important achievements of track design directorate during ... of... · important achievements of...

Important Achievements of Track Design Directorate during last five years (As on December 2017)

Sl No.

Financial Year

Broad Area of Achievement

Title of Achievement

Description of Achievement Likely Benefit Current Status of Implementation

1 2012-13 Economy Development of Explosive Depth Hardened (EDH) CMS Crossing

EDH CMS crossings developed by a firm were put in limited field trial in NR and SCR after inspection by RDSO. The performance of above crossings were found to be satisfactory and extended field trial has been ordered in six zonal railways

Improvement in service life and reduction in the requirement for reconditioning

Under Trial

2 2012-13 Safety Revision of ‘Specification for fusion welding of rails by Alumino-thermic process, IRST-19’.

Specification for fusion welding of rails by Alumino-thermic process, IRST-19 has been revised incorporating all 16 nos. of A&C slips issued. Theses A&C slips were issued for various improvements made in quality of AT welding and advancements made in this area.

Improvement in quality & reliability of AT welds.

Implement is hold back for further revision.

3 2012-13 Safety Revision of ‘Manual for fusion welding of rails by Alumino-thermic process, 1998’

‘Manual for fusion welding of rails by Alumino-thermic process, 1998’ has been revised and issued as ‘Manual for fusion welding of rails by Alumino-thermic process, 2012. All 13 nos. of A&C slips have been incorporated which deal with various improvements made in quality of AT welding and advancements made in this area.

Improvement in quality & reliability of AT welds.

4 2012-13 Safety Revision & printing of ‘USFD Manual’

‘Manual for Ultrasonic testing of rails & welds, 2006’ has been revised and issued as ‘‘Manual for Ultrasonic testing of rails & welds, 2012’. All 09 nos. of A&C slips have been incorporated which deal with various improvements made in area of USFD testing.

Improvement in reliability of USFD testing

5 2012-13 Safety Development of AT welding technology with Compressed air petrol preheating, three piece moulds and Automatic tapping thimble.

In order to reduce human element in AT weld to improve reliability. As welding techniques with Auto tapping thimble was developed by RDSO in association with approved vendors for AT portions. RDSO has successfully developed vendors for the AT welding technique with Compressed air petrol preheating, three piece moulds and Automatic tapping thimble.

To improve quality and in service performance of AT welds.

Implemented w.e.f. 01.02.2013

6 2012-13 Safety Revision of specification for

‘Indian Railway Standard Specification for Ultrasonic Testing of Rails/Welds (Provisional)

Introduction of state-of-the Art USFD rail

ultrasonic rail testing on outsourcing basis

Revised, 2007’ has been revised so as to incorporate the provisions for outsourcing of welds and issued as ‘Indian Railway Standard Specification for Ultrasonic testing of rails/welds (Provisional) - Revised, 2012.

and weld testing m/c on Indian Railways.

7 2012-13 Consultancy Scrutiny and finalization of Standard Gauge SOD of RMGL

The Standard Gauge Schedule of Dimension for RMGL was scrutinized in consultation with all concerned directorates and forwarded to Railway Boar for approval. This facilitated Operation of metro trains on Standard Gauge.

Fast and economical Public transport system in metro city.

Under consideration of Railway Board.

8 2012-13 Safety Amendments in IRSOD, BG- 2004

07 No. Amendment and corrigendum slips proposed to address issues related to safety and enhanced capacity and mobility.

Increased mobility with enhanced safety.

05 out of the 07 amendment/implemented. Remaining 02 are under consideration of Railway Board.

9 2012-17 Mobility & Throughput enhancement

Scrutiny and vetting of speed certificates.

