GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

Safety Guidelines
for
Signalling Cables

CAMTECH/S/PROJ/2022-23/
SP-3A

April-2022

End User: SSE/JE & Signal Maintenance Staff

of Indian Railways
 Safety Guidelines
for
Signalling Cables
Prepared by: Shalini Bansal, SSE/Comp.

(Under the Guidance of Shri N.K. Varma,

Dir/S&T/CAMTECH and P.K. Wakankar,
SSE/Signal/CAMTECH)

Any Suggestions about the pamphlet are welcome and may be sent on
Contact person:
Director(S&T)
Indian Railways Centre for Advanced Maintenance Technology
Maharajpur, Gwalior(MP)-474020
Ph:0751-2470185, Mob. No.: 9752447080 FAX:0751-24700841
E-mail: dirsntcamtech@gmail.com
 Introduction
A Cable is a unit that contains more than one insulated
conductor bunched into a compact form by providing
mechanical Protection and electrical insulation.
Cables which are mainly used inside the building are
called Indoor cables and cable which are laid in the
outdoor are called Outdoor Signalling Cables.
Signalling cables play an essential role in ensuring the
transmission of signals and a continuous power supply
across all trackside signalling equipment applications.
These cables are used for control and signal conveyance
and keep the rail networks, with their passengers and
cargo, moving safely.
In the following sections guidelines for transportation,
laying & testing of signalling cables are given as per
RDSO guidelines on signalling cable laying vide
Document No. RDSO/SI/G/2010, Version 1.1 E
Effective from 04.02.2014.

3
 Planning for Cabling
 Cables for signalling circuits shall be of approved
types.
 The number of conductors required, depending upon
the circuits should be first determined. Adequate spare
conductors to a minimum of 20% of the total
conductors used shall be provided for in each main
cable up to the farthest point zone, beyond this there
should be a minimum of 10% spare conductors of the
total conductors used.
 Where a number of cables have been laid along a
route, the circuits shall be so distributed that cables can
be disconnected for maintenance purpose with the least
possible dislocation to traffic.
 Cable route plan shall also be approved by
Engineering and Electrical departments. Approval of
S&T open line is also required where ever it is
prepared by other than open line. In case of
Construction works cable route plan shall be signed by
Engineering and Electrical departments of executing
agencies as well.
 As far as possible low lying areas, platform copings,
drainages, hutments, rocky terrains, points and
crossings, shall be avoided. Proximity to Electrical Sub
Stations/Switching stations shall be avoided.
 In case of Tunnel, provision of cable duct should form
part of the Tunnel design.

4
 Storage and Transportation
 Cable drums shall not be stacked on flat side.
Suitable stoppers shall be placed for stability.
It is desirable that cable drums are stored in
covered shed to protect against direct
exposure to sun.

 When rolling the cable drum either for

unloading or transportation, the drum shall
always be rotated in the direction of the
‘arrow’ which is marked on the drum.
 During all stages of storage, it is essential that
the ends of the cable are effectively sealed by
end cap or in any other approved manner to
avoid water entry into the cable.
 When unloading is carried out from the
vehicle, the drum shall not be dropped on the
ground directly to avoid damage due to
impact. Fork lifter or ramp shall be used.

5
 Paying Out & Testing
 For paying out cables, the cable drums shall be mounted on
cable wheels. It should be ensured that no kink is formed
while paying out the cable.

 Before the cable is laid in the trench, a visual inspection

of cable shall be made to see that there is no damage to
the cable. It shall be tested for insulation and continuity
of the cores.
 In no case, shall the drum be rolled off on to the road
for laying the cable and the cable dragged on the
ground for laying purposes.
 Whenever mechanized equipment is used, the work
shall be carried out by a trained operator under the
supervision of SSE/JE(Signal), in-charge of the work.
 Where the cable drum is in damaged condition the
cable may be placed on a horizontal revolving platform.

6
 Trenching
 For laying of signalling cables in the station yards from
Home to Home signal Manual trenching is
recommended.
 From Home to distant signal and beyond into
block/automatic section – mechanized trenching is
recommended.
 Under road/platforms/railway tracks/difficult terrain
etc., trench less horizontal directional drilling (HDD)
method may be adopted under the supervision of
competent staff for laying of GI/DWC-HDPE pipe.
 Trenches shall be straight as far as possible and steep
angles shall be avoided, clearing roots of trees, rocks
etc in all types of soils.
 The bottom of the trench shall be levelled and got rid
of any sharp materials like stone chips, iron pieces etc.
 When cables are laid in trunking, it shall be cleared of
all ballast and stones before the cover is secured.
 It is desirable that the trenches do not remain
uncovered for long period; instead cables are laid and
refilling done on the same day.
 Before commencement of the laying, inspection of the
trench and inspection of protection works shall be
carried out.

7
 Laying
 The main cable laid parallel to the track shall normally be
buried at a depth of 1.0 m from top of cables to ground
level, including those laid across the track (1.0 m below the
rail flanges). The depth shall not be less than 0.50 m for tail
cables. In theft prone areas, the cables may be laid at a
depth of 1.2 m with anchoring at every 10 m.

