be used in washable
aprons for both platform & non-platform lines, in
tunnels, bridges and
track at formation
requiring very low
maintenance.
Trial in main line in
BINA-BPL by
RVNL and in
various zonal
railways .
46 2013-14 Safety &
Reliability
Revision in
Specification (IRS-T-
44) of GFN-66
Insulating Liners
Corrigendum No. 4 to the ‘IRS specification no. T-44-1995 for
GFN-66 Insulating Liners’ incorporating change of colour &
location for taking sample for specific gravity test has been
issued to all concerned on 27.11.2013.
With the above change,
uncertainty of quality of
existing insulating liners
with black colour can be
Corrigendum
circulated to zonal
railways for
improved with the use of
insulating liners of the
same material but with
natural colour and use of
spurious material can be
avoided by using virgin
raw material of natural
colour and at the same
time hardness & cross
breaking load values are
not compromised
Implementation
47 2013-14 Safety &
Reliability
Revision in
Specification of Metal
Liners
This specification has been issued bearing the title ‘IRS
specification for metal liners for use with Elastic Rail Clips
(Provisional -2013)’ on 29.11.2013 to all concerned.
It will improve the
quality & serviceability
of metal liner bars as
well as metal liners
henceforth on sustained
basis
Specifications
circulated to zonal
railways for
Implementation
48 2013-14 Throughput
Design of Wider
Sleeper using more
concrete & less steel
for 25T axle load
Various preliminary designs have been sent to Railway Board
for in-principle approval of finalized option for developing
detailed drawings. However design with top rail seat width of
230 mm and bottom of 300 mm against existing 150 mm and
250 mm respectively found most suitable with use of 12 wires
as against 20 wires of 3x3 mm in existing 25 t design.
Following are the
advantages of wider &
heavier sleeper
Increase in
frame resistance
of track & avoiding of
buckling of
track
Increase in rail
seat area
resulting in
increase in
rubber pad life,
Reduction in
ballast pressure
leading to
reduction in ballast
pulverization,
deep screening
Awaiting Rly.
Board’s approval,
RDSO is going
ahead with
developing detailed
drawings.
cycle &
enhanced
drainage
49 2013-14 Safety &
Reliability
Development of 10mm
thick Composite
GRSP for 25t sleeper
assembly
Development of 10mm Composite GRSP for 25t axle load has
been taken up by RDSO. Prototype samples of this pad were
asked from the approved vendors of 6.2mm CGRSP, for
testing in RDSO. The samples of four firms have been tested in
M&C Dte. Of RDSO.
Pad is more sturdier &
increased serviceability
for use in heavy axle
load.
The one firm has
already been
shortlisted. Further
development is in
progress.
50 2013-14 Consultancy
UIC Asia project on
‘Optimisation of
Sleeper Design in
collaboration with CHARMEC Sweden.
The modelling & simulation study has been done for
optimization of various design parameters of design of PSC
sleepers for 22.9 axle load and upto speed 75 kmph & LHB
coaches upto 10 kmph. Good practices of manufacturing are
also been recommended
Rationalization of
various design factors
and appropriate
combination of these factors resulting in
optimised design of PSC
sleeper for 25T axle
load.
After completion of
Phase –I , Phase-II
of the project is in
progress for further
study.
51 2013-14 Safety &
Reliability
Development of
Improved Toe Load J-
Clip
RDSO has developed Modified ERC J-clip for increase in the
toe-load of existing J-clip. Increase in toe-load to
solve the problem of
working out of clips at
fish plated joints.
Drawing of
Prototype samples
have also been got
manufactured. &
samples are under
testing at RDSO for
validation. Gauge
drawing and
application-deflection block
drawing for new
design of J-clip will
be issued after
testing.
52 2013-14 Throughput
Design & development
of 25t sleeper along
with fastening system
Prototype design of the sleeper has been manufactured and
same is found successful during lab testing at RDSO. Design
of sleeper and fastening system has been sent to ECoR, SE, SC
& SW Railways for field trial.
Heavy sleeper &
fastening system for
heavy axle load
Trial is in progress
53 2013-14 Throughput Design & development
of 32.5t sleeper along
with fastening system
RDSO has designed and developed proto-type of a new PSC
sleeper for 32.5t axle load. All laboratory investigations of this
sleeper including Fatigue test have been completed and the
sleeper has passed all the tests successfully.
Load carrying capacity
of PSC sleeper will
increase.
Detail estimate &
indent vetted.
Tender is being
called.
54 2013-14 Safety &
Reliability
Development of
Thermoplastic
Elastomer Pads
Status report on trial after one year service has been sent to
railway board on 15.05.2012.
Further, a letter to all the five nominated railways has also been
sent on 27.08.2013 to send certain specific observations of the
performance of the pads.
