GOVERNMENT OF INDIA MINISTRY OF RAILWAYS (RAILWAY BOARD) No.98/Proj/DL1/30/1Vol. 1 New Delhi, Dated 18.02.2016 ‘The Managing Director, Delhi Metro Rail Corporation Ltd., Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi - 110001. Sub - Approval of Track Structure and Fastening System for Standard Gauge sections of Delhi Metro Ref - i) Railway Board’s letter of even number dated 02.07.2010 ii) Railway Board’s letter of even number dated 28.02.2013 ili) DMRC’s letter no. DMRC/20/11-336/2009 dated 1 1.01.2016 iv) DMRC’s letter no. DMRC/20/11-336/2009/1 dated 25.01.2016 ‘as decided in the meeting held on 19.01.2016 regarding approval of Track Structure for Standard Gauge sections of Delhi Metro, the Annexure ©.) Submitted by DMRC vide letter under reference (iv) has been examined in supe itation with RDSO. Approval of the competent authority is hereby Conveyed for Track Structure for standard gauge corridors of Delfi Metro as per Annexure C-1 of the ‘Procedure for Safety Certification and Technical Clearance of Metro Systems’. Further, approval is also conveyed for Fastening System for standard gauge corridors of Delhi Metro as per Annexure C-2 of the ‘Procedure for Safety Certification and Technical Clearance of Metro Systems’. Encl: 1. Annexure C-1 (23 pages) 2. Annexure C-2 (8 pages) \s (Ruth Changsan) Director/Works Planning Railway Board Tel/Fax — 011-2309 7061 Copy to:- Executive Director/ UTHS, RDSO, Manak Nagar, Lucknow with reference to their letter no. UTHS/66/DMRC/Civil dated 08.02 2016FASTENINGS SYSTEM FOR ' BALLASTLESS TRACK ON STANDARD GAUGE CORRIDOR OF DELHI METRO (Annexure- C2) £, f February 2016 Delhi Metro Rail Corporation LimitedAnnexure C-2 DMRC’s COMPLIANCE OF PERFORMANCE CRITERIA OF FASTENING SYSTEM FOR BALLASTLESS TRACK ON STANDARD GAUGE CORRIDOR OF DELHI METRO | Standard Stipulated DMRC’s Comment 1. Purpose 1.1 The performance criteria define the performance standard of fastening system for ballastless track of Metro Railway System. Apart from other things, the fastening system is required to moderate vibration and noise transmitted through the rail and to reduce the track stiffness and the impact on the track structure, so as to obtain the parameters as detailed in the ensuing paragraphs. 1.2 A new fastening system, which is fully compliant to performance criteria and not approved by MoR can also be used by Metro Railways/MRTS system as they are free to choose fastening systems for ballastiess track complying with this performance criterion. The detail of such fastening system used shall be submitted to MoR and the same shall be kept in observation by MoR for a period of 2 years under service conditions in association of Metro Railways/MRTS system. The Performa for the monitoring performance shall be advised by MoR to concerned Metros Rallways/MRTS system. After successful performance for 2 years, Metro Rallways/MRTS system shall process for approval of MoR for further use of fastening system. 1,3. The fastening system already approved by MOR ‘as per previous performance criteria for ballastless track dated 21.5.2010 will not require fresh clearance as per this revised criteria and any of these systems 1.1 DMRC is using fastening system complying to performance standards for ballastless track as approved by Railway Board vide letter No.98/Proj./DLI/30 (Vol.III) dated 24.1.2013 (Annexure-A). The fastening system is able to |moderate vibration and noise | transmitted through the rail and to reduce the track stiffness and the impact of the track structure, so as to obtain the parameters as detailed in the ensuing paragraphs. 1.2. Noted. Hea 1.3 Noted please. The fastening system 336 approved by MOR vide letter No.98/Proj/DL1/30 (Vol.II) dated 24.1.2013 has been used till date. Page Lof 8can be used by Metro/ MRTS systems. 1.4 In case Metros Railways/MRTS system opts for a new fastening system for ballastiess track which is not fully compliant to these performance criteria, they will approach MoR for approval before finalizing the use of fastening system. 1.4 Noted please Sow 2. Operating Environment: Fastening system is expected to perform generally in the following conditions: 2.4 Gauge —Broad Gauge, 1676/1673mm (nominal) and standard gauge - 1435mm 2.2 Speed potential - 110 kmph(max.) 2.3 Rail section - 60kg(UIC)/60E1, 90 UTS/110 UTS 2.4 Static axle load — BG & SG — 20t(Max) 2.5 Design rail temperature range — 10 degree Celsius to +70 degree Celsius 2.6 Curvature and gradient will be specified in SOD. 2.7 Rail seat inclination (slope) ~ 1 in 20 In addition, the client Railway may specify any other ‘operating condition such as support spacing etc, DMRC's operating environment: 2.1 Standard Gauge-1435mm 2.2.95 kmph (Max.) 2.3 60 kg (UIC)/60E1, grade 1080, Head Hardened 2.4 SG-17 tons 2.5 Yes, comply 2.6 As specified in SOD is being used. 2.7 1in20 | Support spacing: Viaduct =600mm | Underground=700mm 3. Ballastiess Track Structure: Track shall be laid on cast in situ/pre-cast reinforced | plinth or slab, herein after referred to as the ‘track slab’. The track slab shall be designed as plinth beam or slab type ballastiess track structure with derailment guards. ‘The track slab dimensions and the clearance