Professional Documents
Culture Documents
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
Excellence in Maintenance
TECHnology
Maharajpur, GWALIOR - 474 020
Dec, 97
CAMTECH/C/04
HANDBOOK
ON
MAINTENANCE OF
SWITCH EXPANSION
JOINT
Dec, 97
CAMTECH/C/04
CONTENTS
S.No.
Description
Page
1.
INTRODUCTION
2.
MAINTENANCE OF SEJ.
3.
GAPS AT SEJ.
4.
DAMAGE TO SEJ.
5.
BUCKLING OF TRACK
6.
i.
11
ii.
Dec, 97
CAMTECH/C/04
S.No.
Description
Page
iii.
13
iv.
14
v.
15
vi.
16
vii.
17
viii.
18
ix.
19
x.
20
xi.
21
xii.
22
xiii.
23
xiv.
24
Dec, 97
CAMTECH/C/04
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
Date : 10 July,98
R.S.Dubey
Joint Director (Civil)
Dec, 97
CAMTECH/C/04
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
Date : 20th July, 1998
D. K. Saraf
Director
Dec, 97
CAMTECH/C/04
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.
3.
MAINTENANCE OF SEJs
GAPS AT SEJ
Gaps at SEJ shall be adjusted at the time of laying/
subsequent destressing of LWR/CWR.
Rail section laid
52 kg/60kg
others
Gap to be provided at td
40mm
60mm
Dec, 97
CAMTECH/C/04
4.
Dec, 97
CAMTECH/C/04
5.
BUCKLING OF TRACK
General
Buckling or a tendency towards buckling may occur, among
others, in the following circumstances :-
*****
Dec, 97
CAMTECH/C/04
2.
(/)
Rail Section
Area
(cm2)
E
(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 -
Dec, 97
CAMTECH/C/04
Table - II
LONGITUDINAL BALLAST RESISTENCE (R) FOR
VARIOUS SLEEPERS AND SLEEPER DENSITY.
Type of sleeper
Metre Gauge
12.93
11.48
9.92
7.58
13.28
12.14
10.65
7.97
1660 sleepers/km
13.74
12.68
11.04
8.06
1540 sleeper/ km
-3.86
3.47
5.0
Table - III
INITIAL GAP TO BE PROVIDED AT DESTRESSING
TEMPERATURE (td)
Rail Section
60 Kg(UIC)/ 52 Kg
Other
EXAMPLE
40 mm
60 mm
Dec, 97
CAMTECH/C/04
Rail section
Type of sleeper
Sleeper density
Temp. zone
Destressing temp.
Gap at SEJ at td
52 kg/m
PRC
1540 sleeper/ km
IV
td = 48C
40 mm
Dec, 97
CAMTECH/C/04
2.
3.
Dec, 97
CAMTECH/C/04
5.
Dec, 97
CAMTECH/C/04
ABC-
Dec, 97
CAMTECH/C/04
10
*******
Dec, 97
CAMTECH/C/04
11
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.
Dec, 97
CAMTECH/C/04
12
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
59 to 69
60 to 73
td - 35
57
56 to 63
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.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.
Dec, 97
CAMTECH/C/04
13
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
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 :
60 to 65
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.
Dec, 97
CAMTECH/C/04
14
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
55 to 59
56 to 64
57 to 68
td - 35
54
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.
Dec, 97
CAMTECH/C/04
15
Zone I
Zone II
Zone III
Zone IV
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
56 to 60
57 to 65
57 to 69
td - 35
55
td - 40
--
60
61 to 66
td - 45
--
--
66
td - 48
--
--
--
Note :
62 to 69
67 to 70
70
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.
Dec, 97
CAMTECH/C/04
16
Zone I
Zone II
Zone III
Zone IV
28
td + 28
--
--
--
td + 25
--
--
30
td + 20
--
34
30 to 36
28 to 37
td + 15
37
34 to 38
31 to 40
29 to 42
28 to 31
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
td - 35
56
58 to 68
59 to 71
td - 40
--
62
63 to 68
64 to 72
td - 45
--
--
68
69 to 73
td - 48
--
--
--
73
Note :
57 to 62
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.
Dec, 97
CAMTECH/C/04
17
Zone I
Zone II
Zone III
Zone IV
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
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
td - 35
58
61 to 71
61 to 76
td - 40
--
65
66 to 72
td - 45
--
--
72
73 to 77
td - 48
--
--
--
77
Note :
62 to 65
29 to 48
67 to 77
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.
Dec, 97
CAMTECH/C/04
18
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
47
td + 30
--
--
49 47 to 49
td + 25
--
52
td + 20
55
49 to 53
53 to 56
50 to 57
47 to 54
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
Dec, 97
CAMTECH/C/04
19
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 80
72 to 83
td - 35
--
76
76 to 81
76 to 84
td - 40
--
--
81
81 to 84
td - 43
--
--
--
84
72 to 76
Dec, 97
CAMTECH/C/04
20
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
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 83
73 to 86
td - 35
--
78
79 to 83
79 to 87
td - 40
--
--
84
84 to 87
td - 43
--
--
--
87
57 to 71
73 to 78
Dec, 97
CAMTECH/C/04
21
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
td - 43
--
--
125
127 to 136
--
--
--
136
Dec, 97
CAMTECH/C/04
22
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
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
102 to 114
102 to 130
102 to 140
td - 30
100
td - 35
--
115
117 to 132
117 to 143
td - 40
--
--
133
134 to 144
td - 43
--
--
--
144
Dec, 97
CAMTECH/C/04
23
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
92 to 113
91 to 120
td - 35
--
101
102 to 114
103 to 122
td - 40
--
--
125
115 to 123
td - 43
--
--
--
123
91 to 101
Dec, 97
CAMTECH/C/04
24
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 118
95 to 127
td - 35
--
106
107 to 120
108 to 129
td - 40
--
--
120
121 to 130
td - 43
--
--
--
130
95 to 105
Dec, 97
CAMTECH/C/04
**
25
Dec, 97
CAMTECH/C/04
26
NOTES
Dec, 97
CAMTECH/C/04
27
OUR OBJECTIVE
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.
Postal
Address
:
:
Phone
Fax
:
:
Dec, 97