Maintenance of P.

Way

N.R.Kale
AXEN/1
Responsibility of Engineering officials
(Para 201)
 Devote careful and continuous attention towards the
efficient upkeep of track.
 To achieve good and smooth running quality.
 Running quality should be adjudged by riding on -
 Locomotive
 Rear vehicle of fast trains.
 Condition of track is best judged by-
 Track recording cars
 oscillograph cars
 Portable accelerometer etc.
 Maintain record of inspection.
 Ensure compliance of inspections.
Classification of Lines (B.G.)
(As per CS No.109 Dated 15.02.08)
Sr.No. Gauge Route Speed Potential
1 B.G. A Upto 160 kmph
2 B Upto 130 kmph
3 C Suburban section of Mumbai, Delhi, Chennai and
Kolkata
4 D Spl Upto 110 kmph Tfc density -20 GMT or more

4 D Upto 110 kmph Tfc density – less than 20 GMT

5 E Speed up to 100 kmph
6 M.G. Q More than 75 kmph, Tfc. Density - more than 2.5
GMT
7 R 75 kmph, Tfd. density - less than 1.5 GMT
8 S 75 kmph, Tfc. density – less than 1.5
Systems of Track maintenance-
Para 203
 Conventional system of track maintenance
 3-tier system of track maintenance
 Periodical overhauling ( 3 to 5 years)
 After monsoon attention to run down length
as early. Then start -
 Overhauling/trough packing
 Picking up of slacks - 2-3 days in a week
3-tier system of track maintenance
 On track machines (OMU)
 Systematic tamping of plain track/P&Cs
 Intermediate tamping
 Shoulder ballast cleaning
 Ballast profiling/redistribution
 Track stabilisation
 Periodical deep screening
 Mobile maintenance units (MMU)
 MMU-I
 MMU-II
 Sectional gangs
Mobile Maintenance Units (MMU)
 MMU-I (For 90 to 100 km track)
 Rail cum road vehicle based
 Need base spot taming
 In-situ welding
 Casual renewal
 O.H. of LCs
 Replacement of GJs
 Attending Rail failures
 Creep or gap adjustment
 Destressing of LWR/CWR
 Loading unloading of materials
 Any other work as assigned
Mobile Maintenance Units (MMU)

 MMU – II
 Road vehicle based
 One for each sub division
 Reconditioning of P & Cs
 Minor repairs to the equipments of MMU
Mobile Maintenance Units (MMU)

 Sectional Gangs
 Patrolling of track –Daily, Hot/cold, Monsoon
 Watching vulnerable locations
 Attention of emergencies
 Need-based attention to bridges, T/outs, SEJs,
approaches of LCs
 Greasing of ERCs, Lubrication of joints, casual
changing of rubber pads/other fittingss
 Minor cess repairs
Mobile Maintenance Units (MMU)
Sectional gang (Contd. …)
 Cleaning of drains and boxing of ballast
 Attention to loop lines
 Creep and gap adjustment not involving machines
 Cleaning of crib ballast for effective cross
drainage
 Pre & Post tamping attention
 Assistance to OMU/MMU as required
 Any other function as assigned
 Annual Programme for regular Track
Maintenance ( Para 204)
Post monsoon attention a. Attention to run down lengths in the
entire gang beat
(Six months after end of b. One cycle of conventional
monsoon) T.Pkg/Systematic DTM (4-5 days)
c. Remaining days – Picking up of slacks,
attention to bridge approaches, LC,
Lubrication of joints etc

Pre monsoon attention 2-4 days in a week for clearing

(Two months prior to side drains, catch water drains,
monsoon) repairs to cess.

Attention during monsoon Attention to track as required.

(Four about months)
Record of Gang work (Para 206)

 Gang diary
 Gang chart
 Scrutiny of records by ADEN/DEN during
their inspection
 Preserve records for 5 years by SSE/P.Way
(C.S. No. 114)
 Inspection of gang equipments to be
recorded in gang chart/ gang diary by SSE
Contd. …

 Attention to Inspection notes

 Record of work of Artisans and other
workmen employed
 Half Yearly reports on the condition of
Permanent Way to be submitted by SSE to
DEN through ADEN as per Annexure 2/19
(C.S.No 99)
Section Register (Para 210)

