WELCOME

TRANSPORTATION ENGINEERING - II

RAILWAY ENGINEERING SESSIONS (2)+(3)

OUTLINE
Classification of Railway Lines on Indian Railways Railway alignment and Surveys Components of the Track Rails Sleepers

CLASSIFICATION OF RAILWAY LINES (INDIAN RAILWAY SYSTEM)

Basis Future maximum permissible speed. Group A - Speeds upto 160 km/hr
New Delhi Howrah New Delhi Mumbai Central New Delhi Chennai Howrah Mumbai (Via Nagpur)

Group B -

Speeds upto 130 km/hr

CLASSIFICATION OF RAILWAY LINES (INDIAN RAILWAY SYSTEM)

Group C - Suburban sections of Mumbai, Delhi, Chennai & Kolkata Group D - Speed upto 110 km/hr Group D Spl- Speeds upto 110 km/hr & Traffic density 20 GMT Group E - Branch lines with present speed 100 km/hr.

ALIGNMENT & SURVEYS

Need for New Railway Line
Develop backward areas Transportation of minerals from mines to industries Joining ports with industries / trade centres. Trade development between two towns Strategic Considerations. To shorten distance between two cities

ALIGNMENT & SURVEYS

Alignment Selection
Length as short as possible Economy Easy gradient Easy curves Easy to maintain Should pass through important cities & industrial areas Pass through scenic areas: coastal, forest etc.

SURVEYS
Traffic Surveys
Population of the towns : 15 km on either side Position of local industries produce, destination, raw materials. Future prospects of development of new industries Religious festivals, melas etc. Export materials with destination. Road transport facilities available.

SURVEYS
Operating cost & Revenue Earned

SURVEYS
Reconnaissance Survey
Study of existing topographical maps, Satellite Imaginery, Photoghaphs etc Fixing alignment on maps Elevations ; Ruling gradient Survey of major rivers, streams, valley & ridges Nature of soil Rock conditions, geological faults study of geological maps In hilly terrain help of an experienced Geologist.

Alternative Alignments are plotted

SURVEYS
Out Come
Rough idea of various alternative alignments. Decide max gradient & curvature. Geological and geographical details. Rough project cost estimates for various alternatives.

SURVEYS
Preliminary Engg. Cum Traffic Survey
Work is accurate Survey instruments are used Soil data bearing capacity, ground water table, soil conditions in rivers / streams. Availability of materials & labour Geological details Mapping & drilling Details of existing culverts, bridges, tunnels Level crossing details. Highest flood levels & low water levels of rivers.

From preliminary survey Most economical & suitable route is determined.

SURVEYS
Final Location Survey
Alignment is stacked on ground with pegs at every 30m Chainage written. Masonry pillars at about 600m interval Chainage & levels written. Tangent Points & Transition curves are marked. Alignment plan & Longitudinal section are prepared. Cross sections are prepared

SURVEYS
Full data on bridges, culverts & tunnels collected spans decided. General Arrangement drawing prepared Preparation of detailed Project Report
Detailed drawings & estimates. Construction methodology & phasing Cost Estimates Return on Investment

COMPONENTS OF RAILWAY TRACK

RAILS
Functions
Provide continuous and level surface Smooth pathway and less friction Bear stresses and transmit the same to the sleeper Serve as a lateral guide to running wheel

VARIOUS TYPE OF RAILS

Double Headed

VARIOUS TYPE OF RAILS

Bull Headed

VARIOUS TYPE OF RAILS

Flat Footed

REQUIREMENT OF A RAIL SECTION

Economical consistent with strength, stiffness and durability Centre of gravity near the centre of height Maximum tensile stress and Maximum compressive stress equal Head - adequate depth to allow for vertical wear

REQUIREMENT OF A RAIL SECTION

Web Sufficiently thick Corrosion Withstand stresses Foot Sufficiently thick Allow corrosion Withstand horizontal and vertical forces

REQUIREMENT OF A RAIL SECTION

Height of rail adequate to have vertical stiffness acts as a beam Fishing angles transmission of load from rails to fish plates

