HANDBOOK ON MAINTENANCE OF SWITCH EXPANSION JOINT on... · Handbook on Maintenance of Switch Expansion Joint Dec, 97 6 FOREWORD Indian Railways have a running track of about 81,000

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Handbook on Maintenance of Switch Expansion Joint Dec, 97

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

HANDBOOK ON

MAINTENANCE OF SWITCH EXPANSION JOINT

FOR L.W.R./C.W.R.

CAMTECH/C/04 December - 1997

Centre

for

Advanced

Maintenance

TECHnology

Excellence in Maintenance

Maharajpur, GWALIOR - 474 020

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HANDBOOK ON

MAINTENANCE OF SWITCH EXPANSION

JOINT

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CONTENTS

S.No. Description Page 1. INTRODUCTION 1 2. MAINTENANCE OF SEJ. 1 3. GAPS AT SEJ. 1 4. DAMAGE TO SEJ. 2 5. BUCKLING OF TRACK 3 6. GAPS OF SEJ FOR VARIOUS 4 TEMPERATURE AND VARIOUS TYPE TRACK STRUCTURE.

i. B.G. 60 Kg PRC sleeper, 1660 nos/km, 11 r = 13.74 kg/ cm/ rail. ii. B.G. 60 Kg PRC sleeper, 1540 nos/ km,

12 r = 13.28 kg/cm /rail.

v

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S.No. Description Page

iii. B.G. 60 Kg ST sleeper, 1540 nos/ km, 13 r = 12.14kg/ cm/ rail. iv. B.G. 52 Kg PRC sleeper, 1660 nos/ km, 14 r = 13.74 kg/ cm/ rail. v. B.G. 52 Kg PRC sleeper, 1540 nos/ km, 15 r = 13.28 kg/ cm/ rail. vi. B.G. 52 Kg ST sleeper, 1540 nos/ km, 16 r = 12.14 kg/ cm/ rail. vii. B.G. 52 Kg CST-9 sleeper, 1540 nos/ km, 17 r = 10.65 kg/ cm/ rail. viii. B.G. 90 R PRC sleeper, 1540 nos/ km, 18 r = 13.28 kg/ cm/ rail. ix. B.G. 90 R ST sleeper, 1540 nos/ km, 19 r = 12.14 kg/ cm/ rail. x. B.G. 90 R CST-9 sleeper, 1540 nos/ km, 20 r = 10.65 kg/ cm/ rail. xi. M.G. 90 R ST sleeper, 1540 nos/ km, 21 r = 3.86 kg/ cm/ rail. xii. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 22 r = 3.47 kg/ cm/ rail. xiii. M.G. 90 R ST sleeper, 1540 nos/ km, 23 r = 3.86 kg/ cm/ rail. xiv. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 24 r = 3.47 kg/ cm/ rail.

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PREFACE

The track structure on Indian Rlys has now been modernised to a great extent. The old concept of Rail Joint being a “ necessary evil no longer holds true. Rails are now being welded as long continuous welded rails to provide joint less track with smooth side. The officers and supervisors staff of civil engineering department have since long felt book for maintenance of switch expansion joints for long welded rails and continuous welded rails. Most of the data, sketch and information are available in some form or other in various books or other printed matter of various railways. The objective of this handbook is to serve as a ready reckoner for day to day problems on field with all standard practices schedules. A lot of initiative was shown enormous assistance was received from all technical staff of civil wing. I shall be grateful to the readers for pointing out errors if any and invite their valuable suggestions for improving this handbook in order to enhance its utility. Gwalior R.S.Dubey Date : 10 July,98 Joint Director (Civil)

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FOREWORD Indian Railways have a running track of about 81,000 Kms. As on 31.03.97, 60618 Kms. has been modernised into Welded Track out of which 31,914 Kms. is with long Continuous Welded Rails and 28,704 Kms. is with Short Welded Rails. Due to continuous increase in the amount of LWR and CWR, the proper maintenance of SEJs has assumed great importance in the interest of safe and punctual running of trains. This handbook has been prepared for the assistance of field staff by Centre for Advanced Maintenance Technology in order to consolidate and put together all information related to maintenance of Switch Expansion Joints. The tables for SEJs gaps at various temperatures for varying sleeper density and ballast resistance have been systematically compiled and produced in the handbook to serve as a useful ready reckoner for proper maintenance of SEJ. Gwalior D. K. Saraf Date : 20th July, 1998 Director

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SWITCH EXPANSION JOINT(SEJ)

1. INTRODUCTION Switch expansion Joint is an expansion joint installed at each

end of LWR CWR to permit expansion contraction of the adjoining breathing lengths due to temperature variations.