between rail and derailment guard shall be sufficient to accommodate the base plates of the fastening system and to facilitate easy and convenient replacement of the fastening system. The clearance between rail and derailment guard shall be within the range provided in Page 2 of 8 Yes, comply The track slab dimensions and the clearance between rail and derailment guard is sufficient to accommodate the base plates of the fastening system and facilitates easy and convenient replacement of the fastening system. The clearance of 212.5 mm between rail and derailment guard has been kept which complies the range provided in |Annexure-C-1. In general, track slab on which the fastening and rails are to be fitted shail: i) Resist the track forces, ii) Have adequate edge distance of concrete beyond the anchor bolts to provide resistance against edge failure. ili) Provide a level base for uniform transmission of rail forces. iv) Have geometrical accuracy and enable installation of track to the tolerances laid down. v) Ensure adequate drainage vi) Resist weathering vii) Be construction friendly, maintainable and quickly repairable in the event of a derailment. The ‘Repair and Maintenance methods’ shall be detailed in the "Track Maintenance Manual’ to be prepared and made available before the line or a portion of a line is opened for traffic . viii) Ensure provision for electrical continuity between consecutive plinths/slabs by an appropriate design. Annexure C-1. The track slab on which fastening system is fitted comply to: i) Yes, comply ii) Yes, comply ili) Yes, comply iv) Yes, comply Len v) Yes, comply vi) Yes, comply vii) Yes, comply. Copy of Maintenance Rules for Ballast Track in Manual is enclosed as Annexure-C. vill) Yes, comply-Jumper plates are provided to join the plinths for electrical continuity. |4. Performance Requirement of Fastening System: 4.1 General i) The fastening system shall be designed to hold the two rails of the track strongly to the supporting structure in upright position by resisting the vertical, lateral and longitudinal forces (including thermal forces) and vibrations, ii) The fastening shall be with a proven track record, The | fastening system should have satisfactory performance record of minimum three years in service in regular revenue operation on ballastiess track on any two \ different established railway systems (except exclusive Page 30f8 44 i) Yes, comply. ji) It is certified that the fastening system 336 used by DMRC has highly satisfactory and proven service over 370 track kilometers since last 13 years andhaving speed potential of at least 80 kmph & design axle load 16T irrespective of wheel profile and rail section. In this regard, supplier should submit certificate of performance from user railways administration including proof of use of the fastening system. The supplier has also to submit a certificate that the components of fastening assembly are having same material and specification in case the proven system is having different rail section and wheel profile along with details of test results as per test plan of Table 1. Note: For any metro system having design axle load <16T, the above criteria shall be applicable for the axle load for which the metro system is designed.” iii) The fastening shall provide insulation to take care of return current of traction system. iv) Fastening should satisfy the required performance norms as stated in para 4.2, 4.3, 4.4, 4.5,&4.6. | requirements of fastenings: The Fastening shall i) Have design service life of 30 years in general. However, its components such as rubber pad, rail clip etc. can be designed for 300 GMT or 15 years whichever is less. Anchor bolts or studs used for fixing base plate to the concrete should not be required to be replaced during service life. Its components must not suffer any | degradation during service life to a degree so as to affect the performance and safety of the track. Full service life is to be attained under the following conditions: | a) Atmospheric ultra violet radiation, b) Proximity of track up to 10m from salt water source. c) Contact with oil, grease or distillate dropped from track vehicles. freight tracks) for a length of at least Skm in each metro approved by Railway Board vide letter No.98/Proj/DLI/30/1 (Vol.III) dated 24.1.2013 over design axle load of 17 tons and speed potential of 95 kmph. ‘The fastening system complies to all the parameters in Table-1. Copy of Performance certificate upto 1.11.2011 is enclosed as = Annexure-B. All the stretches indicated in performance certificate are performing _ highly satisfactory till date. It is certified that the components of fastening assembly are having same — material and specification as approved by MOR vide letter dated 24.1.2013. ) Yes, comply |ivyYes, comply 4.2 Following are the technical performance | 4.2 i) Yes, comply. | | Since last 13 years, no anchor bolt, Tension clamp or Elastomeric pad/rail pad has been necessitated to be replaced, a) Comply b) Comply. However there is no salt water source in the vicinity of track alignment. ©) Yes, comply Page 40f8with special tools. upto 12mm using shims. when installed, and later during service. 