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Integrated Course No: 11106 IRICEN/Pune

Guided by

Shri NILMANI Prof. /Track Shri SHAJI ZACKARIAH Sr. Prof/TM

Course Director:

Presented By:



The project preparation and presentation is an integral part of Integrated Course (No: 11106) being run at IRICEN Pune. These courses are mainly to update and refresh the knowledge of the field Engineers. The issue of maintaining the check rail at level crossing is a burning topic for maintenance and it also becomes important for the P. Way Supervisors as the responsibility of maintaining any level crossing to the prescribed standards lies with the field engineers. We are very grateful to Shri, Shaji Zackariah PTM & Course Director for allowing us to select this topic for the project and also his valuable support and guidance extended during the entire course. We are also pleased to express our indebtedness and gratitude to our project guide Shri Nilmani Prof. Track/IRICEN for his active support & kind guidance and inspiration and for giving us useful suggestions which have helped us in completing this project. We are also thankful to Director/IRICEN and all the faculty members of IRICEN/ Pune for providing a pleasant academic atmosphere within the campus, and also enlightening us with their in-depth knowledge and wide experience.

Our special thanks also go to Integrated Course colleagues for giving us a cheerful company during the entire period.

Sudhir Kumar Neeraj Shrivastava Pawan Kumar Bansal.


Sr. No 1 2 3 4 5 6 7 8 SYNOPSIS INTRODUCTION


Page No 1 1 1 2 4 6 9 11


On Indian Railways, at level crossing on PRC sleeper track, check rails are provided on special PRC sleepers. Check rail requires frequent maintenance, as check rail clearance disturbed, breakage of check rail, damage of dowels of Special PRC sleeper for check rail, jamming of plate screws, J- clips inside of PRC provided, which comes out. This paper presents, a case study of Modified check rail using on ordinary PSC sleeper to over come the above demerits.

To overcome maintenance problem of check rail on special PRC sleepers, also non availability of special PRC sleeper at Level crossing, Modified check rail is provided at LC No. 8 UP & DN Line, between Mahidpur Road Luni Richha station, NAGDA- KOTA Section, WC Railway/Kota Division, under SSE/PW/MAHIDPUR Road in August/2010. The Performance of Modified Check Rail is very good.


Existing check rail is prepared by cutting of flange of rail & drilling of hole in the web of rail for fixing of check rail to the special PRC sleeper. Thus, strength of check rail is reduced due to cutting of flange & drilling of hole, resulting in breakage of check rail during movement of road vehicle. ON LCs at PRC sleeper track, Special PRC Sleepers are required. MS bracket is fixed to PRC sleeper with plate screws & check rail is fixed to CI bracket with the bolts. Check rail gap is maintained only by 22 mm dia. bolts which got bent under heavy thrust of road traffic & disturbing the gap of check rail, requiring frequent attention of check rail gap. During service, dowels of Special PRC sleeper got damaged, jammed & rusting of plate screws, and sleeper gets cracked longitudinally. During service due to vertical play in check rail, it presses the ERCs & struck it out.

Existing Check Rail Arrangement at Level Crossing

Broken Check Rail


Modification of check rail is required to avoid breakage of check rail. To avoid breakage of check rail full rail section & transfer of road traffic load in large area is required. This can be achieved by placing check rail inverted i.e. flange on top & rail head at bottom. By placing check rail inverted, ordinary PRC sleeper can be used in place of Special PRC sleepers with minor groove provided in check rail only at sleeper location, because inverted check rail will not obstruct with the insert of ordinary PRC sleeper. The check rail is fixed inverted position with the locally available fittings i.e. slide chair, wooden block, SEJ collar, outer clip of channel sleeper, lug for slide chair for wooden layout, plate screws, fish bolts, slide chair bolts etc.

Check Rail

Lug for slide chair

Running Rail SEJ Collar Outer Clip

Fish Bolt

Slide Chair Bolt Slide Chair

Typical Arrangement of Modified Check Rail


Sr. No

Rail for fabrication of check rail (Length as per road width at LC)

15.0 M

2. 3. 4. 5. 6.

