PRESENTATION ON
!
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Irregular Settlement Defects at special track Positions P&C, joints,
SEJ, LCs Damage of Ballast at places with irregularities
eg. Rail defects, welded joints, insulating rail joints, bridge approaches.
Track maintenance after 30-60 million tonnes / after track has settled about 20 mm
Deep screening after 10 years Complete ballast renewal after 30 years.
PRIME REASONS
High frequency vibrations Uneven settlements
FIG. 1
DISPERSION OF CONTACT STRESSES
1.210100Ballast-Formation
52380Sleeper-Ballast
25510Bearing Plate-sleeper
62200Rail-Bearing Plate
42003Rail- Wheel (25 t -axle load)
Pressure (kg/cm2)
Area (cm2)Location
TRACK MODULUS FOR DIFFERENT TYPES OF SOIL
150-200250-300Concrete bottom /stone/rock
100-150150-200Very good gravel/rock
80-100100Good course sand/gravel 5050Poor soft to rigid
2020Very Poor fine grained MoorumBallast
Track Modulus N/cm3Soil Type
DESIRABLE CHARACTERISTICS
Rail settlement > 1.2 mm
Track Modulus 0.1 N/mm2
Rail foot tension 60 N/mm2
FUTURE SCENARIO
Quarrying may be banned Long lead cost implications Restrictions on maintenance time
Technological development and research in Railway track construction has lead to introduction of BLT usually referred as slab track. This system was first introduced in Japan in late 60s.
BALLAST LESS TRACK (BLT)
A VIEW OF BLT ON ELEVATED TRACK
FIG. - 4
ADVANTAGES Reduced maintenance cost Reduced traffic blocks Low structure height Dust free Road rescue vehicles can ply over BLT in
tunnels
ADVANTAGES & DISADVANTAGES
DISADVANTAGES Requires high precision laying by automated
machines Expert supervision High cost of construction- about 1.5 to 2 times
over the conventional Ballasted track. Derailments can cause costly damage Repair work is more complicated Increase in noise level
ADVANTAGES & DISADVANTAGES
Firm formation (Normally used in tunnels) Investigate upto 6m depth, every 50m Upto 2.5m below, in normal case and upto 4m
in clay soils- earthwork of designed Qlty Take care in deep cuttings Compaction of Highest quality Formation profile +/- 2mm Hydraulically Bonded layer-300mm On formation additional cost 2 to 2.5 times
ESSENTIALS FOR BLT SYSTEM
Efficient drainage in tunnels Design for Piezometric head Transitions to be designed Advance planning for signaling and track
circuiting.
ESSENTIALS FOR BLT SYSTEM
IMPORTANT ISSUES Expected life 50-60 years Not preferred in Earth quake areas Alteration in geometry not possible
Fixed cant values Fixed curvature and transitions
DEFECTS DUE TO WATER INGRESS
DAMAGE TO POLYSULPHIDE
WATER OOZING FROM BOTTOM
TYPES OF SLAB TRACK Rheda- ----continous sleeper trough Rheda-Berlintwin block with
untensioned reinforcement Rheda-2000Modified twin block
sleeper with braced girder reinforcement Heitkamp Design- concrete trough gravel
filling Zublin Design- 10 sleepers inserted into
unset concrete
TYPES OF SLAB TRACK Laid-on design- slab track on asphalt SATO design FFYS design ATD design- BTD design GETRAC design Lawn slab Track- two beams, central
grass
TYPES OF SLAB TRACK FFC design-Concrete sleeper of length Bogl design OBB-Porr design Plate track in Japan (Shinkansen) INFUNDO design- Rail sealed in synthetic
material SFF design longitudinal sleeper SAARGUMMI design
BLT SYSTEMS IN USE AROUND THE WORLD
BLT SYSTEMS
Support @ discrete points Embeded Rail Structure
Netherland
BLT SYSTEMS
Support @ discrete points
Twin Block (bi-block system) Monoblock System
Cast in- situ Prestressed monoblock sleepers into pretensioned slab
BLT SYSTEMS
Cast- in- situ
StedefFrance
SonnevilleFrance
ShinkansenJapan
Edilon blockNetherland Swisswalo
RhedaGermany
ZubinGermany
Prefabricated Germany
BLT SYSTEMS
RhedaGermany
Rheda 2000 Rheda Berlin RhedaRathenow ATD GETRACA 1
BLT SYSTEMSPrestressedmonoblock
sleepersembeded
in to pretensioned slab
OBB-PorrAustria
PorrAustria
ZublinGermany
BLT SYSTEMS
Embeded RailStructure
Low Noise SA 42BB
EmbededRail
ERIA (EmbededRail in Asphalt
FIG.- 3
FEATURES OF SHINKANSEN SLAB TRACK (JAPAN)
Size of Slab: 4.93X2.34X0.19/ 0.16 Cylindrical Stopper: To restrict longitudinal
and lateral movement Sleeper blocks kept in position with rubber pad
below and side and grouted to concrete bed. Blocks are fixed over deck slab having required
cantt.