4.3 Anchor bolts/studs used for fixing the bearing plate in concrete shall have splayed ends. Detailed calculations for the number of anchor bolts required on tangent and curved tracks shall be furnished by the supplier and approved by the Metro system 4,4 For all the fastening components as per approved assembly, the supplier shall furnish detail drawings, specifications and inspection& test plan to the Metros. Metros to ensure that components are supplied as per drawings & specifications... 4.5 The supplier should furnish the ‘Installation and Maintenance Manual’ which shall be approved by the Metro system. Page Sof 8 ili) Be capable of vertical adjustment during service life iv) Permit the attainment of the following tolerances | SI Parameter Installation Maintenance (mm) (mm) 1 Gauge 42-1 44,2 2 XLonstraight track +1.5 45 | 3 SEoncurvedtrack +1.5 $3 4 Vertical alignment +3 +6 cover 20m chord 5 Lateral alignment #2 +6 ‘over 20m chord on | straight track 6 On curves-variation +2 45 over the theoretical versine on 20m chord 4.6 Any change_in component subsequent to the ii) Permit quick and easy installation and replacement ii) Yes, comply iiyYes, comply iv) Yes, comply. A sample of track parameters achieved is enclosed as Annexure-D. Be 423 Yes, comply On tangent track two anchor bolts per seat are installed while on curved track, four anchor bolts are being provided. 4.4 Yes, provided as enclosed with MOR's approval «= vide_—setter- No.98/Proj/DLY/30/1 (VolII) dated 24.1.2013. 4.5 Yes, comply 4.6 Noted please _‘approval of the fastening system by MoR shall be | permitted only for specific requirement of the metro. MoR approval of such changes shall be processed by metro with specific recommendations enclosing test report of the component / whole assembly with detailed justification. 4.7 The rail fastening system shall be tested to the following specifications (Table 1) for different technical | parameters and should meet the acceptance criteria as mentioned in the following table. Test report of the reputed independent institute / laboratory will have to be | submitted. The testing is to be done for Cat B as specified in EN-13481-Part-I 2012 & EN-13481-5 :2012 with rail section to be used in proposed system if other design particulars are meeting the requirement of Cat - B. Table-1 Test Plan for Fastening system (bonded & non bonded) for Ballastiess Track (As per provisions of latest EN 13481 13481-5:2012) 2012 & EN SN] Technical | Fast Recents | Remarks 2” | parameters | Method — | nce LC i cnteria 1 Longjeadinel | ERCTSI4G-1 | 7AN (min) [This fae to be tested railrestraine | 2012 before repeated load test Z| Verseal sence | EN Ise | 35 No shding, yield stiness of | 2012 ime | cracking is alowed fr the | | complete (ran) | fastener pats. fastening assembly oe 3] Dyname/aane [EN 134815 [£4 (ax) | Ratio te calculated by | stiffness rato | 2012 vigng the dynamic | sainess to static vertical L rs, 7 | Gameing | ENTSIAE7 Ts This as to De tested force po (vin) | before repeate oad test Peril } oo} seat = | Becrcal ——PENTSIAS | 6kA Gran) [Higher value may be resistance | 2012 spectied if required by |__| Metros for track circu Page 6 of 8 | 4.7 The test report No.2834a and 2834 b of Technical University of Munich, Germany has been perused by RDSO/MOR and observed compliant to MOR's Performance Criteria vide MOR’s letter dated 24.1.2013. Som ‘Comply, 13.1 KN before repeated load test. Comply, 29.9 KN/eomn Comply. The ratio s 0.84 Comply 22.09 KN Comply 2LT2KN3 Bret of | ENTE] The severe 2012 fatering ‘environmental aeconbly ‘onetions 7 | Betof PENI TNo wear |= repeated | 2012 o | toacina eformati fracture/sipoage FR [On Vertical | ESISI46-+ | variation [Nb sign of Bond Fasurey voz 5 7 [om evar [v |" [engtuainat | 2002 rail restraint vaue | fastener_ Excest the ail and fastener, no siding, yield cor cracking is alowed for | 6. Comply | c. 2 7. Comply ‘7A. Comply, variation upto 7% only. 7B. Comply, variation is 3% only. ) Part-B: Salient features of Fasteni |/S.Nl.[ Components / Provisions in Metro Items. 1. _| Brief description of fastening system Fastening system 336 designed, manufactured and supplied by Vossioh, fee Z Peet | Germany _ | 2] Axle load : 17 tons 3 | Speed potential ‘Operating speed 85 kmph, maximum permissible speed 95 kmph. 4 | Drawing and their numbers FS336 Assembly Dro. for 4 Hole=0.2424d, 2hole:2549 a. 5 | Specifications and their numbers TAs per enclosure with Railway Board’s approval dated 24.1.2013 (Annexure-A.) % | Any variation for straight and curve portion? i If yes, give detail oe 2 Anchor bolts on curves of radius upto 700 Meters 4 Anchor bolts on curves of radius sharper than 700 Meters Page 7 of 87 _ | Vertical stiffness of complete fastening system |] 29.9 KN/mm. 8 _| Service life of fastening system. 30 years 9 | Reference of Railway Board's approval for! 98/Proj/DLI/30/1 (Voll) dated proposed fastening system. | | 24.1.2013(Annex.A) 4 Part: Check List of submissions: 1 Compliance of Part - A 1, Submitted to RDSO 2 Sets of drawings (two numbers) | 2. Submitted to RDSO 3 Performance record of fastening system 3. Submitted to RDSO \_4. Test report of fastening system. 4. Submitted to RDSO a Page 8 of 8