CHAPTER V

WELDING OF RAILS : LAYING AND MAINTENANCE OF SHORT WELDED RAILS,

LONG WELDED RAILS AND CONTINUOUS WELDED RAILS

PART 'A'

Welding of rails

501. General - The welding of rails is carried out in a depot by the "Flash butt welding
process and at site by the "Thermit Welding" process. The length to which the rails can
be welded in a depot depends on the transport facilities available.

502. Alumino thermit Welding of rails: -Alumino Thermit Welding of rails may be
carried out in accordance with the detailed procedure laid down in the "Manual for
Fusion Welding of Rails by Alumino Thermit Process, September 1996". A thermit weld
done in situ shall be joggle fish plated with four clamps and supported on wooden
blocks till tested as good by USFD.

503. Tolerances allowed in the case of flash butt welds �The tolerances allowed
in the case of flash butt welds are the same as allowed in the case of Alumino- thermit
welds (Para 502). In addition to the tolerances mentioned for thermit weld, the
following additional item of tolerance is specified-

In the case of old rails welded together the tolerances can not exceed double the
above values stipulated for new rails, keeping the tolerances to the minimum.

504.Short pre-heat welding process -(1) General- The conventional thermit

welding process takes about 60 minutes for welding of a joint. To reduce this time in
view of non availability of longer time interval between trains this method with shorter
preheating time is used.

The principle of this process is essentially the same as thermit process except that -

(i) Prefabricated mould is used in place of green sand, to reduce the time due to drying
of sand.

(ii) Larger gap of 22 to 24 mm. is provided at the rail ends.

(iii) Rail ends are heated only to 600� C against 950�C.

(iv) Preheatin time is reduced to 10 to 12 minutes.

(v) Thermit portion is double the quantity for this process.

(vi) A stronger burner with larger fuel flow is used.

In this case also, the traffic can be allowed only after 30 minutes have elapsed after
welding of the joint. The code of practice for welding of rail joints Alumino thermic
process issued by R. D. S. O. should be refered for complete details regarding selection
of rails for welding, preliminary work prior to welding, the actual details of work of
execution of welding, and inspection of welds.

PART B

Short Welded Rails (SWR)

505. Definitions - (1)Short Welded Rail (SWR) is a welded rail which contracts and
expands throughout its length.

Note - Normally the length of SWR is 3X 13 M. for Broad gauge and 3X12 M. for Metre
gauge.

(2) Rail temperature is the temperature of the rail as recorded by an approved type of
rail thermometer at site.

This differs from the ambient temperature which is the temperature of air in shade at
that place, as reported by the meterological department.

The Indian Railways have been divided into four rail temperature zones. Annexure
5/1 is a map showing the four temperature zones and the annual mean rail
temperatures at all important places are shown in the map.

(3) Mean annual rail temperature {tm} is the average of the maximum and minimum
rail temperature recorded during the year. tm. will be fixed locally wherever rail
temperature records are available for a reasonable period of five years. Where rail
temperature records are not available tm. can be read from the rail temperature
map(Annexure 5/1)

(4) Installation temperature (ti) is the average rail temperature during the process of
fastening the rails to the sleepers at the time of installation of SWR.

506. Track structure for SWR -

(1) Formation - SWR shall be laid generally on stable and efficiently drained formation.

(2) Rails - The minimum section of rail shall be 90-R for Broad Gauge and 60-R for
Metre Gauge. Only new rails and second hand rails conforming to the standards laid
down in relevant cause of the Code of practice for welding of Rail Joints by the Alumino
thermit process and the Code of Practice for Flash Butt Welding of rails shall be welded
into SWR.

(3) Sleepers -The sleepers approved for use with SWR shall be as under -

(a) Wooden sleepers with anti-creep or elastic fastenings.

(b) Cast iron sleepers and steel trough sleepers with key type or elastic fastenings.

Wooden sleepers with mild steel bearing plates and rail free fastenings may preferably
be used at all fish plated joints when SWR is laid on metal sleepers. Concrete sleepers
should be used in cases where SWR is likely to be converted to LWR/CWR immediately.
In such cases the fish-plated joints shall have wooden sleepers at the joints.
(4) Sleeper Density - Reference may be made to Para 244 (4) of the Manual for the
details.

