Handbook On Maintenance of Switch Expansion Joint PDF

CAMTECH/C/04 1
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
HANDBOOK
ON
MAINTENANCE OF SWITCH
EXPANSION JOINT
FOR L.W.R./C.W.R.
CAMTECH/C/04
December - 1997
Centre
for
Advanced
Excellence in Maintenance
Maintenance
TECHnology
Maharajpur, GWALIOR - 474 020
Handbook on Maintenance of Switch Expansion Joint Dec, 97

CAMTECH/C/04 2
HANDBOOK
ON
MAINTENANCE OF
SWITCH EXPANSION
JOINT

CAMTECH/C/04 3
CONTENTS
S.No. Description Page
1. INTRODUCTION 1
2. MAINTENANCE OF SEJ. 1
3. GAPS AT SEJ. 1
4. DAMAGE TO SEJ. 2
5. BUCKLING OF TRACK 3
6. GAPS OF SEJ FOR VARIOUS 4

TEMPERATURE AND VARIOUS
TYPE TRACK STRUCTURE.
i. B.G. 60 Kg PRC sleeper, 1660 nos/km, 11

r = 13.74 kg/ cm/ rail.
v
ii. B.G. 60 Kg PRC sleeper, 1540 nos/ km,
12
r = 13.28 kg/cm /rail.

CAMTECH/C/04 4
S.No. Description Page
iii. B.G. 60 Kg ST sleeper, 1540 nos/ km, 13

r = 12.14kg/ cm/ rail.
iv. B.G. 52 Kg PRC sleeper, 1660 nos/ km, 14

r = 13.74 kg/ cm/ rail.
v. B.G. 52 Kg PRC sleeper, 1540 nos/ km, 15

r = 13.28 kg/ cm/ rail.
vi. B.G. 52 Kg ST sleeper, 1540 nos/ km, 16

r = 12.14 kg/ cm/ rail.
vii. B.G. 52 Kg CST-9 sleeper, 1540 nos/ km, 17

r = 10.65 kg/ cm/ rail.
viii. B.G. 90 R PRC sleeper, 1540 nos/ km, 18

r = 13.28 kg/ cm/ rail.
ix. B.G. 90 R ST sleeper, 1540 nos/ km, 19

r = 12.14 kg/ cm/ rail.
x. B.G. 90 R CST-9 sleeper, 1540 nos/ km, 20

r = 10.65 kg/ cm/ rail.
xi. M.G. 90 R ST sleeper, 1540 nos/ km, 21

r = 3.86 kg/ cm/ rail.
xii. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 22

xiii. M.G. 90 R ST sleeper, 1540 nos/ km, 23

xiv. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 24


CAMTECH/C/04 5
PREFACE
The track structure on Indian Rlys has now been modernised to

a great extent. The old concept of Rail Joint being a “
necessary evil no longer holds true. Rails are now being welded
as long continuous welded rails to provide joint less track with
smooth side.
The officers and supervisors staff of civil engineering

department have since long felt book for maintenance of switch
expansion joints for long welded rails and continuous welded
rails.
Most of the data, sketch and information are available

in some form or other in various books or other printed matter
of various railways. The objective of this handbook is to serve
as a ready reckoner for day to day problems on field with all
standard practices schedules.
A lot of initiative was shown enormous assistance was

received from all technical staff of civil wing.
I shall be grateful to the readers for pointing out errors

if any and invite their valuable suggestions for improving this
handbook in order to enhance its utility.
Gwalior R.S.Dubey
Date : 10 July,98 Joint Director (Civil)

CAMTECH/C/04 6
FOREWORD
Indian Railways have a running track of about 81,000 Kms. As
on 31.03.97, 60618 Kms. has been modernised into Welded
Track out of which 31,914 Kms. is with long Continuous
Welded Rails and 28,704 Kms. is with Short Welded Rails.
Due to continuous increase in the amount of LWR and

CWR, the proper maintenance of SEJs has assumed great
importance in the interest of safe and punctual running of
trains.
This handbook has been prepared for the assistance of

field staff by Centre for Advanced Maintenance Technology in
order to consolidate and put together all information related to
maintenance of Switch Expansion Joints. The tables for SEJs
gaps at various temperatures for varying sleeper density and
ballast resistance have been systematically compiled and
produced in the handbook to serve as a useful ready reckoner
for proper maintenance of SEJ.
Gwalior D. K. Saraf
Date : 20th July, 1998 Director