2. MAINTENANCE OF SEJs

Once in a fortnight SEJs shall be checked by PWI. Packing & Alignment on SEJ shall be corrected

regularly in every fortnight. Oiling & greasing of stock rails & tongue rail of SEJ

shall be done.. Tightening or fastening shall be done regularly. Movement of SEJ shall be checked in every fortnight

if found any abnormal behavior action taken for destressing of LWR.

3. GAPS AT SEJ Gaps at SEJ shall be adjusted at the time of laying/

subsequent destressing of LWR/CWR. Rail section laid Gap to be provided at ‘td’ 52 kg/60kg 40mm others 60mm

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The gaps at SEJ at various rail temperatures shall not differ by more than +/- 20mm from the theoretical range

Where fishplated or SWP track is joined on one side of SEJ,

the gap between the reference mark and tongue rail tip/ stock rail corner on LWR/CWR side shall not differ by more than +/- 10mm from half the theoretical range.

4. DAMAGE TO SWITCH EXPANSION JOINT The damaged/broken SEJ shall be replaced. The new SEJ

shall be adjusted as per para 3. Traffic may be allowed if necessary at a restricted speed and thereafter restriction relaxed progressively.

If damaged 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 fish plates.

The traffic over the clamped joints may be permitted at the

restricted speed. 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-situweld.

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5. BUCKLING OF TRACK General Buckling or a tendency towards buckling may occur, among

others, in the following circumstances :-

Failure to adhere to the temperature ranges specified for operation on LWR/CWR.

Inadequate resistance to longitudinal, lateral and

vertical movement of track due to deficiencies in ballast section or/ and inadequate ballast consolidation.

Use of ineffective fastenings or missing fastening

resulting in loss of creep resistance and torsional resistance.

Excessive settlement of formation. Improper functioning of SEJ.

*****

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GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE AND TRACK STRUCTURE

1. Gaps at SEJ depends on following factors :-

(a) Longitudinal Ballast Resistance of sleepers (b) Area of rail section (c) Modulous of Elasticity (E) for rail steel (d) Coefficient of linear expansion ( a ) for rail steel (e) Destressing temperature of the section where

gap at SEJ is required (f) Initial gap at SEJ at destressing temperature

2. Values of above variable for Indian Conditions are

tabulated below:

Table - I PARAMETERS FOR STANDARD I.R. RAIL SECTIONS

Rail Section Area E (cm2) (Kg/cm2) (/°) 60 Kg (UIC) 78.86 2.15 x 106 1.152 x 10-5

52 Kg 66.15 - do - - do - 90 R 56.95 - do - - do - 75 R 47.37 - do - - do -

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Table - II

LONGITUDINAL BALLAST RESISTENCE (R) FOR VARIOUS SLEEPERS AND SLEEPER DENSITY.

Type of sleeper Longitudinal Ballast Resistance in Kg/cm/rail Broad Gauge Metre Gauge 1310 sle- 1540 sle- 1660 sle- 1540 sleepers/km epers/km epers/km eper/ km PRC 12.93 13.28 13.74 -- ST 11.48 12.14 12.68 3.86 CST-9 9.92 10.65 11.04 3.47 Wooden 7.58 7.97 8.06 5.0 Note : The value given are indicative and can vary as per site conditions.