(5) Ballast:- Only stone ballast shall be used. The recommended depth of ballast below
the bottom of sleepers is as indicated in Para 263 (2), the minimum in no case being
less than 200 mm. both for Broad Gauge and Metre Gauge. 100 mm. extra width of
shoulder ballast over and above the standard ballast section on tangent track shall be
provided on outside of curves upto 875 metres radius in Broad Gauge, 600 metres
radius in Metre Gauge. In the case of sharper curves, the extra width shall be 150mm.
On existing SWR lengths, where this width is not available, this may be provided on a
programmed basis. In the case of 60 kg. Rails LWR profile shall be adopted.

507. Condition of laying : (1) Alignment -SWR shall not be laid on curves sharper
that 500 meters radius in both Broad Gauge and Metre Gauge. However, on PSC
Sleepers, SWR may be laid on curves with radius not less than 440 meters.

Existing SWR laid on sharper curves may, however, be allowed to continue if there is
no difficulty experienced in maintaining these lengths. Chief Engineer's approval should
be taken in such cases.

(2) Junction with insulated joints and points and crossings - SWR shall not butt
againist insulated joints, heel of crossing and stock rail joints. Two standard length
rails (13M./12M.) shall be interposed to isolate the SWR from such locations. These
standard length rails shall be anchored effectively to arrest movement in either
direction.

(3) Junction with standard length rails on wooden sleepers - When SWR track butts
against track laid with standard length rail (13M. for Broad Gauge and 12 M. for Metre
Gauge) on wooden sleepers, the latter shall be adequately anchored for at least six rail
lengths to check the creep of rails. These six rail lengths shall have a sleeper density of
M+7. Additional shoulder ballast should also be provided.

(4) Regarding laying of SWR in Level Crossings and Bridges, Para 921 of Chapter on
Level Crossings, Para 272(4) of Chapter on Permanent Way Maintenance-Track
Structure on Bridges may be referred to.

508. Laying of short welded rails (SWR) - The gaps to be provided for SWR at the
time of laying shall be in accordance with Table 1 depending on the installation
temperature (ti) and the Zone in which the rails are laid -

TABLE 1

Initial laying gaps for SWR for various installation temperatures

For Zones 1 and II

 Rail temperature at the time of installation (ti) (in centigrade) -

If the laying has to be done outside the temperature range given in table above, or
wherever joint gaps could not be provided as per the table, readjustment of gap shall
be carried out within two days of laying before the track consolidates. Along with the
gap adjustment, any respacing of sleepers, if required, must be carried out.

509. Maintenance of short welded rails -Regular maintenance operation -

(1) Regular track maintenance including all operations involving packing, lifting,
aligning, local adjustment of curves, screening of ballast other than deep screening,
and scattered renewal of sleepers may be carried out without restriction when the rail
temperature is below tm. +25� C in the case of zone I & II and tm + 20�C in the
zone III and IV. However on curves of less than 875 metres radius Broad Gauge, and
less than 600 meteres radius in Metre Gauge or yielding formation, the above
temperature limit shall be restricted to tm. +15� C in the case of Zone I and II
and tm. + 10�C in the case of Zone III and IV.

(2) If the maintenance operations have to be undertaken at temperature higher than

that mentioned above in Para 509 (1), not more than 30 sleeper spaces in one
continuous stretch shall be opened, leaving at least 30 fully boxed sleeper spacer
between adjacent lengths which are opened out. Before the end of the days work it
shall be ensured that the ballast is boxed up.

(3) As an additional precaution, during summer months, to be specified by the Chief

Engineer, for attention to run down track, even if temperature is less the temperature
specified in Para 509 (1) not more than 30 sleepers in one continuous stretch shall be
opened, leaving at least 30 boxed sleeper spaces between adjacent lengths which are
opened up. Further, if joint gaps are not available at the time of opening of the track
even when rail temperature are less than those specified in clause Para 509 (1). not
more than 30 sleepers in one continuous stretch should be opened leaving at least 30
boxed sleeper spaces between adjacent lenghts which are opened up.

(4) Major lifting, major alignment of track, deep screening and renewal of sleepers in
continuous length. - Each of these operations shall be done under suitable precautions
and normally when the rail temperature is below tm. +15 C in the case of Zones I and
II, and tm. +10 C in the case of Zones III and IV. If it becomes necessary to
undertake such works at rail temperature exceeding the above values adequate speed
restrictions shall be imposed.