CAMTECH/C/04 1
SWITCH EXPANSION JOINT(SEJ)
1. INTRODUCTION
Switch expansion Joint is an expansion joint installed at each

end of LWR CWR to permit expansion contraction of the
adjoining breathing lengths due to temperature variations.
2. MAINTENANCE OF SEJs
 Once in a fortnight SEJs shall be checked by PWI.
 Packing & Alignment on SEJ shall be corrected

regularly in every fortnight.
 Oiling & greasing of stock rails & tongue rail of SEJ

shall be done..
 Tightening or fastening shall be done regularly.
 Movement of SEJ shall be checked in every fortnight

if found any abnormal behavior action taken for
destressing of LWR.
3. GAPS AT SEJ
Gaps at SEJ shall be adjusted at the time of laying/
subsequent destressing of LWR/CWR.
Rail section laid Gap to be provided at ‘td’
52 kg/60kg 40mm
others 60mm

CAMTECH/C/04 2
The gaps at SEJ at various rail temperatures shall not differ

by more than +/- 20mm from the theoretical range
Where fishplated or SWP track is joined on one side of SEJ,

the gap between the reference mark and tongue rail tip/ stock
rail corner on LWR/CWR side shall not differ by more than
+/- 10mm from half the theoretical range.
4. DAMAGE TO SWITCH EXPANSION JOINT
The damaged/broken SEJ shall be replaced. The new SEJ

shall be adjusted as per para 3. Traffic may be allowed if
necessary at a restricted speed and thereafter restriction
relaxed progressively.
If damaged SEJ is not available for replacement, both the

damaged SEJ and the undamaged SEJ on the opposite rail at
the same location, shall be replaced by a closure rail and
connected to LWR/CWR with special clamps and fish
plates.
The traffic over the clamped joints may be permitted at the

restricted speed. The restriction may be relaxed only after the
new SEJ has been inserted in the correct position and the
clamped joint has been replaced with in-situweld.

CAMTECH/C/04 3
5. BUCKLING OF TRACK
General
Buckling or a tendency towards buckling may occur, among

others, in the following circumstances :-
 Failure to adhere to the temperature ranges specified

for operation on LWR/CWR.
 Inadequate resistance to longitudinal, lateral and

vertical movement of track due to deficiencies in
ballast section or/ and inadequate ballast
consolidation.
 Use of ineffective fastenings or missing fastening

resulting in loss of creep resistance and torsional
resistance.
 Excessive settlement of formation.
 Improper functioning of SEJ.
*****

CAMTECH/C/04 4
GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE

AND TRACK STRUCTURE
1. Gaps at SEJ depends on following factors :-
(a) Longitudinal Ballast Resistance of sleepers

(b) Area of rail section
(c) Modulous of Elasticity (E) for rail steel
(d) Coefficient of linear expansion ( a ) for rail steel
(e) Destressing temperature of the section where
gap at SEJ is required
(f) Initial gap at SEJ at destressing temperature
2. Values of above variable for Indian Conditions are

tabulated below:
Table - I
PARAMETERS FOR STANDARD I.R. RAIL SECTIONS
Rail Section Area E 

(cm2) (Kg/cm2) (/°)
60 Kg (UIC) 78.86 2.15 x 106 1.152 x 10-5
52 Kg 66.15 - do - - do -
90 R 56.95 - do - - do -
75 R 47.37 - do - - do -

CAMTECH/C/04 5
Table - II
LONGITUDINAL BALLAST RESISTENCE (R) FOR

VARIOUS SLEEPERS AND SLEEPER DENSITY.
Type of sleeper Longitudinal Ballast Resistance in Kg/cm/rail
Broad Gauge Metre Gauge
1310 sle- 1540 sle- 1660 sle- 1540 sle-

epers/km epers/km epers/km eper/ km
PRC 12.93 13.28 13.74 --

ST 11.48 12.14 12.68 3.86
CST-9 9.92 10.65 11.04 3.47
Wooden 7.58 7.97 8.06 5.0
Note : The value given are indicative and can vary

as per site conditions.
Table - III
INITIAL GAP TO BE PROVIDED AT DESTRESSING

TEMPERATURE (td)
Rail Section Intial gap at Td (mm)
60 Kg(UIC)/ 52 Kg 40 mm
Other 60 mm
EXAMPLE