 Administration
 Change in SSE/SE/PWS/Clerks
 Change in Jurisdiction
 Permanent Way
 Formation – Section giving frequent trouble and
remedial measures adopted if any
 Track Structure
 Track with SWR/LWR incidence of buckling
Section Register (contd. …)
 Grades – Details of regrading
 Curves – Details of realignment
 Ballast – Location having deficiency, details of
deep screening
 Creep adjustment
 P.Way Renewals
 Station yard and sidings – Extension or alteration
done if any
 Rail failures
Section Register (contd. …)
 Rail testing and renewals – Record of USFD testing and
removal of defective rail/welds
 Fish plate failures
 Lubrication of rail Joints
 Material under trial
 Track recording
 Bridges and floods
 Record of rain fall
 Damage due to floods
 List of RAW
 List of vulnerable locations where stationary watchman to
be posted.
Section Register (contd. …)

 Miscellaneous
 Availability of labour on section
 Details of Encroachment and steps taken to
remove them
 Infringement particulars
 Accidents attributed to P.Way.
 List of reference books available in the section
 Any other information necessary
Para 211-Permanent plan and
diagram
ADEN shall have a set of following –
 IRS track manual or IRS type plans

pertaining to track section and turnouts of

their section.
 Plan and longitudinal section of the line.

 Drawing of bridges, LC, protective work and

yard layout of their section.

 Permanent diagram of their section.
Records of Material under trial (Para
212)
 Register – To be maintained by ADEN
 Particulars of entries
 Trial lengths – If possible, near ADEN’s H.Q.
 Indication plates
 Submission of register to DEN
 SSE’s Records – To be scrutinized by ADEN
during inspection
Other para of chapter no.2

 Para 213 – Strength of gang.

 Para 214 – Musters
 Para 215 – Custody of gang tools
 Para 216 – Section limit boards
 Para 217 – Km and gradient posts
 Para 218 – Telegraph pole Numbers
 Para 219 – Verification of land boundaries
 Para 220 - Provision of Trolley refuse as per CS
No 116 of IRPWM
Location Distance
Maximum distance should not be more than 1Km subject to
following
Cutting in straight 200M
Cutting in curve 100M
High Embankment 200M
Tunnel 100M
Bridges with span less than 100 m 100M
Bridges with spans of 100 m or more On each pier
 Para 222 – Felling of trees obstructing views.
 Para 223 – Side drains, catch water drains
and water ways.
MANUAL
MAINTENANCE OF
TRACK
Through Packing (Conventional
maintenance by beater packing)
 This is the main activity of track
maintenance under manual track
maintenance.
 Trough packing is done on a programme
basis after the monsoon from one end of
the section to the other.
 Generally started from 1st October of every
year.
Sequence of activity

 Through packing consists of the following

works being done systematically in the
following sequence
i) Opening of road
ii) Examination of rail, sleepers and fastenings
iii) Squaring of sleepers
iv) Alignment of track
Contd. …

V) Gauging
vi) Packing of sleepers
vii) Repacking of joint sleepers
viii) Boxing ballast section and tidyng
Opening of road

Under this operation, ballast is opened out on

either side of the rail seat for a depth of 50
mm below the bottom of sleeper with the help
of shovel or Powrahs.
The width of opening should be up to end of
sleeper on out side and on the inside it
should be 450 mm for B.G, 350 mm for M.G
and 250 mm for N.G.
Examination of rails, sleepers and
fastenings
a) Rails should be examined, the underside for
corrosion, the ends for cracks, the head for side
wear.
b) Sleepers should be inspected for their condition
and soundness particularly at the rail seat.
Defective if any to be replaced.
c) All Fastenings are checked and tightened, missing
fittings are recouped.
d) Kinks if any, in the rails are removed by jim-
crowing
Squaring of sleepers
 Gauge variations and kinks inevitably results
from sleepers getting out of square.
 The spacing of sleepers on the sighting rail
should first be checked and correctly chalk
marked the transferred to opposite rail using
the square at every point.
 Squaring should be done by planting the
crow bars firmly against the sleepers and
pushing it.
Aligning the track

