TURNOUTS

ON
INDIAN RAILWAYS

BY:
P.UPADHYAY
DY.DIRECTOR/TRACK
RDSO/LUCKNOW
 1. VARIOUS TYPES OF TURNOUTS WITH CURVED SWITCHES AND CMS
CROSSINGS ON FANSHAPED PSC SLEEPERS BG 60/52 Kg
Rail T.O. SEA Switch Length Length Lead Xing. Length of Length Speed
Sec Drg.. Drg. of of Rad. Drg. No. Xing. of T.O Potential
. NO. NO Switch T/Rail S.J to
mm mm mm mm HOC Kmph
mm

52 1:8.5 0º-46´- RT- 6400 11900 232260 RT-4867 3300 28511 25

Kg RT-4865 59" 4866
60 1:8.5 0º-46´- RT- 6400 11900 232260 RT-4967 3300 28511 25
Kg RT-4865 59" 4966

60 1:8.5 0º-46´- RT- 6400 11900 232260 RT-4967 3300 28511 25

Kg RT-6279 59" 6280
(Thick (Zu-1-
Web )
60)

52 1:12 0º-20´- RT- 10125 12356 441360 RT-4734 4350 39975 50

Kg RT-4732 00" 4733
52 1:12 0º-20´- RT- 10125 12356 441360 RT-4734 4350 39975 50
Kg RT- 00" 5169
(CR-
100) 5168
52Kg 1:12 0º-20´- RT- 10125 12356 441360 RT-4734 4350 39975 50
(Thick
web)
RT-5268 00" 5269
(Zu-2-49)
Contd…..

Rail T.O. SEA Switch Length Length Lead Xing. Length Length Speed
Section Drg.. Drg. of Radius Drg. of Xing. of T.O Potential
of No
N0 NO Switch Tongue S.J to
mm Rail mm HOC Kmph
mm mm
mm

60Kg 1:12 0º-20´- RT- 10125 12356 441360 RT- 4350 39975 50
00" 4219 4220
RT-
4218
60Kg 1:12 0º-20´- RT- 10125 12356 441360 RT- 4350 39975 50
(Thick RT- 00" 6155 4220
web) 6154
(Zu-
1-60)
60Kg 1:16 0º-20´- RT- 11200 12935 784993 RT- 5400 51582 66
RT- 00" 5692 5693
5691
60Kg 1: 20 0º-20´- RT- 12460 13000 1283100 RT- 6200 63924 85
RT- 00" 5859 5860
5858
 SPECIAL LAYOUTS
• A. SYMMETRICAL SPLITS
Rail T.O. SEA Switch Length Length Lead Xing. Length Length Speed
Section Drg.. N0 Drg. of of Radius Drg. of of T.O Potential
NO Switch Tongue No Xing. S.J to
Rail HOC Kmph
mm mm mm mm mm

52KG 1:8.5 0º-46´- RT- 6400 11900 464070 RT- 3300 28538 40
RT-5353 59" 5354 4867
60 KG 1:8.5 0º-46´- RT- 6400 11900 464070 RT- 3300 28538 40
RT-5353 59" 5354 4967
52Kg 1:12 0º-20´- RT- 10125 12356 882290 RT- 4350 39975 70
RT-5553 00" 5554 4734
60Kg 1:12 0º-20´- RT- 10125 12356 882290 RT- 4350 39975 70
RT-5553 00" 5554 4220
B. 1:8.5 B.G 52 Kg DIAMOND CROSSING ON PSC
SLEEPERS
 Without slips : RT- 5362
 With Single Slips : RT- 5363
 With double slips : RT- 5364
 Obtuse crossing (CMS) : RT- 5265
 Acute crossings (CMS) : RT- 4867

C. 1:8.5 BG 60 Kg SCISSORS CROSS

OVER ON PSC SLEEPERS

• Crossing assembly : RT-6092

• Acute LH (CMS) : RT- 6093
• Acute RH (CMS) : RT-6096
• Obtuse (CMS) : RT-6099

D. DERAILING SWITCHES ON PSC SLEEPERS

• 1:8.5 BG 52 Kg : RT- 5836

• 1:8.5 BG 60 Kg : RT-6068
•Nominated LH or RH according to location of tongue rail & not like direction of turnout
 HEAT TREATED WELDED CROSSING
(1 : 12 B.G. 60 Kg)
A.N.C.