CAMTECH/C/04 6
To find out the gap at SEJ at rail temperature of 58°C with

the following data :
i) Rail section 52 kg/m

ii) Type of sleeper PRC
iii) Sleeper density 1540 sleeper/ km
iv) Temp. zone IV
v) Destressing temp. td = 48°C
vi) Gap at SEJ at td 40 mm
First of all hysteresis curve of movement of tongue/ stock

rail of SEJ will be drawn at different temperatures.
1. Movement of tongue/ stock rail from the stage of

destressing temperature (point O) to the stage of maximum
temperature (point A) for rising trend of temperature will be
= A E2 t2/ 2R

CAMTECH/C/04 7
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 48)2 / 2 x

13.28
= 0.557 cm
= 5.57 cm
Hence coordinate of maximum temperature (point A) will be

(td + 28, + 5.57)
2. Movement of tongue/ stock rail from stage of maximum

temperature (point A) to stage of minimum temperature
(point B) for decreasing trend of temperature will be
= A E2 t2/ 4R
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28
= 2.052 cm
= 20.50 mm
Hence coordinate of minimum temperature (point B) will be

(td + 28-76, + 5.57 - 20.52)
3. Movement of tongue/ stock rail from stage of minimum

temperature (point B) to stage of maximum temperature
(point A) for increasing trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28

= 2.052 cm
= 20.52 mm

CAMTECH/C/04 8
Hence coordinate of maximum temperature (point A) will be

(td -48+76, -14.95 + 20.52) or (td + 28, +5.57)
Temperature at which gap at SEJ is required is 58°C i.e.

(td +10) °C say point P.
4. Value of movement of tongue/ stock rail at (td + 10) °C

point P for falling trend of temperature will be
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 58)2 / 4 x

13.28
= 0.115 cm
= 1.15 mm
Hence coordinate at point P for falling trend of temperature

will be :
(td + 10, +5.57 - 1.15) or (td + 10, +4.42)
5. In the same way, value of movement of tongue/ stock at

(td + 10) °C point P for rising trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (58)2 / 4 x 13.28

= 1.195 cm
= 11.95 mm

CAMTECH/C/04 9
A- GAP AT SEJ AT DISTRESSING TEMPERATURE (td)

B- GAP AT SEJ AT 38° C (td + 10°C) FOR FALLING
TREND OF TEMP.
C- GAP AT SEJ AT 38°C (td + 10°C) FOR INCREASING
TREND OF TEMP.
Hence coordinate at point P for rising trend of temperature

will be :
( td + 10, -14.95 + 11.95) or ( td + 10, - 3.0)

CAMTECH/C/04 10
The calculations done above indicatesthat at temperature td

+ 10°C i.e. at 58°C, movement of one side of tongue/ stock
rail for decreasing trend of temperature is + 4.42 and for
increasing trend temperature is -3.0 mm.
Hence taking twice of movement of tongue/ stock rail for

each side of SEJ, minimum gap at SEJ for decreasing trend
of temperature at td + 10 i.e. (58°C) will be 40 -2 x 4.42 =
31.16 mm and maximum gap at SEJ for increasing trend of
temperature at td + 10 i.e. (58° C) will bw = 40 + 2 x 3.0 =
46 mm.
Note : * value of 40 mm taken as gap at SEJ at destressing

temperature td . In case gap is set as 60 mm value of 60 mm
is to be taken for calculation .
Hence theoretical range of gap at SEJ at 58°C shall be

within (31.16 mm to 46 mm). Taking into consideration
allowance as per para 5.6.1 the gap should be (31.16 - 20 =
11.16 mm to 46 + 20 = 66 mm ).
Similarly values of gaps for various temperatures, track