 The alignment of the track is normally

checked by “eye judgment”, sighting the rail
from a distance of about 50 meters
 Slewing is done by about 6 persons by
planting the crow bar deep in the ballast at an
angle not exceeding 30 degree from the
vertical.
Gauging –Tolerances for BG/MG, NG
(With respect to 1676mm)
On straight track -6 mm to +6 mm/
-3 mm to + 6 mm
On curve with radius of -6 mm to +15 mm/
more than 440 m for BG, -3 mm to +15mm
290 m for MG and 175 m
for NG
On curve with radius of Up to + 20 mm
less than 440 m for BG,
275 m for MG and 175 m
for NG
Packing of sleepers
 The base rail is sighted by mate with eye along the
lower edge of the head of rail and the dip or low
joints are lifted correctly to ensure a perfect
longitudinal level of the sighting rail
 The adjacent sleeper to be packed.
 Attend opposite rail after checking with cross level at
every 4th sleeper and every joint.
 No joint or dip should be lifted higher than the
proper level.
Contd. …

 The sleepers are than packed by beaters

 4 men/sleeper
 First break cores with the pick end then use
blunt end for packing.
 First pack the rail seat then towards end and
inside the track.
 The Beaters should not be lifted above the
chest level.
Contd. …

 Ensure that no sleeper is centre bound in

case of wooden/Steel sleepers.
 In case of CST-9 plates main packing should
be done at corners.
 On pot sleepers tamp by crow bars through
holes on top of the pot.
 Mate will check the packing by tapping with
wooden mallet before boxing.
Repacking of Joint sleepers

The joint and shoulder sleepers are once

again repacked before boxing of ballast and
the cross levels checked.
Boxing to ballast section and tidyng

 Ballast section is than properly boxed and

dressed with the help of a special template
 The cess should be dressed up and level
maintained
 Too high cess affect drainage and too low
cess result in ballast spread and wastage.
Systematic Overhauling

 Normally commenced after completion of

one cycle of through packing
 Consists of following operation
a. Shallow screening and making up of ballast
section
b. All items included in through packing
c. Making up the cess
Shallow Screening

 Open out the ballast 50 to 75 mm blow the

bottom of sleeper.
 For machine maintained track 75 to 100 mm.
 Shoulder ballast to be removed to the full
depth.
 Screen the ballast and put back in to track.
Precautions for O.H.

 Ensure that extra quantity of ballast is

available at site.
 The core under the sleepers must not be
disturbed.
 Between two sleeper cribs, where work in
progress, there should be at least two cribs
where ballast is not disturbed.
Contd. …

 Overhauling work should be taken up only in

alternate rail length to preserve the track
geometry.
 In LWR overhauling should be done only in
winter when rail temp not exceed td +10
 In breathing length td +/- 5 degree C.
 Cess when high, should be cut along with
overhauling.
Deep Screening of Ballast

Purpose for deep screening

1) To improve drainage of track

2) To improve elasticity of the track
3) To maintain track geometry
4) To improve running of the track
Contd. …

When Deep Screening is required?

 Prior to CTR

 Prior to TSR

 When the caking of ballast has resulted in

unsatisfactory riding.
 Before conversion of fish plated track in to
LWR
 Entire track once in ten year
Contd. …

 In case of bad formation , treatment should

be carried out along with deep screening.
Prior Survey
 Longitudinal section of the track to be taken
indicating the RL at every 30 meters.
 In station yard, on the through lines, cross
section at every 50 meters indicating
platform level, rail level, clearance of OHE
Contd. …

On the basis of longitudinal and cross

sections, the final levels will be decided
keeping in view -
 The depth of ballast cushion to be provided.

 The relative implications of lifting or lowering

 The possibility of eliminating humps, sags

and unevenness in the existing longitudinal

section.
Preliminary works for D/Screening

 Arrangement of additional ballast at site.

 Cess to be brought up to correct level in
relation to the final Rail level.
 Pegs should be provided at 30 meter
distance, indicating final Rail level.
 Realignment of curve in advance.
 Sleeper renewal if required, in advance.
Procedure for D/Screening

 Remove ballast from space ‘A’ and ‘B’,

Support the rail with wooden blocks.
 Remove ballast from under sleeper ‘1’
 Screen the ballast and place back under
sleeper ‘1’and pack.
 Remove wooden blocks from space ‘A’
 Remove the ballast from space ‘C’, screen
and place at ‘A’
Procedure for D/Screening

A ! B 2 C 3 D 4 E

GL
Contd. …

 Support the rail with wooden blocks at ‘C’

 Remove ballast from under sleeper
‘2’,screen, put back and pack.
 Remove the ballast from space ‘D’, screen
and place at space ‘B’
 Remove the ballast from under sleeper ‘3’,
screen. put back and pack the sleeper.
 Lift the track to final level
Contd. …

 Work to be done opposite to direction of

traffic in D/line section.
 No unscreened length should be left between
screened length.
 When ballast is removed from any sleeper,
ensure that at least four fully supported
sleepers are there between next sleeper
tackled.
Contd. …

 Lifting should be limited to 50 mm at a time.