Table - III

INITIAL GAP TO BE PROVIDED AT DESTRESSING TEMPERATURE (td)

Rail Section Intial gap at Td (mm) 60 Kg(UIC)/ 52 Kg 40 mm Other 60 mm

EXAMPLE

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To find out the gap at SEJ at rail temperature of 58°C with the following data :

i) Rail section 52 kg/m ii) Type of sleeper PRC iii) Sleeper density 1540 sleeper/ km iv) Temp. zone IV v) Destressing temp. td = 48°C vi) Gap at SEJ at td 40 mm First of all hysteresis curve of movement of tongue/ stock

rail of SEJ will be drawn at different temperatures.

1. Movement of tongue/ stock rail from the stage of destressing temperature (point O) to the stage of maximum temperature (point A) for rising trend of temperature will be = A E2 t2/ 2R

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= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 48)2 / 2 x 13.28 = 0.557 cm = 5.57 cm Hence coordinate of maximum temperature (point A) will be

(td + 28, + 5.57)

2. Movement of tongue/ stock rail from stage of maximum temperature (point A) to stage of minimum temperature (point B) for decreasing trend of temperature will be

= A E2 t2/ 4R = 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28 = 2.052 cm = 20.50 mm Hence coordinate of minimum temperature (point B) will be

(td + 28-76, + 5.57 - 20.52) 3. Movement of tongue/ stock rail from stage of minimum

temperature (point B) to stage of maximum temperature (point A) for increasing trend of temperature will be :

= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28 = 2.052 cm = 20.52 mm

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Hence coordinate of maximum temperature (point A) will be (td -48+76, -14.95 + 20.52) or (td + 28, +5.57)

Temperature at which gap at SEJ is required is 58°C i.e. (td +10) °C say point P. 4. Value of movement of tongue/ stock rail at (td + 10) °C

point P for falling trend of temperature will be = 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 58)2 / 4 x

13.28 = 0.115 cm = 1.15 mm Hence coordinate at point P for falling trend of temperature

will be : (td + 10, +5.57 - 1.15) or (td + 10, +4.42) 5. In the same way, value of movement of tongue/ stock at (td + 10) °C point P for rising trend of temperature will be : = 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (58)2 / 4 x 13.28 = 1.195 cm = 11.95 mm

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A - GAP AT SEJ AT DISTRESSING TEMPERATURE (td) B - GAP AT SEJ AT 38° C (td + 10°C) FOR FALLING

TREND OF TEMP. C - GAP AT SEJ AT 38°C (td + 10°C) FOR INCREASING

TREND OF TEMP. Hence coordinate at point P for rising trend of temperature

will be : ( td + 10, -14.95 + 11.95) or ( td + 10, - 3.0)

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The calculations done above indicatesthat at temperature td

+ 10°C i.e. at 58°C, movement of one side of tongue/ stock rail for decreasing trend of temperature is + 4.42 and for increasing trend temperature is -3.0 mm.

Hence taking twice of movement of tongue/ stock rail for

each side of SEJ, minimum gap at SEJ for decreasing trend of temperature at td + 10 i.e. (58°C) will be 40 -2 x 4.42 = 31.16 mm and maximum gap at SEJ for increasing trend of temperature at td + 10 i.e. (58° C) will bw = 40 + 2 x 3.0 = 46 mm.

Note : * value of 40 mm taken as gap at SEJ at destressing

temperature td . In case gap is set as 60 mm value of 60 mm is to be taken for calculation .

Hence theoretical range of gap at SEJ at 58°C shall be

within (31.16 mm to 46 mm). Taking into consideration allowance as per para 5.6.1 the gap should be (31.16 - 20 = 11.16 mm to 46 + 20 = 66 mm ).

Similarly values of gaps for various temperatures, track

structures, temperature zones etc. can be calculated.

*******

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC SLEEPER, 1660 Nos/Km, VALUE OF r (BALLAST RESISTANCE) ASSUMED = 13.74 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg. rails and haviour.