structures, temperature zones etc. can be calculated.
*******

CAMTECH/C/04 11
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC

SLEEPER, 1660 Nos/Km, VALUE OF r (BALLAST RESISTANCE) ASSUMED
= 13.74 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg. rails and haviour.
Temperaure Zone I Zone II Zone III Zone IV
td + 28 -- -- -- 28
td + 25 -- -- 30 28 to 31
td + 20 -- 34 30 to 35 28 to 31
td + 15 36 34 to 38 31 to 40 29 to 42
td + 10 37 to 40 34 to 42 32 to 45 30 to 47
td + 05 37 to 44 35 to 46 33 to 49 32 to 51
td 38 to 47 37 to 50 35 to 53 34 to 55
td - 05 40 to 49 39 to 53 37 to 56 36 to 59
td - 10 41 to 51 41 to 55 40 to 59 39 to 62
td - 15 44 to 53 43 to 57 43 to 62 42 to 65
td - 20 46 to 55 46 to 59 46 to 64 46 to 67
td - 25 49 to 56 50 to 61 50 to 66 50 to 69
td - 30 53 to 56 54 to 62 54 to 67 54 to 71
td - 35 56 58 to 62 59 to 68 59 to 71
td - 40 -- 62 64 to 69 64 to 73
td - 45 -- -- 69 70 to 74
td - 48 -- -- -- 74
Note : The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.

CAMTECH/C/04 12

SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.28 kg/cm/rail AND td = tm + 5° C to tm + 10°C for 52 kg and haviour.
td + 28 -- -- -- 27
td + 25 -- -- 30 27 to 28
td + 20 -- 33 30 to 35 27 to 31
td + 15 36 34 to 38 31 to 40 28 to 37
td + 10 36 to 40 34 to 43 32 to 45 30 to 42
td + 05 37 to 44 35 to 46 33 to 50 32 to 52
td 38 to 47 37 to 50 35 to 53 34 to 56
td - 05 40 to 50 39 to 53 37 to 57 36 to 60
td - 10 41 to 52 41 to 56 40 to 60 39 to 63
td - 15 44 to 54 44 to 58 43 to 63 42 to 66
td - 20 46 to 55 47 to 60 46 to 65 46 to 67
td - 25 50 to 56 50 to 61 50 to 67 50 to 70
td - 30 53 to 57 54 to 62 55 to 68 55 to 72
td - 35 57 56 to 63 59 to 69 60 to 73
td - 40 -- 63 65 to 70 65 to 74
td - 45 -- -- 70 72 to 75
td - 48 -- -- -- 75
CAMTECH/C/04 13
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg ST

= 12.14 kg/cm/rail AND td = tm + 5°C to tm + 10°C kg and haviour.
td + 28 -- -- -- 26
td + 25 -- -- 29 26 to 30
td + 20 -- 33 29 to 35 26 to 36
td + 15 36 33 to 38 30 to 40 27 to 42
td + 10 36 to 40 34 to 43 31 to 46 29 to 48
td + 05 37 to 44 35 to 47 32 to 50 31 to 53
td 38 to 47 36 to 51 34 to 55 33 to 57
td - 05 40 to 50 38 to 54 37 to 59 36 to 61
td - 10 41 to 53 41 to 57 42 to 62 39 to 65
td - 15 44 to 55 44 to 60 43 to 65 43 to 68
td - 20 47 to 56 47 to 62 46 to 67 47 to 71
td - 25 50 to 58 51 to 63 51 to 69 51 to 73
td - 30 54 to 58 55 to 64 56 to 71 56 to 75
td - 35 58 60 to 65 61 to 72 72 to 77
td - 40 -- 65 67 to 73 68 to 77
td - 45 -- -- 73 74 to 78
td - 48 -- -- -- 78
CAMTECH/C/04 14

= 13.74 kg/cm/rail AND td = tm + 5°C to tm + 10° C for 52 kg and haviour.
td + 28 -- -- -- 29
td + 25 -- -- 31 29 to 32
td + 20 -- 35 32 to 36 30 to 37
td + 15 37 35 to 39 32 to 40 30 to 42
td + 10 37 to 40 35 to 42 33 to 44 32 to 46
td + 05 38 to 43 36 to 45 34 to 48 33 to 50
td 39 to 46 37 to 48 36 to 51 35 to 53
td - 05 40 to 48 39 to 51 38 to 54 37 to 56
td - 10 41 to 50 41 to 53 40 to 57 39 to 59
td - 15 43 to 51 43 to 55 42 to 59 42 to 61
td - 20 45 to 53 46 to 57 45 to 61 45 to 64
td - 25 48 to 53 48 to 58 49 to 62 49 to 65
td - 30 51 to 54 52 to 59 52 to 64 52 to 67
td - 35 54 55 to 59 56 to 64 57 to 68
td - 40 -- 59 60 to 65 61 to 69
td - 45 -- -- 65 66 to 69
td - 48 -- -- -- 69
values for comparison of gaps at site.
CAMTECH/C/04 15

