MANUAL MAINTENANCE OF TRACK Through Packing Conventional maintenance

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MANUAL MAINTENANCE OF TRACK

MANUAL MAINTENANCE OF TRACK

Through Packing (Conventional maintenance by beater packing) n n n This is the main

Through Packing (Conventional maintenance by beater packing) n n n 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 1 st October of every year.

Sequence of activity n i) iii) iv) Through packing consists of the following works

Sequence of activity n i) iii) iv) Through packing consists of the following works being done systematically in the following sequence Opening of road Examination of rail, sleepers and fastenings Squaring of sleepers Alignment of track

Contd. … V) Gauging vi) Packing of sleepers vii) Repacking of joint sleepers viii)

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

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) b) c) d) Rails should be examined,

Examination of rails, sleepers and fastenings a) b) c) d) Rails should be examined, the underside for corrosion, the ends for cracks, the head for side wear. Sleepers should be inspected for their condition and soundness particularly at the rail seat. Defective if any to be replaced. All Fastenings are checked and tightened, missing fittings are recouped. Kinks if any, in the rails are removed by jimcrowing

Squaring of sleepers n n n Gauge variations and kinks inevitably results from sleepers

Squaring of sleepers n n n 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 n n The alignment of the track is normally checked by

Aligning the track n n 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.

Packing of sleepers n n The base rail is sighted by mate with eye

Packing of sleepers n n 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 4 th sleeper and every joint. No joint or dip should be lifted higher than the proper level.

Contd. … n n n The sleepers are than packed by beaters 4 men/sleeper

Contd. … n n n 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. … n n Ensure that no sleeper is centre bound in case of

Contd. … n n 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

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 n n n Ballast section is than properly

Boxing to ballast section and tidyng n n n 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 n n a. b. c. Normally commenced after completion of one cycle

Systematic Overhauling n n a. b. c. Normally commenced after completion of one cycle of through packing Consists of following operation Shallow screening and making up of ballast section All items included in through packing Making up the cess

Shallow Screening n n Open out the ballast 50 to 75 mm blow the

Shallow Screening n n 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. n n n Ensure that extra quantity of ballast is

Precautions for O. H. n n n 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. … n n Overhauling work should be taken up only in alternate rail

Contd. … n n 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) 2) 3) 4) To improve

Deep Screening of Ballast Purpose for deep screening 1) 2) 3) 4) To improve drainage of track To improve elasticity of the track To maintain track geometry To improve running of the track

Contd. … When Deep Screening is required? n Prior to CTR n Prior to

Contd. … When Deep Screening is required? n Prior to CTR n Prior to TSR n When the caking of ballast has resulted in unsatisfactory riding. n Before conversion of fish plated track in to LWR n Entire track AFTER 500 GMT OR once in ten year whichever is earlier.

Contd. … n n n In case of bad formation , treatment should be

Contd. … n n n 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

Contd. … On the basis of longitudinal and cross sections, the final levels will be decided keeping in view n The depth of ballast cushion to be provided. n The relative implications of lifting or lowering n The possibility of eliminating humps, sags and unevenness in the existing longitudinal section.

Preliminary works for D/Screening n n n Arrangement of additional ballast at site. Cess

Preliminary works for D/Screening n n n 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 n n n Remove ballast from space ‘A’ and ‘B’, Support

Procedure for D/Screening n n n 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’

Contd. … n n n Support the rail with wooden blocks at ‘C’ Remove

Contd. … n n n 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. … n n n Work to be done opposite to direction of traffic

Contd. … n n n 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. … n n n Lifting should be limited to 50 mm at a

Contd. … n n n 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 JE/SE (P. way)

Proposed schedule for relaxing speed restriction (Manual Packing) Details of the work Day of

Proposed schedule for relaxing speed restriction (Manual Packing) Details of the work Day of work SR (B. G. ) SR (M. G. ) Kmph Deep screening and 1 initial packing First T. Pkg. 2 20 20 45 30 Secong T. Pkg. 3 Picking up slacks as 4 -9 required Third T. Pkg. 10

Proposed schedule for relaxing speed restriction (Manual Packing) Details of the work Day of

Proposed schedule for relaxing speed restriction (Manual Packing) Details of the work Day of work SR (B. G. ) SR (M. G. ) Kmph Picking up slacks as 11 -19 required 75 60 Normal Speed Fourth T. Pkg. 20 21 onwards

Proposed schedule for relaxing speed restriction (Machine Packing) B. G of the work Details

Proposed schedule for relaxing speed restriction (Machine Packing) B. G of the work Details Day of work SR (Kmph) Deep screening and initial 1 packing First Machine pkg. 2 20 Picking up slacks as required Second Machine pkg. 45 3 -5 6

Proposed schedule for relaxing speed restriction (Machine Packing) B. G. Details of the work

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 required 7 -8 75 Third Machine pkg. 9 10 onwards Normal Speed

Picking up slacks n n n Slacks are normally those particular points in the

Picking up slacks n n n 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. … n n During picking up slacks, it may be necessary to pack

Contd. … n n 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 n Level pegs

Lifting of track Following precautions to be taken during lifting operation n Level pegs should be fixed at suitable interval. n Should be done under speed restriction n Maximum 75 mm in one stage. n The easement grade should not be steeper than 25 mm in one rail of 13 meter

Contd. … n n n In single line work should commenced from down hill

Contd. … n n n 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 ths supervision of JE/P. Way

Lowering of track As far as possible lowering should be avoided as this gives

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. n 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. n

Contd. … n n Not more than 75 mm at a stage Easement grade

Contd. … n n 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 n To allow for

Lubrication of Rail Joints Purpose of lubrication/ Oiling and greasing n To allow for free expansion and contraction of rails. n To reduce wear and tear on fishing planes of rails and fish plate. n Duration- Once in a year. In yard this may be extended to once in two year with the approval of chief engineer. n To be done during moderate season avoiding rainy season.

Contd. … Material required for 100 joints Plumbago (Dry Graphite) 5 Kg Kerosine Oil

Contd. … Material required for 100 joints Plumbago (Dry Graphite) 5 Kg Kerosine Oil 2 nd quality 3. 5 liters Black or reclaimed oil 2. 75 liters

Precautions during Lubrication n n Not more than one joint to be opened at

Precautions during Lubrication n n 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.

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