Temperaure Zone I Zone II Zone III Zone IV td + 28 -- -- -- 28 td + 25 -- -- 30 28 to 31 td + 20 -- 34 30 to 35 28 to 31 td + 15 36 34 to 38 31 to 40 29 to 42 td + 10 37 to 40 34 to 42 32 to 45 30 to 47 td + 05 37 to 44 35 to 46 33 to 49 32 to 51 td 38 to 47 37 to 50 35 to 53 34 to 55 td - 05 40 to 49 39 to 53 37 to 56 36 to 59 td - 10 41 to 51 41 to 55 40 to 59 39 to 62 td - 15 44 to 53 43 to 57 43 to 62 42 to 65 td - 20 46 to 55 46 to 59 46 to 64 46 to 67 td - 25 49 to 56 50 to 61 50 to 66 50 to 69 td - 30 53 to 56 54 to 62 54 to 67 54 to 71 td - 35 56 58 to 62 59 to 68 59 to 71 td - 40 -- 62 64 to 69 64 to 73 td - 45 -- -- 69 70 to 74 td - 48 -- -- -- 74 Note : The above values have been calculated with initial setting of gaps at SEJ as 40 mm.

Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above values for comparioson of gaps at site.

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 13.28 kg/cm/rail AND td = tm + 5° C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 28 -- -- -- 27 td + 25 -- -- 30 27 to 28 td + 20 -- 33 30 to 35 27 to 31 td + 15 36 34 to 38 31 to 40 28 to 37 td + 10 36 to 40 34 to 43 32 to 45 30 to 42 td + 05 37 to 44 35 to 46 33 to 50 32 to 52 td 38 to 47 37 to 50 35 to 53 34 to 56 td - 05 40 to 50 39 to 53 37 to 57 36 to 60 td - 10 41 to 52 41 to 56 40 to 60 39 to 63 td - 15 44 to 54 44 to 58 43 to 63 42 to 66 td - 20 46 to 55 47 to 60 46 to 65 46 to 67 td - 25 50 to 56 50 to 61 50 to 67 50 to 70 td - 30 53 to 57 54 to 62 55 to 68 55 to 72 td - 35 57 56 to 63 59 to 69 60 to 73 td - 40 -- 63 65 to 70 65 to 74 td - 45 -- -- 70 72 to 75 td - 48 -- -- -- 75 Note : The above values have been calculated with initial setting of gaps at SEJ as 40 mm.


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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg ST SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 12.14 kg/cm/rail AND td = tm + 5°C to tm + 10°C kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 28 -- -- -- 26 td + 25 -- -- 29 26 to 30 td + 20 -- 33 29 to 35 26 to 36 td + 15 36 33 to 38 30 to 40 27 to 42 td + 10 36 to 40 34 to 43 31 to 46 29 to 48 td + 05 37 to 44 35 to 47 32 to 50 31 to 53 td 38 to 47 36 to 51 34 to 55 33 to 57 td - 05 40 to 50 38 to 54 37 to 59 36 to 61 td - 10 41 to 53 41 to 57 42 to 62 39 to 65 td - 15 44 to 55 44 to 60 43 to 65 43 to 68 td - 20 47 to 56 47 to 62 46 to 67 47 to 71 td - 25 50 to 58 51 to 63 51 to 69 51 to 73 td - 30 54 to 58 55 to 64 56 to 71 56 to 75 td - 35 58 60 to 65 61 to 72 72 to 77 td - 40 -- 65 67 to 73 68 to 77 td - 45 -- -- 73 74 to 78 td - 48 -- -- -- 78 Note : The above values have been calculated with initial setting of gaps at SEJ as 40 mm.


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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg PRC SLEEPER, 1660 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 13.74 kg/cm/rail AND td = tm + 5°C to tm + 10° C for 52 kg and haviour.

Temperaure Zone I Zone II Zone III Zone IV

td + 28 -- -- -- 29

td + 25 -- -- 31 29 to 32

td + 20 -- 35 32 to 36 30 to 37

td + 15 37 35 to 39 32 to 40 30 to 42

td + 10 37 to 40 35 to 42 33 to 44 32 to 46

td + 05 38 to 43 36 to 45 34 to 48 33 to 50

td 39 to 46 37 to 48 36 to 51 35 to 53

td - 05 40 to 48 39 to 51 38 to 54 37 to 56

td - 10 41 to 50 41 to 53 40 to 57 39 to 59

td - 15 43 to 51 43 to 55 42 to 59 42 to 61

td - 20 45 to 53 46 to 57 45 to 61 45 to 64

td - 25 48 to 53 48 to 58 49 to 62 49 to 65

td - 30 51 to 54 52 to 59 52 to 64 52 to 67

td - 35 54 55 to 59 56 to 64 57 to 68 td - 40 -- 59 60 to 65 61 to 69 td - 45 -- -- 65 66 to 69 td - 48 -- -- -- 69 Note : The above values have been calculated with initial setting of gaps at SEJ as 40 mm.

Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above values for comparison of gaps at site.

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg PRC SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 13.28 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour.


td + 28 -- -- -- 29

td + 25 -- -- 31 29 to 32

td + 20 -- 34 31 to 36 29 to 37

td + 15 37 34 to 38 32 to 40 30 to 42

td + 10 37 to 40 35 to 42 33 to 44 31 to 46

td + 05 38 to 43 36 to 46 34 to 48 33 to 50

td 39 to 46 37 to 49 36 to 52 34 to 54

td - 05 40 to 48 39 to 51 38 to 55 37 to 57

td - 10 41 to 50 41 to 54 40 to 57 39 to 60

td - 15 43 to 52 43 to 55 42 to 60 42 to 62

td - 20 46 to 53 46 to 57 46 to 62 45 to 64

td - 25 48 to 54 49 to 58 50 to 63 49 to 66

td - 30 51 to 54 52 to 59 53 to 64 53 to 68



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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg ST SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 12.14 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour.


td + 28 -- -- -- 28

td + 25 -- -- 30 28 to 31

td + 20 -- 34 30 to 36 28 to 37

td + 15 37 34 to 38 31 to 40 29 to 42

td + 10 37 to 40 35 to 42 32 to 45 30 to 47

td + 05 37 to 44 36 to 46 33 to 49 32 to 51

td 38 to 46 37 to 49 35 to 53 34 to 55

td - 05 40 to 49 39 to 52 37 to 56 36 to 58

td - 10 41 to 51 41 to 55 40 to 59 39 to 62

td - 15 44 to 53 43 to 57 43 to 61 40 to 64

td - 20 46 to 54 46 to 59 46 to 64 46 to 67

td - 25 49 to 55 50 to 60 50 to 65 52 to 69

td - 30 52 to 56 53 to 61 54 to 67 54 to 70



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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg CST-9 SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 10.65 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour.


td + 28 -- -- -- 26

td + 25 -- -- 29 26 to 30

td + 20 -- 33 29 to 35 27 to 36

td + 15 36 33 to 38 30 to 40 28 to 42

td + 10 36 to 40 34 to 43 31 to 46 29 to 48

td + 05 37 to 44 35 to 47 32 to 50 30 to 52

td 38 to 47 36 to 51 34 to 54 33 to 57

td - 05 40 to 50 38 to 54 37 to 58 36 to 61

td - 10 42 to 53 41 to 57 42 to 61 39 to 65

td - 15 44 to 55 44 to 59 43 to 64 43 to 68

td - 20 47 to 56 47 to 61 47 to 67 47 to 70

td - 25 50 to 57 51 to 63 51 to 69 51 to 73

td - 30 54 to 58 55 to 64 56 to 70 56 to 74



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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R PRC SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 13.28 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 47 td + 30 -- -- 49 47 to 49 td + 25 -- 52 49 to 53 47 to 54 td + 20 55 53 to 56 50 to 57 48 to 58 td + 15 55 to 58 53 to 59 50 to 60 49 to 61 td + 10 56 to 60 54 to 62 51 to 64 50 to 65 td + 05 57 to 63 55 to 65 53 to 67 51 to 68 td 58 to 65 56 to 67 54 to 69 53 to 71 td - 05 59 to 67 58 to 69 56 to 71 56 to 73 td - 10 61 to 68 60 to 71 59 to 73 58 to 75 td - 15 63 to 69 62 to 72 61 to 75 61 to 77 td - 20 65 to 70 65 to 73 64 to 77 64 to 79 td - 25 67 to 70 67 to 74 67 to 78 67 to 80