= 13.28 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour.
td + 28 -- -- -- 29
td + 25 -- -- 31 29 to 32
td + 20 -- 34 31 to 36 29 to 37
td + 15 37 34 to 38 32 to 40 30 to 42
td + 10 37 to 40 35 to 42 33 to 44 31 to 46
td + 05 38 to 43 36 to 46 34 to 48 33 to 50
td 39 to 46 37 to 49 36 to 52 34 to 54
td - 05 40 to 48 39 to 51 38 to 55 37 to 57
td - 10 41 to 50 41 to 54 40 to 57 39 to 60
td - 15 43 to 52 43 to 55 42 to 60 42 to 62
td - 20 46 to 53 46 to 57 46 to 62 45 to 64
td - 25 48 to 54 49 to 58 50 to 63 49 to 66
td - 30 51 to 54 52 to 59 53 to 64 53 to 68
td - 35 55 56 to 60 57 to 65 57 to 69
td - 40 -- 60 61 to 66 62 to 69
td - 45 -- -- 66 67 to 70
td - 48 -- -- -- 70
CAMTECH/C/04 16
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg ST

td + 28 -- -- -- 28
td + 25 -- -- 30 28 to 31
td + 20 -- 34 30 to 36 28 to 37
td + 15 37 34 to 38 31 to 40 29 to 42
td + 10 37 to 40 35 to 42 32 to 45 30 to 47
td + 05 37 to 44 36 to 46 33 to 49 32 to 51
td 38 to 46 37 to 49 35 to 53 34 to 55
td - 05 40 to 49 39 to 52 37 to 56 36 to 58
td - 10 41 to 51 41 to 55 40 to 59 39 to 62
td - 15 44 to 53 43 to 57 43 to 61 40 to 64
td - 20 46 to 54 46 to 59 46 to 64 46 to 67
td - 25 49 to 55 50 to 60 50 to 65 52 to 69
td - 30 52 to 56 53 to 61 54 to 67 54 to 70
td - 35 56 57 to 62 58 to 68 59 to 71
td - 40 -- 62 63 to 68 64 to 72
td - 45 -- -- 68 69 to 73
td - 48 -- -- -- 73
CAMTECH/C/04 17
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg CST-9

td + 28 -- -- -- 26
td + 25 -- -- 29 26 to 30
td + 20 -- 33 29 to 35 27 to 36
td + 15 36 33 to 38 30 to 40 28 to 42
td + 10 36 to 40 34 to 43 31 to 46 29 to 48
td + 05 37 to 44 35 to 47 32 to 50 30 to 52
td 38 to 47 36 to 51 34 to 54 33 to 57
td - 05 40 to 50 38 to 54 37 to 58 36 to 61
td - 10 42 to 53 41 to 57 42 to 61 39 to 65
td - 15 44 to 55 44 to 59 43 to 64 43 to 68
td - 20 47 to 56 47 to 61 47 to 67 47 to 70
td - 25 50 to 57 51 to 63 51 to 69 51 to 73
td - 30 54 to 58 55 to 64 56 to 70 56 to 74
td - 35 58 62 to 65 61 to 71 61 to 76
td - 40 -- 65 66 to 72 67 to 77
td - 45 -- -- 72 73 to 77
td - 48 -- -- -- 77
CAMTECH/C/04 18
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R PRC