WELDED VEE

ERC MK III
INSULATION

RUBBER PAD

SECTION AT ACTUAL NOSE OF CROSSING

 1:12 B.G. 60 Kg HEAT TREATED WELDED
CROSSINGS
• SALIENT FEATURES
• Developed for 1:12 BG 60 Kg for Indian Rly.
• ‘V’ made by welding points & splice rails. Electroslag process of welding adopted
• 400 mm length of wing rail on either side of ANC location (total 800 mm) heat treated to
330+/-20 BHN. This portion of wing rails considered to be most wear prone
• 16 mm thick sand witch plate used between point and splice rails
• Web thickness at ANC kept 49 mm( 2 web +16 mm)
• Special bearing plate used to fix crossing on sleepers with ERC
• 15 Nos. special PSC sleepers used (SL no 64 to 78 ) to lay this xing. Other sleepers are same as
in 1:12 layout to Drg.No. RDSO/T-4218
• On same 15 special sleepers Swing Nose Crossings can also be laid
• Overall parameters of this xing. is same as of 1:12 BG 60 Kg wooden xing.to drg. No RT-2580
• About 2000 nos. of such xings. Supplied to Rlys between 1996-2000 and have been laid on E,SE,
C,N,W,SC & S. Rlys
• Recently 4 nos. of such Xings. were modified to suit existing sleepers and three have been laid
at Bhopal for trial . After modifications these xings have been laid on existing PSC sleepers of
CMS xings. with special liners of different sizes
• Performance of these xings are satisfactory
 1:12 BG 60 Kg SWING NOSE CROSSING
• SALIENT FEATURES
• Developed for 1:12 BG 60 Kg by M/S BMW Jamshedpur
• Made by using normal 60 Kg (UIC) rails
• ‘V’ of crossing is movable. It gives better riding
• Operation of swing nose is syncronized with the operation of switch as per requirement of
movement of traffic
• 260 mm stroke point machine is required for its operation
• It gives continuous, impact free and smooth path to moving wheels
• Nose thickness of this crossing at ANC is 72 mm i.e. full head width as against 16.5 mm kept
for normal built up/CMS crossing. As full rail head thickness is available throughout the
crossing , its wear and tear is expected to be similar to that of any normal running rail.
• No weakness of reduced head in crossing. Full head can sustain impact as of normal rail
• Can be used with 1:12 BG 60 Kg fan shaped PSC sleeper turnouts to drawing no RDSO/T-4218
• This crossing requires 15 nos .of special PSC sleepers. On same sleepers H.T. welded xing. can
also be laid
• One crossing laid at Gamaharia station of CKP division of SE Rly on 30.7.1997 has undergone
1mm wear
• Negligible wear . Expected to give same life as that of a normal rail in track without any
reconditioning etc
• Bracket of point clamp lock has recently been modified and SE Rly have been advised to lay
further SNX with this system
• 100 sets have been procured and supplied to E, SE, C, W, & N Rly. Other Rly will shortly lay
these crossings after getting feed back from SE Rly
• This is a future generation of crossing suitable for high speed & heavy traffic routes
• Positive comments from field is solicited for further improvement of the design to serve its
purpose of giving impact free movement to moving wheels
 WELDABLE C.M.S. CROSSING (1:12 B.G. 60Kg)
SPECIAL ALLOY WELDED JOINTS
A.N.C.

WELDED JOINTS

C.M.S.CROSSING.
60Kg (UIC) RAIL PIECES
 WELDABLE C M S CROSSING

 SALIENT FEATURES AND ADVANTAGES

 Two rail pieces on either end are welded with CMS crossing
 Special alloy steel is used for welding rail with CMS crossing
 The chemical composition of special alloy is such that it suits to welding with CMS
crossing as well as 60 Kg (UIC) rails
 Joints in vicinity of crossings are kept a bit away from ANC
 These rail pieces can further be welded with adjacent rails to avoid joints nearby
crossing
 The technology of welding CMS with normal rail is not available in India but available
in abroad
 M/s Voest Alpine Austria had supplied 20 nos. of such crossings which were laid on
N.Rly in 1995 and still performing well with two reconditioning
 M/s Cogifer France had supplied such crossings to DMRC
 Rly. Board is planning to procure this technology from abroad in near future
 With this arrangement , it would be possible to continue LWR through turnouts
 THICK WEB CURVED SWITCHES
• TWO TYPES OF TWS USED BY INDIAN RLY
• Zu-2-49 for 52 kg
• Zu-1-60 for 60 Kg (Both non over riding type)