td - 30 70 71 to 74 71 to 78 71 to 81

td - 35 -- 74 75 to 79 75 to 82

td - 40 -- 62 79 79 to 82 td - 43 -- -- -- 82

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R ST SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 12.14 kg/cm/rail AND td = tm + 5° C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 45 td + 30 -- -- 48 45 to 48 td + 25 -- 52 48 to 52 46 to 53 td + 20 55 52 to 55 49 to 57 47 to 58 td + 15 55 to 58 52 to 59 49 to 61 48 to 62 td + 10 55 to 61 53 to 62 51 to 64 49 to 65 td + 05 56 to 63 54 to 65 52 to 67 51 to 69 td 57 to 65 56 to 68 54 to 70 53 to 72 td - 05 59 to 67 58 to 70 56 to 73 55 to 74 td - 10 61 to 69 60 to 72 59 to 75 58 to 77 td - 15 63 to 70 62 to 73 62 to 77 61 to 79 td - 20 65 to 71 65 to 74 65 to 78 64 to 81 td - 25 68 to 71 68 to 75 68 to 79 68 to 82

td - 30 71 72 to 76 72 to 80 72 to 83

td - 35 -- 76 76 to 81 76 to 84

td - 40 -- -- 81 81 to 84 td - 43 -- -- -- 84

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R CST - 9 SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 10.65 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 43 td + 30 -- -- 46 43 to 47 td + 25 -- 50 46 to 51 44 to 52 td + 20 54 51 to 55 47 to 56 45 to 57 td + 15 54 to 58 51 to 59 48 to 61 46 to 62 td + 10 55 to 61 52 to 62 49 to 65 47 to 66 td + 05 56 to 64 54 to 66 51 to 68 49 to 70 td 57 to 66 55 to 69 53 to 71 52 to 73 td - 05 59 to 68 57 to 71 56 to 74 54 to 76 td - 10 61 to 70 61 to 73 58 to 77 57 to 79 td - 15 63 to 71 63 to 75 62 to 79 61 to 81 td - 20 66 to 72 66 to 76 65 to 81 65 to 83 td - 25 69 to 73 69 to 77 69 to 82 69 to 85

td - 30 73 73 to 78 73 to 83 73 to 86

td - 35 -- 78 79 to 83 79 to 87

td - 40 -- -- 84 84 to 87 td - 43 -- -- -- 87

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 3.86 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 14 td + 30 -- -- 22 14 to 24 td + 25 -- 34 23 to 36 16 to 38 td + 20 43 34 to 46 24 to 49 18 to 52 td + 15 44 to 53 36 to 57 27 to 62 21 to 65 td + 10 45 to 62 38 to 67 31 to 73 25 to 77 td + 05 48 to 70 42 to 76 35 to 83 31 to 87 td 52 to 77 47 to 84 41 to 92 37 to 97 td - 05 56 to 83 53 to 91 48 to 99 45 to 105 td - 10 62 to 87 59 to 96 56 to 106 53 to 113 td - 15 69 to 91 67 to 101 65 to 112 63 to 119

td - 20 77 to 94 76 to 105 75 to 117 73 to 125

td - 25 86 to 95 86 to 107 86 to 121 85 to 129

td - 30 96 97 to 109 98 to 123 98 to 132

td - 35 -- 109 111 to 125 111 to 134

td - 40 -- -- 125 127 to 136 td - 43 -- -- -- 136

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9 SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 3.47 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 9 td + 30 -- -- 18 9 to 24 td + 25 -- 31 18 to 34 11 to 36 td + 20 41 31 to 44 20 to 48 13 to 51 td + 15 42 to 52 33 to 56 23 to 62 17 to 65 td + 10 44 to 62 36 to 68 27 to 74 21 to 78 td + 05 47 to 71 40 to 78 32 to 85 27 to 90 td 51 to 79 45 to 86 39 to 95 35 to 101 td - 05 56 to 85 52 to 94 47 to 104 43 to 110 td - 10 62 to 90 59 to 100 55 to 112 52 to 119 td - 15 70 to 95 68 to 106 65 to 118 63 to 126 td - 20 79 to 97 78 to 110 76 to 123 75 to 132 td - 25 89 to 99 89 to 113 89 to 127 88 to 137 td - 30 100 102 to 114 102 to 130 102 to 140 td - 35 -- 115 117 to 132 117 to 143 td - 40 -- -- 133 134 to 144 td - 43 -- -- -- 144