td + 33 -- -- -- 47
td + 30 -- -- 49 47 to 49
td + 25 -- 52 49 to 53 47 to 54
td + 20 55 53 to 56 50 to 57 48 to 58
td + 15 55 to 58 53 to 59 50 to 60 49 to 61
td + 10 56 to 60 54 to 62 51 to 64 50 to 65
td + 05 57 to 63 55 to 65 53 to 67 51 to 68
td 58 to 65 56 to 67 54 to 69 53 to 71
td - 05 59 to 67 58 to 69 56 to 71 56 to 73
td - 10 61 to 68 60 to 71 59 to 73 58 to 75
td - 15 63 to 69 62 to 72 61 to 75 61 to 77
td - 20 65 to 70 65 to 73 64 to 77 64 to 79
td - 25 67 to 70 67 to 74 67 to 78 67 to 80
td - 30 70 71 to 74 71 to 78 71 to 81
td - 35 -- 74 75 to 79 75 to 82
td - 40 -- 62 79 79 to 82
td - 43 -- -- -- 82

CAMTECH/C/04 19
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R ST

= 12.14 kg/cm/rail AND td = tm + 5° C to tm + 10°C for 52 kg and haviour.
td + 33 -- -- -- 45
td + 30 -- -- 48 45 to 48
td + 25 -- 52 48 to 52 46 to 53
td + 20 55 52 to 55 49 to 57 47 to 58
td + 15 55 to 58 52 to 59 49 to 61 48 to 62
td + 10 55 to 61 53 to 62 51 to 64 49 to 65
td + 05 56 to 63 54 to 65 52 to 67 51 to 69
td 57 to 65 56 to 68 54 to 70 53 to 72
td - 05 59 to 67 58 to 70 56 to 73 55 to 74
td - 10 61 to 69 60 to 72 59 to 75 58 to 77
td - 15 63 to 70 62 to 73 62 to 77 61 to 79
td - 20 65 to 71 65 to 74 65 to 78 64 to 81
td - 25 68 to 71 68 to 75 68 to 79 68 to 82
td - 30 71 72 to 76 72 to 80 72 to 83
td - 35 -- 76 76 to 81 76 to 84
td - 40 -- -- 81 81 to 84
td - 43 -- -- -- 84

CAMTECH/C/04 20
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R CST - 9

= 10.65 kg/cm/rail AND td = tm + 5°C to tm + 10°C for 52 kg and haviour
td + 33 -- -- -- 43
td + 30 -- -- 46 43 to 47
td + 25 -- 50 46 to 51 44 to 52
td + 20 54 51 to 55 47 to 56 45 to 57
td + 15 54 to 58 51 to 59 48 to 61 46 to 62
td + 10 55 to 61 52 to 62 49 to 65 47 to 66
td + 05 56 to 64 54 to 66 51 to 68 49 to 70
td 57 to 66 55 to 69 53 to 71 52 to 73
td - 05 59 to 68 57 to 71 56 to 74 54 to 76
td - 10 61 to 70 61 to 73 58 to 77 57 to 79
td - 15 63 to 71 63 to 75 62 to 79 61 to 81
td - 20 66 to 72 66 to 76 65 to 81 65 to 83
td - 25 69 to 73 69 to 77 69 to 82 69 to 85
td - 30 73 73 to 78 73 to 83 73 to 86
td - 35 -- 78 79 to 83 79 to 87
td - 40 -- -- 84 84 to 87
td - 43 -- -- -- 87
CAMTECH/C/04 21
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST

td + 33 -- -- -- 14
td + 30 -- -- 22 14 to 24
td + 25 -- 34 23 to 36 16 to 38
td + 20 43 34 to 46 24 to 49 18 to 52
td + 15 44 to 53 36 to 57 27 to 62 21 to 65
td + 10 45 to 62 38 to 67 31 to 73 25 to 77
td + 05 48 to 70 42 to 76 35 to 83 31 to 87
td 52 to 77 47 to 84 41 to 92 37 to 97
td - 05 56 to 83 53 to 91 48 to 99 45 to 105
td - 10 62 to 87 59 to 96 56 to 106 53 to 113
td - 15 69 to 91 67 to 101 65 to 112 63 to 119
td - 20 77 to 94 76 to 105 75 to 117 73 to 125
td - 25 86 to 95 86 to 107 86 to 121 85 to 129
td - 30 96 97 to 109 98 to 123 98 to 132
td - 35 -- 109 111 to 125 111 to 134
td - 40 -- -- 125 127 to 136

