Geo-Synthetics

Specifications for Railway

Sector

Rajesh Agarwal, Director, RDSO

 RDSO – Research Design & Standard Organization
 Only R & D organization of IR
 Deals from Track formation to Bridges to Coaches to signal
to OHE
 Made specifications of products for Railway Use
 Latest Achievements includes
 AC Double Decker Coach
 4500 HP Hotel load locomotive
 Video Surveillances for running train
 Designing of Track including formation for HAL


 Geotechnical Directorate

 Deals with R & D of soil mechanics – for the

use of Railways in

 Formations
 Cuttings
 Ground improvement
 RE wall constructions ( ROB )
 Introduction
 Geosynthetics :Generally Polymer based -
Polypropylene, Polyester, PVC, Polyamide,
Polyethylene
 Various types of Geosynthetics can be used in
Railways

 Geotextiles
 Geogrids
 Geonets
 Geocell
 Geomembranes
 Geocomposites
 Prefabricated Vertical Drains (Band Drains)
Functions of Geosynthetics
 Geo-synthetics can perform one or several functions
to improve mechanical or hydraulic behaviour of the
Railway Formations (Base structure)
 The basic functions performed by geo-synthetics are:

 Separation
 Filtration
 Drainage
 Reinforcement
 Barrier
 Basal Layer
Functions of Geosynthetics
Separation

Filtration

Natural Soil

Geo-textile
Water Flow Direction

Granular Soil
Functions of Geosynthetics

Reinforcement

Drainage
Functions of Geosynthetics

Barrier
Scope for use of geosynthetics

Vision 2020

 New Lines -- 25000 km route expansion

 DFC- Western & Eastern Corridor
 Double/Multiple lines – 30000 Kms
Need for Use of Geo-Synthetics
Existing Lines

• Indian Railways is upgrading infrastructure to

meet future demand of growing traffic.
• Geosynthetics can also be used in
rehabilitation/strengthening of existing weak
formation of length about 700 kms PR & 2000km
TSR.
Scope for use of geosynthetics

ROB/RUB
 Road Over Bridge ( 600 ROB constructed per year)
 Application In Railway (General)

 Steep Slope Construction ( Non Railway Loading)

 Construction of high banks on soft soil (PVD)
 Erosion control of slope
 Protection against rock falls
 ROB for Road Loading
 Use of Synthetic
Geogrids for Erosion
Control of Natural
Existing Slopes
Construction of RE Embankment
 Typical Cross Section of Embankment
with Prefabricated Vertical Band Drains

Initial Sand
Embankment Blanket

Band
Soft drains
Clay
Layer
Firm
Soil
15
 Application In Railway (Specific)

 Track Bed Design

 Reinforced Earth Embankment (Railway
Loading )
 Formation Rehabilitation
GEOSYNTHETICS APPLICATION IN RAILWAY FORMATION

USES OF GEO-GRID
GEOSYNTHETICS APPLICATION IN RAILWAY FORMATION
 Geotechnical Directorate

Locations Specification requirement

Formations To be designed for Rly Loadings
Cuttings No issue with Rlys
Ground improvement No issue with Rlys
RE wall constructions ( ROB) No issue with Rlys
Specifications and scope for use of
geo-synthetics in World Railways
European Railways (UIC)
Code 719 R

New Construction
 Geotextiles between blanket and prepared
subgrade if prepared subgrade has fines
more than 15%

Existing Track
 Geotextiles and geogrids for Formation
Rehabilitation
Specifications and scope for use of
geo-synthetics in World Railways
European Railways (UIC)
Code 719 R

New Construction
 Geotextiles between blanket and prepared
subgrade if prepared subgrade has fines
more than 15%

Existing Track
 Geotextiles and geogrids for Formation
Rehabilitation
Specifications and scope for use of
geo-synthetics in World Railways
American Railways
AREMA Manual Part 10

New Construction
 Geotextiles between Ballast & sub-ballast
 Geotextiles beneath sub-ballast
 Erosion Control on slopes

Existing Track
 For Formation Rehabilitation
Specifications and scope for use of
geo-synthetics in World Railways
Australian Railways
Reconditioning Guidelines RTS3430

Existing Track
 Geotextiles and Geogrids for Formation
Rehabilitation
Specifications and scope for use of
geo-synthetics
Indian Railways (specific to railway use)

 Jute geotextiles ( for erosion control) Issued

 Geo-grids under trial
 Geotextiles (beneath track & slope protection) under
preparation
 Jute Geo-Textile
 Guidelines for application of Jute Geo-textile in
Railway Embankment & Hill slopes issued for
erosion control.