FEATURES OF GERMAN SLAB TRACK
15 cm reinforced bed. 20 cm light concrete 14 cm, M35 concrete Concrete sleeper embedded grouted 10mm rod passes through 3 cm dia. hole
horizontally.
A VIEW OF BLT
FEATURES OF BLT ON KONKAN RAILWAY
Total length 22 km on Roha-Mangalore Section. Existing PSC sleeper are embedded into the
concrete bed. Rubber pad below sleeper. Polyethylene Foam used around the sleeper.
FASTENINGS OF SLAB TRACK
Insulation & resilience GRP under rail seat Microcellular pad below bearing plates Steel clips/ Liners with insulation coating Anchor bolts Hole in slab for fixing inserts with epoxy 2 stages of resilience. Resilient pad below sleeper block CAM under Concrete slabs (Japan)
GENERAL METHOD OF CONSTRUCTION
Sleeper cast into concrete slab In embedded sleeper - cast into slab, rubber
boots provided for elasticity Special slip form paver lay concrete slab
following which sleeper fitted with pads position and cast in suite
OBB-Porr, monoblock sleeper enclosed in rubber are cast in prefabricated slab.
In top-down system place rails & lock first in position and casting using corkelast to provide elasticity
BLT SYSTEMS IN USE IN DIFFERENT COUNTRY
Germany, Netherland, Tyavan, Spain, Bretain,DMRC,SR
1993-2006
160-350270++Rheda Family 2
1964
Year of Laying
Tokyo, S.Koria & Rome
350 km1010 (D/L)
Shinkansen(Japan)
1
Country Speed Potential
KMName of System
Sr.No
DEVELOPMENT IN INDIA Introduction of BLT in India started decades
back, first by Calcutta Metro followed by Konkan Railway, Chennai Metro and Delhi Metro.
The scope for development of the system is very large due to future development planned for Mumbai Metro, Bangalore Metro and introduction of high speed Routes.
Technological innovation is therefore a must to accomplish the task of above mentioned Metro Systems.
FIG - 2
FIXED DIMEN SION
A
A
A
SHEAR CONNECTORIN VER T LINING
KERB CONCRETE
C.L. OF TUNNEL & TRACK
FINISHED LINE
OVER T LINING
MINIMUM EXCAVATION L INE
DR AIN
RAIL TOP
STEEL RIBS ISHB 150 X 150 @ 34.6 KG /M
100 MM TH. SH OTCRETE WITH WIR E MESH
FUTURE DEVELOPMENT Modified form of KRCL earlier design/development. Based on indigenous fittings Embedded systems/ Slab system Top down construction
FASTENINGS
BEARING PLATE AND ANCHOR BOLTS ELATOMERIC PADS ELASTIC FITTINGS INSULATIONS SHEAR CONNECTOR
WORK IN PROGRESS-MTP
PERFORATED PLATE
FIG.- 5
BALLASTLESS TRACK
RAIL TOP
DRAIN
STEEL RIBS ISHB 150 X 150 @ 34.6 KG /M100 MM TH. SHOTCRETE WITH WIRE MESH
OVERT LINING
C.L. OF TUNNEL
MINIMUM EXCAVATION LINE
FINISHED LINE
300mm THICK LININGSTEEL RIBS ISHB 150 X 150 @ 34.6 KG /M
LEVEL LING COURSE 1:3:6
NEED FOR MAINTENANCE MANUAL
Check of wear on fastenings. Level and gauge Rail defects Concrete slab defects
CONCLUSION An effort should be made in the right earnest to
develop future BLT for mass utilization for the construction in Indian Railways with high precision accuracy by automated machines which infact can save lot of Foreign Exchange revenues.