More than 500 No. speed certificates were vetted from track point of view including some very important operations as mentioned below: 1. Operation of 22.32t (CC+6t+2t) axle load

wagons. 2. Operation of BG RS-2 and RS-3 DMRC

Coaches. 3. Operation of 22.82t (CC+8+2t) axle load

wagons. 4. WAP7 class of locomotive up to a maximum

speed of 140kmph. 5. Multi-operation of 3WDG3A/3WCG2

locomotives and 59 BOXN wagons ( loaded to CC+8+2t) over Lonavala-Palasdhari Ghat Section.

6. Operation of MEMU Coaches fitted with pneumatic suspension up to a maximum speed of 110kmph.

7. Operation of Shatabdi express and other similar trains with 18 numbers of LHB AC EOG coaches at 140kmph.

8. Operation of BG AC EOG Double Decker Chair Car coaches (width 3050mm) at maximum speed of 160kmph.

Increased Mobility and Throughput.

Implemented.

9. Operation trials of long haul train-two freight trains amalgamated into one train (python).

10. Operation of WDP4D twin cab class of locomotive up to 135kmph.

11. Operation of second class Non AC EOG LHB variant coaches (LS2) up to a speed of 135kmph with pay loads upto 16T maximum.

10 2012-13 Safety and reliability

Revision in IRPWM Increasing of cant deficiency on curves: The subjected matter was studied at RDSO and was discussed on 84th Meeting of Track Standard Committee has recommended of 100mm cant deficiency on C & M-1, Vol.-I track. Railway Board also approve the same.

Increased Mobility and Throughput

Implemented

11 2012-17 Safety Amendments in IRSOD, BG- 2004

07No. Amendment and corrigendum slips proposed to address issues related to safety and enhanced capacity and mobility.

Increased mobility with enhanced safety.

05 out of the 07 amendment/implemented. Remaining 02 are under consideration of Railway Board.

12 2013-14 Economy Grooved Rubber sole plates (GRSP) with horn for turnouts

RDSO has developed new designs of GRSP with horn for lead portion, under check rail at crossing, beyond crossing and for approach and exit sleeper for 1 in 12 & 1 in 8.5 turnouts and the same issued to all Zonal Railways for trial.

Solution for working out of rubber pads leading to increased service life of sleepers and other track components.

Under Trial

13 2013-14 Consultancy Scrutiny and finalization of SOD of Gurgaon Metro (RMGL)

The Standard Gauge Schedule of Dimension for RMGL was scrutinized in consultation with all concerned directorates and forwarded to Railway Board for approval. This facilitated Operation of metro trains on Standard Gauge.

Fast and economical Public transport system in metro city.

implemented

14 2013-14 Reliability, Economy

Review of Design of Spring Setting Device(SSD)

The design of SSD was reviewed to address

problems experienced in field. As a consequence,

Drawings for SSD and their parts –RDSO/T-6216,

RDSO/T-6945 and RDSO/T-6217/1-32 have been

altered and issued to Zonal Railways. The revised

‘Laying and Maintenance Instructions’ incorporate

frequency of inspection and oiling & greasing of

Improved Reliability and acceptibility of SSD in field which in turn shall enhance the service life of switch.

Implemented

SSD has also been issued to ensure smooth

operation of SSD.

15 2013-14 Safety, Economy

Finalization of Drawing for Combination SEJ

Drawings for Comination SEJ with 60 Kg tongue

rail and 52 Kg stock rail have been finalized and

issued to Zonal Railways. Such SEJ can be used

at the location of change in rail section from 52 Kg

to 60 Kg (or vice versa)

Improved safety due to elimination of Compound fish plate. Cost reduction as only one SEJ is required in place of two SEJs for different rail sections.

Implemented

16 2013-15 Throughput & Economy

Development of Ballastless Track with Indigenous Fastening System (BLT-IFS) including tunnels and viaducts

BLT-IFS design has been completed including proto-type development in a record time of 3 months and its drawings and construction guidelines has been prepared which has been approved by the Railway Board vide letter dt. 13.12.2013. The drawing & construction guidelines have been sent to zonal railways on 16.12.2013 for undertaking the trial. The BLT-IFS design can also be used in tunnels & viaducts with suitable modification in the pad stiffness. Softer rubber pads & transition arrangement in tunnels developed & sent to SCR.