• A. Zu-2-49 thick web switches

• About 600 nos. procured in 1984-1990 for wooden sleeper layout with 115 mm throw
• Were laid on E , SE, SC, S, C, & N Rlys.
• Had out lived lives about 10 to 12 times more than the life of conventional switches
• Most of these switches were replaced by fan shaped PSC layouts prematurely due to non
availability of wooden sleepers for renewals
• Very less switches were replaced on account of wear
• Would have still given more life if wooden sleepers were made available
• Four set of these switches were laid at Faridabad station of C.Rly in 1985 on main line out
of which three sets are still lying in track
• 320 sets were procured by KRCL in 1996-97 for PSC sleeper layout with 145 mm throw with
SSD. Performance of these switches on KRCL are satisfactory
 CONTD-
 Zu-1-60 THICK WEB SWITCHES
 Salient features and advantages
 400 sets procured in 1996-2000 for PSC sleeper layout with 160 mm throw and SSD. These switches
were procured as per firms own design (five designs)
 Use of SSD , enable uniform gauge in switch portion , thus avoiding floating tight gauge and rattling of
switch/stretcher bar fittings
 With use of SSD , wear on tongue rail will considerably be reduced which in turn will increase the life
of tongue rails
 Point clamp lock with 220 mm stroke IRS Point machine are used which gives positive & direct
locking of stock & tongue rail on high speed route
 PSC sleepers will give more sound & uniform base than the wooden sleepers which will enhance its
service life
 Zu-1-60 thick web switches with 160 mm throw & SSD on PSC sleepers is expected to give more life
as was achieved with Zu-2-49 TWS on wooden sleepers
 As a policy, Rly Board has decided to lay TWS on entire ‘A’ route of Indian Rly . It has been planned
to lay about 2000 sets of TWS every year .Procurement of TWS are in process at RLY. Board level
 Initial procurement cost of TWS is about 3 to 4 times more than the cost of conventional 60Kg
switches but considering its expected enhanced life by more than 12-15 times, it will certainly be
economical in long run
 RDSO has developed design of 1:12 and 1:8.5 thick web switches with 160 mm throw and SSD for
use on respective existing PSC sleepers so that TWS may be introduced on entire ‘A’ route as per
planning by simply replacing the existing switch assembly by TWS switches
 RDSO’s design of slide chairs for TWS are provided with ERC, leaf springs & wedge arrangement. With
this system LWR may also be continued through turnouts in future
 DMRC has used canted turnouts in their project using 60 D rails for making tongue rails through M/S
COGIFER FRANCE.This rail has special feature of flat bottom and top canted to 1:20 . Stock rails are
made canted by giving 1:20 cant in slide chairs . DMRC has continued LWR through turnouts at some
of the location which is working satisfactorily
 HEAT TREATED SWITCH TIPS FOR 10125 mm CURVED
SWITCHES BG 60/52 Kg ON PSC SLEEPERS

 SALIENT FEATURES WITH ADVANTAGES

 It is a part of tongue rail fitted with web of tongue rail after stubbing
 It covers those area of tongue rail which is very much prone to wear. It is about two
meter in length from ATS
 Being heat treated, The head of tongue rail causes negligible wear during service
 Normally tongue rail wear in about two meter length from ATS and rest of tongue rail
has no wear but every time full length of tongue is replaced on account of wear
 Tongue rail fitted with switch tips need to be replaced the tip portion only and there is
no need to replace full tongue rail
 Worn switch tip after reconditioning may again be fitted on stubbed tongue rails
 The wear pattern observed so for on switch tips are very negligible
 Tongue rail fitted with switch tips will have long service life . Thus will require lesser
consumption of tongue rails as well as lesser frequency of reconditioning of worn
tongue rails
 42 sets of Heat treated switch tips for 6400 mm straight switches BG 52 Kg were
procured in 1990 for wooden layouts and laid on E, SE, C, N, SC, S & W Rlys. These
switch tips had given service life of 4 to 6 years with negligible wear before replaced
by fan shaped PSC switches
 C. Rly is procuring 90 sets of 10125 mm curved switches fitted with switch tips for
BG 60 & 52 Kg for PSC layouts through three firms out of which 15 sets have so far
been supplied
 These switches have been laid in suburban section of Mumbai Division on C. Rly and
performance of these switches are satisfactory
 Other Rly. may also procure and lay switch tips after gaining experience by C.Rly.
FAN SHAPED TURNOUTS