(5) Adequate number of joggled fish-plates with special clamps shall be provided to
the gangs for use in emergencies.

(6) In the case of any fracture in the weld or in the rail, the portion of rail with fracture
is cut, and removed for a length of not less than 4 M. to carry out the rewelding duly
introducing a rail piece of equivalent length, also ensuring that no weld lies closer than
4M. from the fish-plated joint.

(7) Conversion of 10 rail/5 rail panels into shorter panels - It will be desirable to
convert the existing 10 rail panels and 5 rail panels into 2-V2 rail panels wherever
maintenance problems cannot be solved otherwise. Whereever conditions permit,
conversion of SWR into LWR may also be considered.

510. Gap survey and adjustment of gap-

(1) General - Gap survey and rectification of gaps is to be carried out, in stretches
where track develops excessive creep jammed joints, sun kinks, buckling, wide gaps,
battered and hogged joints, fractures at joints and bending of bolts etc. In SWR the
gap survey and adjustment should normally be done before the end of February once a
year (i.e., before onset of Summer).

(2) Gap Survey- (a) The gap survey shall be conducted on a clear and sunny day in
the cool hours of the day.

(b) The length over which gap survey is to be done should, whereever possible, be
divided into suitable sub-sections, each bounded by fixed points such as level
crossings, points and crossings etc. The survey should be completed during as short a
time as possible, by employing adequate number of parties so that the rail
temperature is not likely to vary appreciably.

(c) The joint gaps shall be measured by taper gauge in mm. (shown below) and the
readings entered in the pro forma as shown in Annexure5/2.
(3) Recommended range of value of gaps - The recommended range of value of gaps
(in mm.) during service for various ranges of rail temperature is indicated in the table
given below :-

TABLE

For Zones I and II

Note : -(i) The values given above are for 3 rail panels.

(ii) The gaps given above are to be distinguished from the values given in Para 508
(Table I) which are intended to be provided at the time of initial laying of SWR.

(iii) Gap survey should be carried out when rail temperature is in rising trend only.

(4) Calculations for adjustment- The average of the measured gaps is worked out as
shown in the pro forma for gap survey (Annexure 5/2). A comparison of the results
of the gap measurements recorded and the permissible values of gap (concerned
range for gap) given above will lead to one of the following cases :-

Case 1 - Average gap is within the recommended range, but some of the individual
gaps fall outside the range.

Case 2 - Average gap falls outside the recommended range.

Case 3 - Average gap as well individual gaps fall within the range.

(5) Action to be taken - The action to be taken is as follows :-

Case 1 - Rectification work should be restricted to correcting the individual gaps, which
falls outside the recommended range. Rectification should be done by pulling the
minimum number of rails. Under no circumstances shall the adjustment be done by
cutting a rail or introducing a longer rail.

Case 2 -The joint gaps shall be systematically adjusted from one end to the other end
of the subsection. The rails shall be unfastened over convenient lenghts, the gaps
adjusted to the initial laying gaps as per Para 508 and rails fastened. In this case
introduction of a longer or shorter rail will be involved. Efforts should be made to see
that only the minimum number of joint sleepers are disturbed.

Case 3 - No action is to be taken.

As far as possible, the day chosen for rectification should be a day on which the rail
temperature is not likely to vary much during rectification period.

511. Conversion of SWR into LWR - The following additional precuations should be
observed when converting SWR into LWR :-

(1) The anticipated residual life shall be at least 10 years.

(2) The rails shall be tested ultrasonically and all defective rails replaced before
conversion into LWR.

(3) Rail ends which are hogged or battered or have a history of cracks in bolt hole
region, shall be cropped before conversion into LWR.

PART 'C'

Long welded rails/Continuous welded rails

512.Referenceto LWR/CWR Manual - Detailed instructions for laying and
maintenance of long welded rails/continuous welded rails are contained in
the "Manual of Instructions on long welded rails 1996". It is very important that
instructions contained thereon are carefully studied by all Permanent Way officials
connected with the laying and maintenance of long welded rails/ continuous welded
rails.
ANNEXURE-5/1 PARA 505

MAP OF INDIA SHOWING RAIL TEMPERATURE ZONES