The BLT design has been developed using indigenous fastening system resulting in cost saving and easy availability of fastening components. The proposed BLT-IFS can be used in washable aprons for both platform & non-platform lines, in tunnels, bridges and track at formation requiring very low maintenance.

Trial in main line

in BINA-BPL by

RVNL and in

various zonal

railways .

Trial in tunnel to

be taken by

SCR.

17 2013-14 Safety & Reliability

Revision in Specification (IRS-T-44) of GFN-66 Insulating Liners

Corrigendum No. 4 to the ‘IRS specification no. T-44-1995 for GFN-66 Insulating Liners’ incorporating change of colour & location for taking sample for specific gravity test has been issued to all concerned on 27.11.2013.

With the above change, uncertainty of quality of existing insulating liners with black colour can be improved with the use of insulating liners of the same material but with

Corrigendum circulated to zonal railways for Implementation

natural colour and use of spurious material can be avoided by using virgin raw material of natural colour and at the same time hardness & cross breaking load values are not compromised


Revision in Specification of Metal Liners

This specification has been issued bearing the title ‘IRS specification for metal liners for use with Elastic Rail Clips (Provisional -2013)’ on 29.11.2013 to all concerned.

It will improve the quality & serviceability of metal liner bars as well as metal liners henceforth on sustained basis

Specifications circulated to zonal railways for Implementation

19 2013-14 Throughput

Design of Wider Sleeper using more concrete & less steel for 25T axle load

Various preliminary designs have been sent to Railway Board for in-principle approval of finalized option for developing detailed drawings. However design with top rail seat width of 230 mm and bottom of 300 mm against existing 150 mm and 250 mm respectively found most suitable with use of 12 wires as against 20 wires of 3x3 mm in existing 25 t design.

Following are the advantages of wider & heavier sleeper

• Increase in frame resistance of track & avoiding of buckling of track

• Increase in rail seat area resulting in increase in rubber pad life,

• Reduction in ballast pressure leading to reduction in ballast pulverization, deep screening cycle & enhanced drainage

Awaiting Rly. Board’s approval, RDSO is going ahead with developing detailed drawings.

20 2013-14 Consultancy Scrutiny and finalization of MMOPL SOD

The Standard Gauge schedule of dimension for MMOPL was scrutinized in consultations with all concerned directorate and approved by Railway Board. This facilitated operations of Metros on Standard Gauge.

Fast and economical Public transport system in metro city

Implemented


Development of 10mm thick Composite GRSP for 25t sleeper assembly

Development of 10mm Composite GRSP for 25t axle load has been taken up by RDSO. Prototype samples of this pad were asked from the approved vendors of 6.2mm CGRSP, for testing in RDSO. The samples of four firms have been tested in M&C Dte. Of RDSO. After satisfactory testing of samples in M&C Dte. of RDSO, firms are being shortlisted for 10mm thick CGRSP.

Pad is more sturdier & increased serviceability for use in heavy axle load.

Eight firms have already been shortlisted. Further development is in progress.

22 2013-14 Consultancy

UIC Asia project on ‘Optimisation of Sleeper Design in collaboration with CHARMEC Sweden.

The modelling & simulation study has been done for optimization of various design parameters of design of PSC sleepers for 22.9 axle load and upto speed 75 kmph & LHB coaches upto 10 kmph. Good practices of manufacturing are also been recommended

Rationalization of various design factors and appropriate combination of these factors resulting in optimised design of PSC sleeper for 25T axle load.

After completion

of Phase –I ,

Phase-II of the

project is in

progress for

further study.

Draft reports

received &

under study at

RDSO.


Development of Improved Toe Load J-Clip

RDSO has developed Modified ERC J-clip for increase in the toe-load of existing J-clip.