 Guidelines no. RDSO/2007/GE : G-0008

Use of IS of geo-synthetics by IR

Geo Jute
All properties is to be checked with IS codes
Properties Test Method (IS)
Weight (gsm) IS: 2387
Maximum length & width IS: 1954
Ends/dm & picks/dm IS: 1963
Thickness IS: 7702
Aperture size IS: 2405
Minimum Breaking Load IS:1969
Maximum Elongation at IS: 1969
Break
Use of IS of geo-synthetics by IR

Geo Grid
All properties is to be checked with IS codes
Properties Test Method (IS)
Mass per unit area IS: 14716
Ultimate Tensile Strength IS: 13162 (Part V)
Load at 2% & 5% strain IS: 13162(Part V)
Strain at Ultimate Tensile Strength IS: 13162(Part V)
Use of IS of geo-synthetics by IR

Geo Textiles
All properties is to be checked with IS codes
Properties Test Method (IS)
Mass per unit area IS: 14716
Tensile Strength IS 13162
Elongation at break IS: 13162
Apparent opening size IS: 14294
Water flow rate normal to IS: 14324
the plane
 Geo-grid in IR
 Biaxial geo-grid has been used in South Central
Railway, Northern Railway (Polypropylene – strength
30 kN/m with aperture size of 61mm x 61mm) has
been used for formation rehabilitation/strengthening.

 Observations in field at SCR & NR have indicated

improvement of overall track performance after the
application of Geo-grid.
 Geo-grid+Geo-textile on IR
 NF Railway also tried use of Geo-grid (Polyester based –
knitted & coated with strength of 40 kN/m & aperture size
of 25mmx25mm) in combination of geo-textile and sand
layer for formation rehabilitation.
 The performance report of the trial section of NF Railway
is satisfactory.

For low density routes, geotextile along with sand layer and brick
soling has been used in Sitamarhi – Darbangha project, ECR.
 Geo-grids
 Field trials for formation rehabilitation Geo-
grid in SCR

 Issues involved for optimum benefit

 Aperture size ( As per ballast size if IR)

 Junction strength (As per Axle load)
 Material type (As per Soil/Atmospheric condition)
 Geo-grids

40X40 mm to 60X60 mm aperture size are not

available for trial.

These sizes may be provided/manufactured.

Scope- Early Rehabilitation of approx. 2000 km track.

Specifications of Geogrids for Extended Trials on South Central Railway

Item Property Test Method Values

1 Material of Geo- • Any organic polymer based material to provided

grid required mechanical properties (like
Polypropylene/Polyester/HDPE or similar polymer).
• Atleast, both Polypropylene and Polyester geo-grid
material must be used in trial.

2 Aperture size 1. 30-40 mm – Square (preferably 35mmx35mm)

(clear) 2. 40-50 mm – Square (preferably 45mmx45mm)
3. 50-60 mm – Square (preferably 55mmx55mm)
4. 30-40 mm x 60-65 mm – Rectangular
5. 40-50 mm x 60-65 mm – Rectangular
Aperture sizes of geo-grid of square/rectangular shape
in each above group should differ atleast by 8-10mm.

3 Roll width As per requirement of width attachment to fit with BCM,

in the range 3.8m to 4.0m.
4 Roll length 50 m (Minimum)
 Mechanical Properties & other Tests
Item Property Test Method Values

5.1 Ultimate Tensile Strength IS: 13162 part 5 & IS: Two types
(MD & CD) 13325/ASTM D 1. 20 kN/m
6637/BS EN ISO: (minimum)
10319 2. 30 kN/m
(minimum)
5.2 Strain at Ultimate Tensile IS: 13162 part 5 & IS: 8-5% (Range)
Strength 13325/ASTM D
(MD & CD) 6637/BS EN ISO:
10319
5.3 Junction Efficiency (CD & MD) GRI-GG2-87 and GRI- Desirable 95%
(Non Essential Test) GG1-87 (Test to be done
prior to insertion)
Non Essential Tests : These tests are to be conducted on geo-grid samples before
laying and test values are to recorded for further decision.
6.1 Radial stiffness at low strain ISO 10319: 1996
(@0.5% strain)(Non Essential
Test)
 Property Test Values
Item Method

6.5 Resistance to chemical EPA 9090

degradation
(Non Essential Test)
6.6a Resistance to UV Light ASTM D4355
Weathering
(Non Essential Test)
6.6b Carbon Black Test BS2782 Part-4 Method, 452B: 1993
(where applicable as
per polymer type
material)
(Non Essential Test)
6.7 Creep limited Strength ASTM D 5262/ASTM D6992/ISO 13431
for 15 years period at
30° C temp.
(MD & CD)
(Non Essential Test)
 Specification of Non-woven Geo-textile