td - 43 -- -- -- 136

CAMTECH/C/04 22
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9

td + 33 -- -- -- 9
td + 30 -- -- 18 9 to 24
td + 25 -- 31 18 to 34 11 to 36
td + 20 41 31 to 44 20 to 48 13 to 51
td + 15 42 to 52 33 to 56 23 to 62 17 to 65
td + 10 44 to 62 36 to 68 27 to 74 21 to 78
td + 05 47 to 71 40 to 78 32 to 85 27 to 90
td 51 to 79 45 to 86 39 to 95 35 to 101
td - 05 56 to 85 52 to 94 47 to 104 43 to 110
td - 10 62 to 90 59 to 100 55 to 112 52 to 119
td - 15 70 to 95 68 to 106 65 to 118 63 to 126
td - 20 79 to 97 78 to 110 76 to 123 75 to 132
td - 25 89 to 99 89 to 113 89 to 127 88 to 137
td - 30 100 102 to 114 102 to 130 102 to 140
td - 35 -- 115 117 to 132 117 to 143
td - 40 -- -- 133 134 to 144

td - 43 -- -- -- 144

CAMTECH/C/04 23
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST

td + 33 -- -- -- 22
td + 30 -- -- 28 22 to 30
td + 25 -- 38 29 to 40 23 to 42
td + 20 46 39 to 48 30 to 51 25 to 54
td + 15 46 to 54 40 to 57 23 to 61 28 to 64
td + 10 48 to 62 42 to 66 35 to 71 31 to 74
td + 05 50 to 68 45 to 73 39 to 79 37 to 83
td 53 to 74 49 to 80 44 to 86 41 to 91
td - 05 57 to 79 54 to 85 50 to 93 47 to 98
td - 10 62 to 83 60 to 90 57 to 99 54 to 104
td - 15 67 to 86 66 to 94 64 to 103 62 to 109
td - 20 74 to 88 74 to 97 72 to 107 71 to 114
td - 25 81 to 99 82 to 99 81 to 110 84 to 117
td - 30 90 91 to 101 92 to 113 91 to 120
td - 35 -- 101 102 to 114 103 to 122
td - 40 -- -- 125 115 to 123

td - 43 -- -- -- 123

CAMTECH/C/04 24
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9

td + 33 -- -- -- 18
td + 30 -- -- 25 18 to 26
td + 25 -- 36 25 to 38 19 to 40
td + 20 44 36 to 47 27 to 50 21 to 53
td + 15 45 to 54 38 to 57 29 to 61 24 to 65
td + 10 46 to 62 40 to 66 33 to 72 28 to 75
td + 05 49 to 69 43 to 75 37 to 81 33 to 85
td 52 to 76 48 to 82 42 to 89 39 to 94
td - 05 57 to 81 53 to 88 49 to 97 46 to 102
td - 10 62 to 85 60 to 94 56 to 103 54 to 109
td - 15 68 to 89 67 to 98 64 to 108 62 to 115
td - 20 76 to 91 75 to 101 74 to 113 72 to 120
td - 25 84 to 93 84 to 104 84 to 116 83 to 124
td - 30 93 95 to 105 95 to 118 95 to 127
td - 35 -- 106 107 to 120 108 to 129
td - 40 -- -- 120 121 to 130

td - 43 -- -- -- 130

CAMTECH/C/04 25
** Movement of rail shall be positive in the direction of

traffic on double lines and in the direction of heavier
traffic on single lines which shall be specified.
(a) and (b) will almost always be positive.
Left and right rails on single lines are determined,

looking in the direction of increasing kilometrage.
The reference line for each SEJ shall be marked by two

rail pieces in such away that it is central with respect to
the tip of the tongue and the edge of the foot of stock
rail where planning ends (a+b) at the time of
destressing done immediately after laying of LWR/
CWR. The following line should not be shifted at any
subsequent destressing.
The reference marks at the centre of LWR/ CWR shall

consist of (a) saw marks on the rail pieces fixed as
reference pillars on the cess and (b) paint marks on the
non-gauge side of the rail heads of the LWR/ CWR
rails. Additional reference pillars may erected to
observe the behaviou of movement of LWR/ CWR.
***