Increase in toe-load to solve the problem of working out of clips at fish plated joints.

Modified drawings of J-Clip & corr. In specification issued in Nov 2014.

24 2013-14 Throughput

Design & development of 25t sleeper along with fastening system

Prototype design of the sleeper has been manufactured and same is found successful during lab testing at RDSO. Design of sleeper and fastening system has been sent to ECoR, SE, SC & SW Railways for field trial.

Heavy sleeper & fastening system for heavy axle load

Trial is in progress

25 2013-15 Throughput Design & development of 32.5t sleeper along with fastening system

RDSO has designed and developed proto-type of a new PSC sleeper for 32.5t axle load. All laboratory investigations of this sleeper including Fatigue test have been completed and the sleeper has passed all the tests successfully.

Load carrying capacity of PSC sleeper will increase.

Tender floated by Store Dte of RDSO last date as 19.02.2015.


Development of Thermoplastic Elastomer Pads

Status report on trial after one year service has been sent to railway board on 15.05.2012. Further, a letter to all the five nominated railways has also been sent on 27.08.2013 to send certain specific observations of the performance of the pads.

One of the main reasons of deterioration of existing rubber pads is attributed to the effect of extreme environmental conditions in field which in turn affects the overall functioning of elastic fastening system. The Thermoplastic Elastomer Rail Pad is made of polymer and therefore, it is resistant to the effect of extreme environmental conditions in field and imparts longevity.

Final reports after 3 years trial sent to Rly. Bd. In Feb’ 2015

27 2013-14 Throughput Revision of Specification of PSC Sleeper

These revised specifications have been discussed with the manufacturers and finally approved by Railway Board. Now revised specifications have been implemented. Further, vide letter no. 2011/TK-II/22/11/1/Specification dated 11.03.2013, Railway Board has amended the Guarantee Clause no. 8.1 of the IRS T-39 (Fourth Revision – August 2011) which has been issued to zonal railways as Corrigendum no. 1 to IRS T-39-85 (Fourth Revision – August 2011) vide RDSO letter no. CT/SRC/Specification dated 22.04.2013 after taking all necessary action as per ISO guidelines of RDSO

Revision of specification of PSC sleeper (T-39) has been taken up to fine tune it in line with latest practice / production techniques and experienced gained by IR.

Implemented

28 2014-15 Safety Standardization of drawing for automatic banner flag on manual level-crossing for

The red banner flag is to be placed across the track by the gate man whenever gate is kept in open condition for passage of road vehicle at non-interlocked level crossing. Need of automation in implantation of banner flag was being felt so that

To improve safety Drawing no. RDSO/T-8416 issued for field trial.

field trial banner flag automatically comes on track when gate is opened by gate man. The drawing for automatic banner flag has been standardized and issued to all zonal railways for field trials.

29 2014-15 Throughput Speed certificate of 5 tier EUR rakes on BRN/BRNA/BRNAHS wagon.

RDSO has issued a speed certificate for operation of roller rake composed of 21 BRN/BRNA/BRNAHS wagons carrying total 60rail panels of 260m length each loaded in 5 layers and one 8 wheeler covered wagon BCNM1/BCNAM1 (or BCN variant wagon) on Indian railways.

This will facilitate the faster movement of long welded rail panels.

Implemented.

30 2014-15 Safety, Reliability, Economy

Development of Rail Free Fastening System(RFFS) for H-beam sleeper

RDSO has developed an innovative design for RFFS for H-Beam sleeper with SGCI bearing plate and SGCI liners for continuation of welded rail/LWR on girder bridges. Field Trial of RFFS has been ordered on 5 nos. bridges on NWR, NWR, SER and NFR for validation of design.

Improved service life, likely to be cheaper and user friendly

Under Trial.