Wooden Block (65cm in length) Slide Chair (RT-4596) of 60 Kg PSC Turn Out Outer Clip (RT-5157) of Channel Sleeper (35 mm thick) SEJ Collar (60 kg, RT-2656) of two holes Lug for Slide Chair (T-2631) of Stock Rail of wooden layout 60 kg 1:12 Fish Bolt of size 25x130 mm Slide Chair Bolt (T-11504) of size 25x110 mm GR Pad (T-3711/T-3703) Plate Screw

8 Nos 8 Nos 8 Nos 8 Nos 8 Nos

7. 8. 9. 10.

16 Nos 8Nos 26 Nos 32 Nos

Slide Chair (RT-4596) of 60 Kg. PSC Turn Outs

SEJ Collar for 60 kg (RT-2656)

Lug for Slide Chair (T-2631) of Stock Rail of w/layout 60 kg

Outer Clip (RT-5157) of Channel Sleeper

Fish Bolt 25x130mm & Slide Chair Bolt (T-11504) 25x110 mm


6.1 Check Rail
Cutting of rail length of 7.5 m or as required as per road width at LC. Marking flared end on the foot of check rail on both end, at edge of check rail 20 mm width cutting in 40 cm tapered in length, required to get minimum 70 mm gap at flare end. Cutting of flare end by using gascutting equipments. Marking & Cutting of grooves 25 mm deep & 90 mm long ( as per size of insert of PRC sleeper, check rail gap & rail section) on the head of check rail to fix it near the insert of the sleeper, otherwise the insert will obstruct the check rail. Drilling of holes 4 nos (or as per required length) in the web of each check rail for fixing the fittings in it.
Lug for slide chair Running Rail

40CM 20 MM

Check Rail Flange at Top

Flare End

6.2 Fittings
Marking for drilling of 28 mm dia. holes, two nos are given on the slide chair for
fixing the SEJ collar. The location of hole will be 286 mm from face of slide chair lug as per calculation of check rail gap, size of SEJ collar & Rail section, then drilling of 28 mm dia. two holes inside in every slide chair at the marking point is done.

Existing strengthening flat which is provided in the middle of SEJ collar is removed
by gas cutting equipment. One hole in each SEJ collar at middle point is drilled to fit it to the check rail and the lug for slide chair which is used as distance block between check rail & running rail.

Projected portion of outer clip of channel sleeper is grinded; otherwise it will cause
obstruction with SEJ collar/slide chair, because it is used as distance piece between slide chair & SEJ collar.


Ballast between the sleeper spaces is opened where wooden block is to be placed & wooden blocks are fixed at proper location as per holes done in the check rail. Slide chairs are fixed on the wooden block in such a way, the lug flushing with the web of running rail & rest portion of slide chairs will be inside of the track side. Groove in wooden block is made to accommodate head of fish bolt, and then fish bolt of 25x130 mm in the hole of slide chair is inserted for fixing of check rail. Holes are drilled by auger in wooden block for fixing to the slide chair, at the location of holes of slide chair & then with the help of plate screws, slide chair is tightened to the wooden blocks.

New check rail is placed in inverted position. GR pad is placed at every sleeper top / under the head of check rail to avoid wear/ damage on the concrete sleeper. Distance pieces (i. e. lug for slide chairs) are then placed in between check rail & running rail. On other side of check rail, SEJ collar is fixed with two fish bolts to the slide chairs which is earlier placed, also put Outer clip (35 mm thick) in every fish bolts on the slide chair & under the SEJ collar for matching the rail head of check rail. There after distance pieces (lug for slide chairs) is fixed with check rail & SEJ collar by slide chair bolts of 25x110 mm. The check rail gap is corrected by placing extra liners between check rail & distance pieces if required & tightened the all fittings of check rails.

In this modified check rail, Special PRC sleepers not required, only ordinary PRC sleeper are used. Almost full rail section of check rail is used & check rail is placed in inverted position i.e. flange on top & rail head at bottom which provides flat surface on top & more bearing area for road traffic; hence strength is much more as compared to flange cut existing check rail. Stability of check rail is very good as it is fixed with slide chair & wooden block and also with distance block (lug for slide chair) between running rail (i.e. fixed in vertical as well as horizontal direction). Hence check rail clearance is not disturbed due to movement of train & road traffic. ERC remains intact due to groove provided in the head of check rail which provides proper gauge & stability to track. The fittings used in this check rail, are second hand & easily available in the field. No holes required in running rail, hence increased the life of running rail.