One of the main reasons
of deterioration of
existing rubber pads is
attributed to the effect of
extreme environmental
conditions in field which
in turn affects the overall
functioning of elastic
fastening system. The
Thermoplastic Elastomer
Rail Pad is made of
polymer and therefore, it
is resistant to the effect
of extreme
environmental
conditions in field and
imparts longevity.
Under trial
55 2013-14 Throughput Revision of
Specification of PSC
Sleeper
These revised specifications have been discussed with the
manufacturers and finally approved by Railway Board. Now
revised specifications have been implemented.
Further, vide letter no. 2011/TK-II/22/11/1/Specification dated
11.03.2013, Railway Board has amended the Guarantee Clause
no. 8.1 of the IRS T-39 (Fourth Revision – August 2011)
which has been issued to zonal railways as Corrigendum no. 1
to IRS T-39-85 (Fourth Revision – August 2011) vide RDSO
letter no. CT/SRC/Specification dated 22.04.2013 after taking
all necessary action as per ISO guidelines of RDSO
Revision of specification
of PSC sleeper (T-39)
has been taken up to fine
tune it in line with latest
practice / production
techniques and
experienced gained by
IR.
Implemented
Long Rail Bed at Bhilai Steel Plant
Long Rails are to be cooled down before online
Ultrasonic Testing Ultrasonic test. Its length is 65
metre
Long Welded Rails:
Indian Railways have laid vast stretches of long
welded rails. These rails are able to provide a more
comfortable journey as the fish plated joints have been
replaced with welded joints. Indian Railways is a large
network comprising majority of track on Broad Gauge.
Broad Gauge (1676 mm) track mostly comprises of
UIC 60Kg long/IRS 52 Kg long/Continuously welded
rails laid on pre-stresses mono-block concrete
sleepers on stone crushed ballast bed. On broad
gauge approximately 47,000 Km of track out of total
approx. 63000 Km are already having long welded
rails.
Ballastless Track with Indigenous Fastening System (BLT-IFS)
BLT-IFS design has been completed including proto-type development in a record time of 3 months and its drawings and construction guidelines has been prepared which has been approved by the Railway Board vide letter dt. 13.12.2013. The drawing & construction guidelines have been sent to zonal railways on 16.12.2013 for undertaking the trial
Achievements: Design Development of Track related components
Automatic tapping thimble:
RDSO has successfully developed the technique and vendors for the AT welding technique with Compressed air petrol preheating , three piece moulds and Automatic tapping thimble to improve quality of welds and in service performance
Digital AT weld tester:
RDSO successfully developed dedicated AT weld testers with digital technology in association with industry. These digital tester have facility of recording A-scan pattern and monitoring of growth pattern of flaw.
Digital Double rail tester:
RDSO successfully developed digital single and double rail testers with digital technology in association with industry. These digital tester have facility of recording A-scan pattern and monitoring of growth pattern of flaw.
Manual for Ultrasonic testing of rails & welds- 2006: Manual for Ultrasonic testing of rails & welds, 2006’ has been revised and issued as ‘‘Manual for Ultrasonic testing of rails & welds, 2012’. The copies of revised USFD Manual, 2012 have been printed and being circulated to Zonal Railways & all concerned.
Standard Schedule of Dimensions for DFC:
Standard Schedule of Dimensions for Eastern and Western Dedicated Freight Corridors on Indian Railways Published in January-2013
Thick Web Switch:
Design, Drawings and Specification for 60 Kg BG 1 in 12, 1in 8.5 and 1in 16 thick web switches have been developed by RDSO. 60 Kg 1 in 12 thick web switches of RDSO design have already been laid in track.
Weldable CMS Crossing:
Design, Drawings and Specification for 60 Kg BG 1 in 12 and 60 Kg BG 1in 8.5 Weldable CMS crossing have been developed by RDSO. Trial for such crossings has been ordered.
Improved Switch Expansion Joint (SEJ):
Drawings and Specification for Improved SEJ of two designs – one with maximum 80 mm gap and other with 65 mm gap have been issued to Zonal Railways for regular use. Such SEJs do not have bends augmenting safety and service life.
Composite Sleeper: Composite Sleepers of Tietek design have performed satisfactorily over a period of 10 years on two girder bridges on Indian Railways. Such sleepers are under extended trial at present.
ERC Mk-V:
Higher toe load clip is required for increased speed and axle load and to control the creep in LWR. ERC MK-V has been developed for toe load of 1250 kg. This clip has been adopted on Indian Railways.
6.2mm Composite GRSP: To improve performance/service life of rubber pad, composite GRSP has been developed and adopted on Indian Railway having service life of 300 GMT as compared to 150 GMT of existing GRSP.
32.5t Axle load PSC Sleeper: RDSO has designed and developed a new PSC sleeper for 32.5t axle load. All laboratory investigations of this sleeper including Fatigue test have been completed and the sleeper has passed all the tests successfully.