31 2014-15 Throughput, Economy

Proof checking of drawings for 1:12 Canted Turnouts submitted by DFCCIL

Proof checking of 103 nos. drawings for switch, crossing, PSC sleeper and other components for canted turnout for DFCCIL has done by RDSO on the directive of Railway board. The same was communicated to DFCCIL vide this office letter dated 16.07.2014 paving the way for laying of canted turnouts in DFCCIL.

Canted turnout design is likely to reduce wear of rail on turnout & wheel of rolling stock.

To be laid on live trial on MGS-Sonnagar section of Eastern Corridor of DFCCIL.

32 2014-15 Safety, Reliability, Economy

Modification and improvement and the design of heat treated welded crossing

Modification has been carried out in the drawing for heat treated welded crossing (HTWX) to overcome the problem of working out of liner & ERC due to inadequate toe load when HTWX is laid on fan shaped PSC sleepers designed for CMS crossing. The modified drawings have been issued to CR, ER, NR, SCR &WCR in April 2014 for conducting limited field trial on other than main line to ascertain the effectiveness of modifications in addressing problems associated with the present design.

Modified design of HTWX may be used in place of CMS crossing with continuity of LWR on other than main line. This arrangement shall improved safety and service life.

Under trial

33 2014-15 Safety Safety at Unmanned Level Crossing- Provision of Hoarding to warn road users

Drawing and design of hoarding prepared by RDSO for providing by side of the road on either end of the unmanned level crossings to sensitize and educate the road users

To sensitize and educate the road users

Submitted to Railway Board for further action.

34 2014-15 Throughput Stream-lining the procedure of approval of Quality Assurance Plan (QAP) for Mobile Flash But Welding Plants

Procedure for approval and standard format of QAP of mobile flash butt welding plants have been developed and issued to all concerned for implementation under ACS No. 2 to the Manual for Flash Butt Welding of Rails-2012 duly approved by Railway Board. The soft copy of the same has also been uploaded at RDSO’s website.

Improving the progress of TWR works and working of Mobile flash butt welding plants.

Implemented

35 2014-15 Safety Bracket arrangement for retention of alignment of track on steel channel sleeper

RDSO has prepared a drawing no. EDO/T-2265 for bracket arrangement for retention of alignment of track over steel channel sleeper on girder bridge based on the input from NR & SCR with requisite improvements and issued the same to all zonal railways vide RDSO’s letter dated 18.12.2014

This bracket arrangement holds the steel channel sleeper such that its movement is restricted in all three directions-vertical, lateral and longitudinal and hence misalignment of track on account of movement of steel channel sleeper under traffic is stopped.

Implemented.

36 2014-15 Consultancy Scrutiny and finalization of SOD of HMRL

The Standard Gauge schedule of dimensions for HMRC was scrutinized in consultations with all concerned directorate and approved by Railway Board. This facilitated operations of Metros on Standard Gauge.


Implemented

37 2015-16 Consultancy Scrutiny and finalization of SOD of Kochi Metro

Modified schedule of dimensions (SOD) of Kochi Metro for Standard Gauge(SG) has been vetted from Track Point of view.


Implemented

38 2015-16 Consultancy Scrutiny and finalization of SOD of DMRC

Revised schedule of dimensions (SOD) (November-2015) of Standard Gauge for 3200mm wide stock was vetted from Track Point of view.


Implemented

39 2015-16 Consultancy Scrutiny and finalization of SOD of Lucknow Metro

Schedule of dimensions (SOD) of Lucknow Metro for Standard Gauge has been vetted from Track Point of view.


Implemented

40 2015-16 Safety & Guidelines on RDSO has prepared the methodology of use of Reduction of AT Circulated to

Reliability methodology of use of tailor made 20 rail panels with welded glued joints therein

tailor made 20 rail panels with glued joints welded therein.

welds while doing TRR in yards.

Zonal Railways for adoption and submission of experience after using the methodology for updation needed, if any.