STANDARD RAIL SECTIONS

60 Kg Rail 52 Kg Rail 90R Rail

CONSIDERATIONS FOR DECIDING RAIL SECTIONS

Heaviest axle load Maximum permissible speed Depth of ballast cushion Type and spacing of sleepers

STANDARD FLAT FOOTED SECTION

DIMENSIONS OF VARIOUS RAIL SECTIONS

Section

Wt. in (kg)

Area in (Sq mm)

90 R

44.61

5895
6615 7686

142.9
156 172

136.5
136 150

66.7
67 74.3

13.9 43.7 20.6

15.5 51 16.5 51 29 31.5

52 kg (IRS) 51.89 60 kg (UIC) 60.34

52 KG RAIL SECTION

60 KG RAIL SECTION

A(

A(

60

FUTURISTIC RAIL SECTIONS

Type of rail

Area of x section

Weight of rail per metre

IRS 52 kg/m
UIC.60 kg/m 68 kg/m ZU I60

66.15 Sq. Cm.

76.86 Sq. cm 86.13 Sq. Cm. 93.00 Sq. Cm.

51.89 Kg/m
60.34 kg/m 67.36 Kg/m 73.00 Kg/m

STANDARD LENGTH OF RAILS

Longer rails desirable Limitations
Difficulty in Transportation Difficulty in Handling Uneconomical in Manufacturing Heavy internal stresses in long rails

13m, 26m & 65m rails

UTS OF RAILS
Medium Manganese Rails 72 kg/mm2 Service Life 350 GMT 90 UTS Rails service life 50% more.

SERVICE LIFE OF RAILS

52 kg (72 UTS): 350 GMT 52 kg (90 UTS): 525 GMT 60 kg (90 UTS): 800 GMT 90 UTS rails Superior wear characteristics Higher hardness 270 BHN

HEAD HARDENED RAILS

Head hardened by passing through a thermal treatment plant. Depth 12 mm from top surface

CAUSES OF RAIL DETERIORATION

Corrosion Wear of rail table Flattening of rail table Wear on gauge face Hogging of Rail joints Battering of Rail joints

HOGGING OF RAIL JOINTS

BATTERING OF RAIL ENDS

CAUSES OF RAIL FAILURES

Inherent defects in the Rail Defects due to faulty rolling stock Excessive corrosion Badly maintained joints Defects in welded joints Improper maintenance of track Derailments

RAIL FLAW DETECTION

Visual Examination of Rail Ends Ultrasonic Rail Flaw Detection (USFD)

ULTRA SONIC FLAW DETECTION

Single rail tester Double rail tester

SINGLE RAIL TESTER (USFD)

LIMITS OF PERMISSIBLE DEFECTS

Portion of Rail
1. 2. 3. 4. Head Web Web & foot junction Foot

Permissible defect
1.5 mm dia through hole 2.0 mm dia through hole 2.0 mm dia through hole 0.5 mm deep, 12.5 mm long and 1.0 mm wide notch (inclined at 20o with vertical axis)

CLASSIFICATION OF RAIL DEFECTS

IMR defects OBS defects

SLEEPERS
Function of sleepers
Maintaining correct gauge and alignment Firm & even support to rails Transferring the load evenly to wider area of ballast Elastic medium between rail & ballast Provide longitudinal & lateral stability to the track Facilitate rectification of track geometry

REQUIREMENT OF A GOOD SLEEPER

Economical Initially & during service Weight to be moderate Removal and fixing of rails to be easy Sufficient bearing area Possible to maintain & adjust track gauge High insulation properties for track circuiting Sleeper should not break during packing Anti sabotage & Anti theft properties

DIFFERENT TYPES OF SLEEPERS

Wooden sleepers Cast Iron sleepers Steel sleepers Concrete sleepers

Wooden Sleeper

WOODEN SLEEPERS
Advantages
Cheap and easy to manufacture. Absorbs shocks and has got good capacity to dampen the vibrations thereby retains packing well Easy handling without damage Suitable for track circuited sections Suitable for areas having yielding formations Alignment can easily be corrected

WOODEN SLEEPERS
More suitable for modern methods of maintenance Can be used with or without stone ballast Can be used on bridges and ash pits also Can be used for gauntleted track