 Before closing the day work, ensure proper
packing, cross levels and grade run off.
 Work should be done under SR 20 kmph.
 Speed should be increased gradually as per
schedule given in IRPWM.
 Work must be done in the presence of
certified PWS (competency certificate should
be issued by CTE)
Proposed schedule for relaxing speed
restriction (Manual Packing)
Details of the work Day of SR (B.G.) SR (M.G.)
work Kmph Kmph
Deep screening and 1 20 20
initial packing
First T.Pkg. 2

Secong T.Pkg. 3

Picking up slacks as 4-9 45 30

required
Third T.Pkg. 10
Proposed schedule for relaxing speed
restriction (Manual Packing)
Details of the work Day of SR (B.G.) SR (M.G.)
work Kmph Kmph
Picking up slacks as 11-19 75 60
required
Fourth T.Pkg. 20

21 Normal Normal
onwards Speed Speed
Proposed schedule for relaxing speed
restriction (Machine Packing) B.G
Details of the work Day of work SR
(Kmph)
Deep screening and initial 1 20
packing
First Machine pkg. 2

Picking up slacks as 3-5 45

required
Second Machine pkg. 6
Proposed schedule for relaxing speed
restriction (Machine Packing) B.G.
Details of the work Day of work SR (B.G.)
Kmph
Picking up slacks as 7-8 75
required
Third Machine pkg. 9

10 onwards Normal
Speed
Picking up slacks

 Slacks are normally those particular points in

the track where running is bad.
 Generally it occur in the following cases-
 Stretches of yielding formation
 Curves, when not realigned properly.
 Approaches to level crossing, girder bridges etc.
 Portions of track having poor drainage
Contd. …

 During picking up slacks, it may be

necessary to pack only following-
 Joint sleepers and two other sleepers on
either side.
 A few sleepers in approach of level crossings
and bridges.
 Stretches of track running rough as revealed
from inspection notes.
Lifting of track

Following precautions to be taken during lifting

operation
 Level pegs should be fixed at suitable
interval.
 Should be done under speed restriction

 Maximum 75 mm in one stage.

 The easement grade should not be steeper

than 25 mm in one rail of 13 meter
Contd. …

 In single line work should commenced from

down hill and carried out in the direction of
rising gradient.
 In double line work should be done in the
opposite direction of traffic.
 Work should only be done under supervision
of competent authority
Minimum Supervision level (As per
CS No.128 dated 05.03.12)
Type of work Supervision Remarks
Level
Lifting / lowering during through Gang mate
packing or picking of slacks during
normal maintenance
Lifting / lowering up to 50 mm during PWS
in other maintenance
Lifting / lowering beyond 50 mm Certified Competency certificate
PWS issued by CTE
Mechanized lifting / lowering SE / SSE
P.Way
Note: For LWR track, provision of LWR manual will be followed
Lowering of track

 As far as possible lowering should be

avoided as this gives unstability to the track,
quite a difficult, time consuming and costly
proposal.
 In unavoidable cases this should be done

with following precautions

I) Trenches should be made across the track at
every 30 meter interval to the final level.
Contd. …

 Not more than 75 mm at a stage

 Easement grade not to exceed 25 mm in one
rail of 13 meter.
 Should be done in the direction of falling
grade.
 Work should be done under the supervision
of JE/P.way
 Lubrication of Rail Joints
Purpose of lubrication/ Oiling and greasing
 To allow for free expansion and contraction of rails.

 To reduce wear and tear on fishing planes of rails and

fish plate.
 Duration- Once in a year. In yard this may be

extended to once in two year with the approval of chief

engineer.
 To be done during moderate season avoiding rainy

season.
Contd. …
Material required for 100 joints

Plumbago (Dry Graphite) 5 Kg

Kerosine Oil 2nd quality 3.5 liters

Black or reclaimed oil 2.75 liters

Precautions during Lubrication

 Not more than one joint to be opened at a

time.
 Work should not be done during extreme
temperature or when the rails are in tension.
 Only one fish plate to be tackled at a time.
 Spare fish plate and bolts must be available
at site.
Thanks