41 2015-16 Throughput Field Trial of High Yield Strength Rails viz Niobium Rails & Vanadium Rails

Micro-alloyed Niobium and Vanadium rails with high yield strength to tensile strength ratio were developed by RDSO in association with RDCIS/Ranchi. These rails have exhibited better yield strength and fracture toughness during lab evaluation. Vanadium rails in Chakradhar division and Niobium rails in Khragpur division of SER were laid for performance evaluation. Based upon laboratory evaluations and field performance of Nb and V rails, the trial has been concluded and a report on “Development and Field trials of Niobium and Vanadium Micro Alloyed Rails” (Report no. CT-27, July 2015) was prepared and submitted to Railway Board.

Defect Generation Rate and extent of Gauge Corner Cracks in Vanadium Rails has been observed much less as compared to 880 grade C-Mn rails.

Improvement in rail chemistry, fracture toughness and corrosion resistance shall be pursued further to meet the Indian Railways needs.

42 2016-17 Reliability Drawing of 1 m long combination Fish Plate 60 Kg (UIC) & 52 Kg (IRS) (Drawing no. RDSO/T-8533 to 8536)

The drawing no. RDSO/T-8533 to 8536 for 1 m long combination fish plate (52/60 Kg) has been developed. The drawing has been issued for trial on seven Railways.

This will improve the alignment of the joint.

After satisfactory performance from Zonal Railways, drawing will be standardized.

43 2017-18 Consultancy Scrutiny and finalization of SOD of Navi Mumbai Metro

Schedule of dimensions (SOD) Rev. 5, February 2017 of Navi Mumbai Metro for Standard Gauge has been has been vetted from Track Point of view.


Implemented

44 2017-18 Consultancy Scrutiny and finalization of SOD of Nagpur Metro

Schedule of dimensions (SOD) version-G(June 2017) of Nagpur Metro for Standard Gauge has been vetted from Track Point of view.


Implemented

45 2015-16 Consultancy Technical eligibility As per Railway Board's instructions vide letter Uniformity of tender Railway Board

criteria and special condition for design and construction of ballastless washable apron

dated 03.11.15, draft "Technical eligibility criteria and special conditions" for inviting tender by Zonal Railways for design' and construction of ballastless washable apron has been prepared in consultation with stakeholders

technical condition among all Zonal Railways.

has approved it and issued instructions to Railways on 11.02.2016.

46 2015-16 Throughput Revision of specification and STR for PSC sleepers

Railway Board vide letter dated 15.10.151 instructed Track Design Dte and QA/Civil,Dte to review STR and specification of PSC sleepers and propose modifications I amendments, if any. The SAG committee of ED/QAlCivil & EDITrack-ll. RDSO has examined existing STR & specification of PSC sleepers in details and proposed various suggestions for improvement in quality of PSC sleepers in Indian Railwavs.

Increased quality and durability of PSC sleepers.

Implemented on 11.03.2016.

47 2015-17 Economy Reduction ballast requirement using under sleeper pad.

Member Engineering in' meeting with RDSO official on 04.6.15, and 26.6.15 and during his visit to RDSO on 17.7.15 for GCM emphasized the need of reducing the requirement of ballast on Indian Railways track due to less availability of ballast in future from environmental consideration.

Development of cost effective technology using under sleeper pads to achieve the reduction in ballast thickness without compromising track performance.

Based upon the global EOI, RDSO has prepared a draft specification for use of under sleeper pad, which is presently in finallzation with Railway Board.

48 2015-17 Throughput Development of mode r n fastening system suitable for ballasted track on Indian Railways.

Railway Board vide letter 0 1.12. 1 5 directed [RD S a to prepare draft documents for inviting global EOI tor modern fastening system suitable for baltasted track on Indian Railways.

To select global fastening system suitable for Indian Railways.

Based upon global EOI, RDSO has prepared draft specification for modern fastening system for Indian Railways which is presently under finalization wit h Railway Board.