WOODEN SLEEPERS
Disadvantages
Lesser life due to wear, decay and attack by vermin Liable to mechanical wear with beater packing Difficult to maintain gauge Susceptible to fire hazards Scrap value is negligible

Cast Iron Sleeper

CAST IRON SLEEPERS

Advantages
Lesser corrosion Lesser liable to crack at rail seat Easier to manufacture Higher scrap value

CAST IRON SLEEPERS

Disadvantages
Gauge maintenance is difficult as tie bars get bent Provides less lateral stability Unsuitable for track circuited lines Not very suitable for mechanical maintenance and or M.S.P. because of rounded bottom More susceptible to breakage

CST 9 SLEEPERS

STEEL TROUGH SLEEPERS

THICK

A-A

STEEL TROUGH SLEEPERS

Advantages
Longer life Easy to maintain gauge and lesser maintenance problems Better Lateral rigidity Lesser damage during handling and transport Manufacturing process is simple Very good scrap value Free from decay and attack by vermin

STEEL TROUGH SLEEPER

Disadvantages
Liable for corrosion Unsuitable for track circuiting areas Liable to become centre bound because of slopes at two ends Develops cracks at rail seats during service Can only be used for rails for which it is manufactured

Concrete Sleeper

Concrete Sleeper

Concrete Sleeper

Concrete Sleeper

Development of Concrete Sleepers

Development of Concrete Technology in 19th Century Shortage of wood and resultant high prices Austria and Italy produced first promising design other European Railways closely followed High Speeds, Long welded Rails, Heavier Rail Section led to large scale adoption of concrete sleepers.

Development of concrete sleepers in India

Shortage of wooden sleepers over last few decades This led to development of steel and cast iron sleepers At one point of time IR consumed 40% of pig iron Introduction of High Speeds, welding of rails and installation of long welded rails.

Different types of Concrete Sleepers

Twin Block RCC Sleepers Mono Block RCC Sleepers Mono Block Prestrorised Concrete Sleepers.

Comparison of different types of sleepers

Sl Characteristics Wooden Sleepers Steel Sleepers C.I. Sleepers Concrete Sleepers
1. Service life 12 to 15 yrs 40 to 50 yrs 40 to 50 yrs 50 to 60 yrs

2.

Weight for sleepers for BG

83 kg

79 kg

87 kg

267 kg

3.

Handling

Manual handling. No damage to Sleeper while handling

Manual handling. No damage to Sleeper while handling

Manual handling. Liable to break by rough handling

No manual handling, gets damaged by rough handling.

4.

Type of maintenance

Manual or mechanised maintenance

High

Manual or mechanised maintenance

Manual maintenance

Mechanised maintenance only

5.

Cost of maintenance

Medium

Medium

Low

6.

Gauge adjustment

Difficult

Easy

Easy

No Gauge adjustment possible

Advantages of Concrete Sleepers

Being heavy lend strength and stability to the track Best suited for LWR Resistance to Buckling Being flat bottom, suitable for machine maintenance of track Suitable for track circuited areas Neither inflammable and subjected to corrosion Long life 40 to 50 years Mass production using local materials.

Disadvantages of Concrete Sleepers

Being heavy, handling difficult Mechanical methods required for handling and laying high initial expenditure Heavy damage at the time of derailments Unsuitable for manual maintenance To be maintained using heavy on track tampers.

Comparison contd..
Sl Characteristics Wooden Sleepers Steel Sleepers C.I. Sleepers Concrete Sleepers

7.

Track circuiting

Best

Difficult; insulating pads are necessary No damage by white ants but corrosion is possible. Suitable for CF & EF

Difficult; insulating pads are necessary Can be damaged by corrosion Suitable for only CF

Easy

8.

Damage by white ants and corrosion Suitability for fastening

Can be damaged by white ants Suitable for CF & EF

No damage by white ants or corrosion Suitable for only EF

9.

10.

Suitability for track

Suitable for all routes Good

Suitable for all routes

Not suitable for high speed routes Good

Suitable for high speed routes Best

11.

Track elasticity

Good

12.

Creep

Creep is excessive

Less Creep

Less Creep

Creep is minimum

13.

Scrap value

Low scrap value

Higher scrap value than wooden sleeper

High scrap value

No scrap value.

THANK YOU !