IT INDICATES THE TYPE OF LAYING OF PSC SLEEPERS IN LEAD

PORTION OF TURNOUT
LAYING OF PSC SLEEPERS IN TURNOUTS
 Approach sleepers : Perpendicular to normal track
 Switch portion ( Stock joint to Heel) : Perpendicular to straight stock rail
 Lead portion( heel to toe end of crossing) : In fan shape
 Crossing portion (Toe end of crossing to start of exit sleepers) : Perpendicular to bisector of the xing.
 Exit sleepers : Perpendicular to normal track
( 4 nos. in each track)
Precautions to be taken in laying of fan shaped turnouts
 SWITCHES
 Ensure that switches & fittings procured from approved source
 Check & correct the curvature / straightness of curved stock/ tongue rail
 Ensure matching of stock & tongue rail from toe to JOH in free condition before putting str. Bars
 Stock/ Tongue rails are fixed on pre laid PSC sleepers at proper gauge. Str. Bars are put on position
 Ensure fitment of GRSP, special bearing plates at specified locations
 Ensure putting of SCSW with all 25 dia. Bolts and with all plate screws
 Ensure square ness of stock rails at stock joint & tongue rail at ATS
 Ensure proper placing and tightening of HEEL blocks , distance blocks & slide blocks
 Ensure proper fit ment and working of point machine out side track before insertion
CONTD --
B. LEAD
•Ensure offsets as per designed values
•Ensure spacing of fan shaped PSC sleepers
• Ensure proper placement of GRSP, liners and ERC

•C.. CROSSING
• Check spacing of PSC sleepers. All crossing sleepers from toe end of crossing to start of exit
sleepers are laid perpendicular to the bisector of the crossing
•ANC should be fixed at correct location as per crossing drawing
•Check rails are placed on position so that 2/3 portion of straight should lie ahead of ANC
•Ensure fit ment of all check rail blocks with washers & bolts etc
•Ensure 41 mm clearance of check rails
•Ensure complete fittings viz. Horn type GRSP, liners & ERC
•Ensure that joints on either side of crossings are machined joints
•GENERAL
•Ensure proper ballast cushion in turnout portion
•Turnout laid out side track with parameters close to designed values give better service in
field
•Relevant drawings of turnouts should be made available to field staff during laying and
maintenance
•After completion & checking of turnout assembly, ,it is inserted in to the track carefully
•After insertion of turnout ,approach and exit sleepers are provided invariably
•Stock joints and other joints specified in the drawings are welded at the earliest
 RECOMMENDATION
 TO MAKE A GOAL TOWARDS ADOPTION OF AN IDEAL TURNOUTS USING:
 SLEEPERS : FAN SHAPED PSC
 SWITCHES : ZU-1-60 THICK WEB CURVED WITH SSD
 CROSSINGS : SWING NOSE / WELDABLE CMS / HEAT TREATED WELDED
 TO CORRECT PARAMETERS OF TURNOUT OUT, CLOSE TO DESIGNED VALUES DURING
ASSEMLY BEFORE ISERTION IN THE TRACK
 LWR TO CONTINUE THROUGH TURNOUTS
 TO ENSURE COMPLETE AND TIGHTENED FITTINGS IN TURNOUT AT ALL THE TIMES
INCLUDING HORN TYPE GROOVED RUBBER SOLE PLATES
 PROPER BALLAST CUSHION AS PER REQUIREMENT
 MACHINE PACKING OF TURNOUT SLEEPERS
 NO BEND TYPE OF SEJ IN THE VICINITY OF TURNOUTS AS REQUIRED
 TO ADOPT FLATTER ANGLE TURNOUTS TO INCREASE SPEED ON TURNOUTS
 FURTHER IMPROVEMENT IN DESIGN OF FITTINGS OF TURNOUTS