49 2015-16 Consultancy Inspection of canted turnout sleeper for

Railway Board vide letter dated 16.12.14 advised DFCCIL to engage inspection agency including RDSO for inspection of canted turnout sleeper.

RDSO has inspected turnout sleepers for the first

RDSO has inspected turnout sleeper

DFCCIL. DFCCIL vide letter dated 28.12.14 approached RDSO to inspect canted PSC sleeper for 1:12 turnout

time as canted turnout sleeper will be using in Indian Railways for the first time.

sets and provided necessary training to SER officials.

50 2015-16 Consultancy Design of mix gauge BG & NG sleeper for use in yard in SECR.

SECR vide letter dated 10/16.03.15 requested RDSO to design PSC sleeper for mix gauge BG & NG having three rail seats f p r 60 kg rail for use in Motibagh Yard of Nagpur Division

Design and mix gauge BG & MG Sleepers

RDSO work completed on 17.04.2015.

51 2016-17 Safety Trial of steam curing cycle at reduced temperature for manufacturing of PSC sleeper.

AS per literature study and various suggestions received from UIC study, it has been planned to reduce steam curing cycle below 60 degree Celsius from the p resent maximum curing temperature of 70 to 80°c to eliminate chance of Delayed Ettringite Formation (DEF) which may result in internal splitting in sleeper from 2 to 10 years.

More durable sleepers manufacturing.

Rosa has conducted limited and extended field trials in all Sleeper plants o f Indian Railways and based upon the trial results the revised curing cycle has been revised which has been approved by Railway Board.

52 2016-17 Throughput PSC sleeper for special location for 25 t axle loads.

Railway Board vide letter dated 27.12.16 asked ROSO, for development of PSC sleepers for special locations viz level crossing, SEJ, turnout sleepers for 25t axle load.

Development of special location sleepers.


53 2016-17 Safety Improvisation in rubber pad and insulating liners.

As per direction of Railway Board vide letter dated 06.06.16, the work of improvisation in exiting rubber pad and liners has been taken in hand. Draft generic specification for “High performance Rail Pads" and "High Viscous Nylon 66 insulating liners" have been framed in consultation with M&C Dte of RDSO.

More durable fastening components.

The draft generic specification are under fina1lization with Railway Board.

54 2016-17 Throughput Reduction maximum cement content in concrete mix design of various sleeper

In view of reduction in cement content in latest version of IS code for prestressed concrete sleeper "1S: 1343-2012" from 530kg/~ for 450kg/m [ROSO has proposed the amendment in specification IRS/T- 39. Limits of concrete workability have also

More durable concrete sleeper.


plants of Indian Railways.

been proposed.

55 2016-17 Safety Design and drawing for rerailing train for 60kg running rail and 52kg check rail.

ROSO had designed rerailing ramp for bridge approach on request of SCR in the year 2013- 14. On the basis of suggestions received from SCR vide their letter dated 17.11.15, ROSO has further updated all drawings.

Safety during derailment in bridge approach will improve.

Revised drawings have been sent to SCR on 04.04.2016.

56 2016-17 Throughput Revision of specification of PSC turnout sleeper (IRS/T-45-1996).

Previously IRS/T-39, the specification of PSC line sleeper for BG & MG and IRS/T-45 specification of PSC turnout sleeper for BG & MG were revised simultaneously in year 1996. Subsequently IRS/T-39 was revised in year 2011 and 2016. However, IRS/T-45 has not been revised since 1996. In order to have uniformity of instruction the work of revision in IRSIT-45 was I taken in hand.

More durable PSC turnout sleeper.

Final revised specification have been sent on 17.11.2016.

57 2015-17 Safety Revision of IRS specification for 6mm thick GRSP and 6.2mm thick CGRSP.