CAMTECH/C/04 26
NOTES 

CAMTECH/C/04 27
OUR OBJECTIVE
To upgrade Maintenance
Technologies and Methodologies
and achieve improvement in
productivity and performance
of all Railway assets and manpower
which inter-alia would cover
Reliability, Availability,
and Utilisation.
If you have any suggestion & any specific comments,

please write to us :
Contact person : Jt. Director (Civil)
Postal : Centre for Advanced

Address : Maintenance Technology,
Maharajpur, Gwalior (M.P.)
Pin code – 474 020
Phone : (0751) - 470869, 470803

Fax : (0751) - 470841

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CAMTECH/C/04 1

Maharajpur, GWALIOR - 474 020

Handbook on Maintenance of Switch Expansion Joint Dec, 97

Handbook on Maintenance of Switch Expansion Joint Dec, 97

6. GAPS OF SEJ FOR VARIOUS 4

i. B.G. 60 Kg PRC sleeper, 1660 nos/km, 11

Handbook on Maintenance of Switch Expansion Joint Dec, 97

S.No. Description Page

iii. B.G. 60 Kg ST sleeper, 1540 nos/ km, 13

iv. B.G. 52 Kg PRC sleeper, 1660 nos/ km, 14

v. B.G. 52 Kg PRC sleeper, 1540 nos/ km, 15

vi. B.G. 52 Kg ST sleeper, 1540 nos/ km, 16

vii. B.G. 52 Kg CST-9 sleeper, 1540 nos/ km, 17

viii. B.G. 90 R PRC sleeper, 1540 nos/ km, 18

ix. B.G. 90 R ST sleeper, 1540 nos/ km, 19

x. B.G. 90 R CST-9 sleeper, 1540 nos/ km, 20

xi. M.G. 90 R ST sleeper, 1540 nos/ km, 21

xii. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 22

xiii. M.G. 90 R ST sleeper, 1540 nos/ km, 23

xiv. M.G. 90 R CST-9 sleeper, 1540 nos/ km, 24

Handbook on Maintenance of Switch Expansion Joint Dec, 97

The track structure on Indian Rlys has now been modernised to

The officers and supervisors staff of civil engineering

Most of the data, sketch and information are available

A lot of initiative was shown enormous assistance was

I shall be grateful to the readers for pointing out errors

Handbook on Maintenance of Switch Expansion Joint Dec, 97

Due to continuous increase in the amount of LWR and

This handbook has been prepared for the assistance of

Handbook on Maintenance of Switch Expansion Joint Dec, 97

SWITCH EXPANSION JOINT(SEJ)

Switch expansion Joint is an expansion joint installed at each

 Once in a fortnight SEJs shall be checked by PWI.

 Packing & Alignment on SEJ shall be corrected

 Oiling & greasing of stock rails & tongue rail of SEJ

 Tightening or fastening shall be done regularly.

 Movement of SEJ shall be checked in every fortnight

Rail section laid Gap to be provided at ‘td’

Handbook on Maintenance of Switch Expansion Joint Dec, 97

The gaps at SEJ at various rail temperatures shall not differ

Where fishplated or SWP track is joined on one side of SEJ,

4. DAMAGE TO SWITCH EXPANSION JOINT

The damaged/broken SEJ shall be replaced. The new SEJ

If damaged SEJ is not available for replacement, both the

The traffic over the clamped joints may be permitted at the

Handbook on Maintenance of Switch Expansion Joint Dec, 97

Buckling or a tendency towards buckling may occur, among

 Failure to adhere to the temperature ranges specified

 Inadequate resistance to longitudinal, lateral and

 Use of ineffective fastenings or missing fastening

 Excessive settlement of formation.

 Improper functioning of SEJ.

Handbook on Maintenance of Switch Expansion Joint Dec, 97

GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE

1. Gaps at SEJ depends on following factors :-

(a) Longitudinal Ballast Resistance of sleepers

2. Values of above variable for Indian Conditions are

Rail Section Area E 

60 Kg (UIC) 78.86 2.15 x 106 1.152 x 10-5

Handbook on Maintenance of Switch Expansion Joint Dec, 97

LONGITUDINAL BALLAST RESISTENCE (R) FOR

Type of sleeper Longitudinal Ballast Resistance in Kg/cm/rail

Broad Gauge Metre Gauge