Laid parallel to track 1.0 m depth Laid across to track 1.0 m depth

Tail cable: Depth ≥ 0.5 m In rocky area; Depth ≥ 0.5m with

adequate protection

 The ducts being used shall be of such design and length to

prevent/minimise damages to cable by any other future
digging activities in the vicinity. The ducts shall have
suitable covers to prevent water collection in the duct.
8
 Laying
 Cables belonging to other department must not
be laid in the same trench along with Signal &
Telecommunication cables.
(a) A distance of approximately 10 cm must be
maintained between cables of other
department and signalling cables.
(b) The signalling cables must be separated
from LT power cables by a row of bricks or
any other approved means and from HT
power cables a minimum of 3m separation
shall be maintained.
 Where it is necessary to take the cable between
the tracks, it shall be carried in
trunking/Duct/pipe kept sufficiently below the
ballast level. RCC duct for laying
 Where several cables of different categories of Signalling cables
have to be laid in the same trench, they shall
be placed as far as possible in the following
order starting from the main track side, so that
in the event of failures, the maintenance staff
may easily recognize the damaged cables.
(a) Telecommunication cable
(b) Signalling cable
(c) Power cable
 Signalling cables for outdoor circuits should
not normally be laid above ground. In
exceptional cases where it becomes
unavoidable, the following precautions should 9
be taken:
 Laying
(a) The cable should be suspended in wooden
cleats, from cable hangers or in any other
approved manner so that no mechanical
damage occurs to the cable even under
exposed condition.
(b) The cable supports shall be so spaced as to
avoid sag.
(c) In station yards, cable shall be laid in ducts
suitably protected.
(d) Indoor signalling cable should normally be
laid on ladders, channels or in any other
approved manner. The cables should be
neatly tied/laced.
 While laying the cables in accordance with the
above instructions, the following instructions
should be adhered: Cable laying along
(a) Outside the station section, the cables should Track side
generally be laid at not less than 5.5 m from
the centre of the nearest track.
(b) Within the station section, the trenches
shall preferably be dug at a distance of not
less than 3 meters from the centre of the track,
width of the trench being outside the 3m
distance.
(c) At each end of the main cable an extra
loop length of 6 to 8 m should be kept.
 After laying the cables, back filling of the
trenches should be done properly. The soil
excavated shall be put back on the trench, 10
rammed and consolidated.
 Laying
 Where the cables are entering the Cable room/Relay
Room/apparatus case etc., the cables shall be firmly held
with suitable clamping arrangement, so as to avoid
downward displacement.

Cable Crossing
 When a cable has to cross the track, is should be
ensured that-
(i) The cable crosses the track at right angles.
(ii) The cable does not cross the track under points and
crossings.
(iii) The cable is laid in concrete/GI/DWC-HDPE pipes of
approved type, suitable ducts or in any other approved
manner while crossing the track.
(iv) Wherever feasible horizontal directional drilling
method may be used.

Cable Laying in RE Area

 The cable shall be so laid that it is not less than one
meter from the nearest edge of the mast supporting the
catenary or any other live conductor, provided the depth
of the cable does not exceed 0.5 m. When the cable is
laid at a depth greater than 0.5 m, a minimum distance of
3 m between the cable and the nearest edge of the O.H.E
structure shall be maintained. If it is difficult to maintain
these distances, the cable shall be laid in DWC-
HDPE/Concrete Ducts or any other approved means for
a distance of 3 meters on either side of the Mast. When
so laid, the distance between the cable and the mast may 11
be reduced to 0.5 m.
 Cable Laying in RE Area
 In the vicinity of traction sub stations and feeding posts,
the cable shall be at least One m away from any metallic
part of the O.H.E and other equipment at the substation,
which is fixed on the ground, and at least One m away
from the substation earthing. As far as possible, the cable
shall be laid on the side of the track opposite to the
feeding post. In addition, the cable shall be laid in
concrete or DWC-HDPE pipes (approved type)/Split
RCC pipes or other approved means for a length of 300
m on either side of the feeding point.
 In the vicinity of the switching stations, the cable shall be
laid at least One m away from any metallic body of the
station, which is fixed in the ground, and at least 5 m
away from the station Earthing. The distance of 5 m may
be reduced to One m provided the cables are laid in
concrete pipes/DWC-HDPE-pipes of approve type/ducts
or any other approved means.
 Where an independent Earth is provided for an O.H.E
structure, i.e. where the mast is connected to a separate
Earth instead of being connected to the rail, the cables
shall be laid at least one metre away from the Earth.
 Where there are O.H.E structures along the cable route,
the cable trenches shall as far as possible, be dug not less
than 5.5 m away from the centre of the nearest Track.
 The use of G.I pipes or any form of metallic pipes is
prohibited within a distance of 300 m from feeding post.
Similarly, galvanized iron metallic pipes are prohibited
in close proximity to switching station earth or traction
mast. 12
 Testing of Cables
 Periodical of Signalling cables:
a) First measurement of insulation of the cable should be
carried out after laying of the cable and after first
monsoon for all the conductors.
b) After major work in a yard, all cables should be
meggered afresh.
c) In all other cases, Insulation Resistance shall be tested
periodically as given below:

Type of Cable Periodicity

Main Cable Every 2 years
Tail Cables – Signal/Track/Points etc Once in a year
Spare Conductors Once in a year

 No excavation in the vicinity of underground signal

cables shall be undertaken without a representative of the
signal & telecommunication department present and
without taking suitable precautions for the safety of the
existing cables. Suitable instructions in this regard shall
be issued by the Railway in the form of a joint circular.
 The protective works provided for the cables at places
like track crossings, culverts, bridges etc shall be
regularly inspected by the maintenance staff, special
attention being paid to these protective works soon after
the monsoon.
 Earth Leakage Detector (ELD): Shall be provided in
all signalling installations and shall be interfaced with 13
Data logger (wherever feasible) for remote monitoring.
DISCLAIMER: The information given in this document does not
supersede any existing provisions laid down in Signal Engineering
Manual, Railway Board and RDSO publications. This document is not
statutory and instructions given in it are for the purpose of guidance
only. If at any point contradiction is observed, then S.E.M., Rly.
Board/RDSO guidelines or Zonal Rly. instructions may be followed.