Railway Board vide letter dated 05.05.15 has nominated a committee compromising of ED/Track-I, ED/Track-II & EO/QA/Civil to examine and review the STR, QAP and specification of various P.way fittings. The committee has suggested various changes in specification and STR of GRSP & CGRSP

More durable Rail Pads.

Implemented in 2017.

58 2016-17 Economy EOI for intendent and low relaxation HTS strands.

Railway Board vide letter dated 06.06.16 asked ROSO to frame performance parameters I generic specification for inviting EOI for intendent HTS wires and low relaxation HTS wires for prestressing.

Economy in sleeper design.

ROSO has invited theEOI , however, no proposal has been received from any indigenous firm who can supply intendent and low relaxation HTS strands. ROSO has further recommended to go for Global EOI, on which Railway Board reply is awaited.

59 2015-2017

Safety Development of AT welding technology with Single shot crucible.

In order to reduce human element in AT weld to improve reliability. As welding techniques with single shot crucible was developed by RDSO in association with approved vendors for AT portions. RDSO has successfully developed vendors for the AT welding technique with single shot crucible.

To improve quality and in service performance of AT welds.

Implemented w.e.f. 01.04.2016

60 2016-2017

Safety Technical Specification and Special Technical Conditions for Procurement of Six numbers Self Propelled Ultrasonic Rail Testing (SPURT) Car

In order to increase the USFD testing speed and to improve the reliability of USFD testing.

To improve the quality of USFD testing of Rails and welds at high speed.

Specification Approved by railway Board in December 2017

Achievements: Design Development of Track related components

Automatic tapping thimble: RDSO has successfully developed the technique and vendors for the AT welding technique with Compressed air petrol preheating , three piece moulds and Automatic tapping thimble to improve quality of welds and in service performance

Single Shot Crucible: RDSO has successfully developed the technique and vendors for the AT welding technique with Single Shot crucible to improve quality of welds and in service performance

Manual for Ultrasonic testing of rails & welds- 2006: Manual for Ultrasonic testing of rails & welds, 2006’ has been revised and issued as ‘‘Manual for Ultrasonic testing of rails & welds, 2012’. The copies of revised USFD Manual, 2012 have been printed and being circulated to Zonal Railways & all concerned.

Standard Schedule of Dimensions for DFC: Standard Schedule of Dimensions for Eastern and Western Dedicated Freight Corridors on Indian Railways Published in January-2013

Thick Web Switch: Design, Drawings and Specification for 60 Kg BG 1 in 12, 1in 8.5 and 1in 16 thick web switches have been developed by RDSO. 60 Kg 1 in 12 thick web switches of RDSO design have already been laid in track.

Weldable CMS Crossing: Design, Drawings and Specification for 60 Kg BG 1 in 12 and 60 Kg BG 1in 8.5 Weldable CMS crossing have been developed by RDSO. Trial for such crossings has been ordered.

Improved Switch Expansion Joint (SEJ): Drawings and Specification for Improved SEJ of two designs – one with maximum 80 mm gap and other with 65 mm gap have been issued to Zonal Railways for regular use. Such SEJs do not have bends augmenting safety and service life.

Composite Sleeper: Composite Sleepers of Tietek design have performed satisfactorily over a period of 10 years on two girder bridges on Indian Railways. Such sleepers are under extended trial at present.

ERC Mk-V: Higher toe load clip is required for increased speed and axle load and to control the creep in LWR. ERC MK-V has been developed for toe load of 1250 kg. This clip has been adopted on Indian Railways.

6.2mm Composite GRSP: To improve performance/service life of rubber pad, composite GRSP has been developed and adopted on Indian Railway having service life of 300 GMT as compared to 150 GMT of existing GRSP.

32.5t Axle load PSC Sleeper: RDSO has designed and developed a new PSC sleeper for 32.5t axle load. All laboratory investigations of this sleeper including Fatigue test have been completed and the sleeper has passed all the tests successfully.

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