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 3.86 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 22 td + 30 -- -- 28 22 to 30 td + 25 -- 38 29 to 40 23 to 42 td + 20 46 39 to 48 30 to 51 25 to 54 td + 15 46 to 54 40 to 57 23 to 61 28 to 64 td + 10 48 to 62 42 to 66 35 to 71 31 to 74 td + 05 50 to 68 45 to 73 39 to 79 37 to 83 td 53 to 74 49 to 80 44 to 86 41 to 91 td - 05 57 to 79 54 to 85 50 to 93 47 to 98 td - 10 62 to 83 60 to 90 57 to 99 54 to 104 td - 15 67 to 86 66 to 94 64 to 103 62 to 109 td - 20 74 to 88 74 to 97 72 to 107 71 to 114 td - 25 81 to 99 82 to 99 81 to 110 84 to 117 td - 30 90 91 to 101 92 to 113 91 to 120 td - 35 -- 101 102 to 114 103 to 122 td - 40 -- -- 125 115 to 123 td - 43 -- -- -- 123

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GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9 SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED = 3.47 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour. Temperaure Zone I Zone II Zone III Zone IV td + 33 -- -- -- 18 td + 30 -- -- 25 18 to 26 td + 25 -- 36 25 to 38 19 to 40 td + 20 44 36 to 47 27 to 50 21 to 53 td + 15 45 to 54 38 to 57 29 to 61 24 to 65 td + 10 46 to 62 40 to 66 33 to 72 28 to 75 td + 05 49 to 69 43 to 75 37 to 81 33 to 85 td 52 to 76 48 to 82 42 to 89 39 to 94 td - 05 57 to 81 53 to 88 49 to 97 46 to 102 td - 10 62 to 85 60 to 94 56 to 103 54 to 109 td - 15 68 to 89 67 to 98 64 to 108 62 to 115 td - 20 76 to 91 75 to 101 74 to 113 72 to 120 td - 25 84 to 93 84 to 104 84 to 116 83 to 124 td - 30 93 95 to 105 95 to 118 95 to 127 td - 35 -- 106 107 to 120 108 to 129 td - 40 -- -- 120 121 to 130 td - 43 -- -- -- 130

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** Movement of rail shall be positive in the direction of

traffic on double lines and in the direction of heavier traffic on single lines which shall be specified.

(a) and (b) will almost always be positive. Left and right rails on single lines are determined,

looking in the direction of increasing kilometrage. The reference line for each SEJ shall be marked by two

rail pieces in such away that it is central with respect to the tip of the tongue and the edge of the foot of stock rail where planning ends (a+b) at the time of destressing done immediately after laying of LWR/ CWR. The following line should not be shifted at any subsequent destressing.

The reference marks at the centre of LWR/ CWR shall

consist of (a) saw marks on the rail pieces fixed as reference pillars on the cess and (b) paint marks on the non-gauge side of the rail heads of the LWR/ CWR rails. Additional reference pillars may erected to observe the behaviou of movement of LWR/ CWR.

***

CAMTECH/C/04


26

NOTES

CAMTECH/C/04


27

To upgrade Maintenance Technologies and Methodologies

and achieve improvement in productivity and performance

of all Railway assets and manpower which inter-alia would cover

Reliability, Availability, and Utilisation.

OUR OBJECTIVE

If you have any suggestion & any specific comments, please write to us : Contact person : Jt. Director (Civil) Postal : Centre for Advanced Address : Maintenance Technology, Maharajpur, Gwalior (M.P.) Pin code – 474 020 Phone : (0751) - 470869, 470803 Fax : (0751) - 470841

Documents

HANDBOOK ON MAINTENANCE OF SWITCH EXPANSION JOINT on... · Handbook on Maintenance of Switch Expansion Joint Dec, 97 6 FOREWORD Indian Railways have a running track of about 81,000