SL Property Test Method Values

1 Polymer Polypropylene/ High Density Polyethylene/
polyamide, polyester or similar polymer
2 Weight/Mass per unit area IS: 14716 / 300 g/m2
ASTM D: 3776 (Minimum)
3 Thickness of Fabric at 2 Kpa ASTM 5199 2.0 mm (minimum)
4 Roll width 5.0 metre (minimum).
5 Roll Length 50 m (minimum)
Mechanical Properties
1 Elongation at break IS: 13162 / 40 % to 70 %
ASTM D 4595 /
EN ISO: 10319
2 Tensile Strength IS: 13162 / ASTM D 15 kN/m (minimum)
4595 /
EN ISO: 10319
Hydraulic Properties
IS: 14294 / ASTM D
1 Apparent opening size O95 4751 / 40 to 85 microns
EN ISO: 12956
Water Flow Rate Normal to the IS 14324 / 20 lit. /m2/s
2 Geotechnical
Plane ASTM D 4491 (minimum) Engg./RDSO
36
 Specification of woven geo-textile
SL Property Test Method Values
1 Polymer Polypropylene/ High Density Polyethylene/
polyamide/ polyester or similar polymer
2 Mass per unit area IS: 14716 / 240 g/m2 (Minimum)
ASTM D: 3776
3 Thickness at 2 Kpa ASTM: 5199 0.65 mm (minimum)
4 Roll width 5.0 metre (minimum)
5 Roll Length 50 m (minimum)
Mechanical Properties
1 Tensile Strength
Warp IS: 1969 / 40kN/m (Minimum)
ASTM D 4595 /
Weft 35kN/m (Minimum)
EN ISO: 10319
2 Elongation at Maximum Load
Warp IS: 1969 / 15%-30 %
ASTM D 4595 /
Weft 15%-30 %
EN ISO: 10319
3 Puncture Strength IS: 13162 /
600 N (Minimum)
ASTM D: 4833
Hydraulic Properties
IS 14294 /
1 Apparent opening size O95 ASTM D: 4751 / 425 microns (maximum)
EN ISO: 12956
Water Flow Rate Normal To The IS: 14324/ Geotechnical
2 15 lit. /m2/s (minimum)
37 Plane ASTM D: 4491 Engg./RDSO
Reinforced Earth Design for Railway Loading

By KRCL in USBRL Projects

Bridge no 40 at Riasi
Bank of 16m to 56 m high
Design Approved by IIT/D

Cost effective (whether or not)

Road Over Bridge without Reinforced Earth Wall (Conventional ROB)
Road Over Bridge With Retaining Wall
Road Over Bridge With Reinforced Earth Wall
 General Issues
 Specification- Generic in nature
 To avoid monopoly
 Material to be readily available (Time
constraint)

 Cost effective
 Should be competitive with Alternates
 Research with Blending of Jute with PP etc.
being explored by Railways
Issues concern
 Testing facilities
 Contracts to be awarded division wise & to be
passed by divisional authorities
 How testing of material to be monitored

 Works contract/Supply contract

 Railway prefers works contract
 Application of Geo-syntheticis

 Analysis of behavior of different Geo-synthetics to

be used in Railway Formations

 Validation through Lab model,

 FEM model
 And site measurements etc.

 Draft Guidelines For Geo-synthetics Prepared & under active

discussion with in Railway
THANKS
 Other Use Of Geosyntheticis in IR

Different Zonal Railways may be use the

Geosynthetic on their railway as per requirement
and site conditions such as:
Steep Slope Construction, Embankment Slip
repairs, Construction of high banks on soft soil
(PVD), Erosion control of slope And Protection
against rock falls etc.
 Formation treatment with blanket &
geotextile by formation rehabilitation m/c
The limitations of Indian railways

 The formation rehabilitation m/c very costly

 Line Block Requirement - 6 to 8 Hrs.
(Very difficult for running track)
 Progress very slow- 300 to 400 m per day
 Geotextile life is very short 4 -5 years, Indian Railway
want long life such as 10 to 15 years.
 Cost effectiveness - Cost consideration not match
 QUALITY ASSURANCE & QUALITY
CONTROL PLAN FOR GEOSYNTHETICS
The manufacturer must have in house integrated
testing facilities for all the tests as per specifications
to be carried out on the product. The testing
facilities may be more for Geosynthetics in India.

 The Railway Authorities may witness the tests

carried out at independent testing facilities.
 CONCLUSIONS
 Geo-synthetics can be used effectively in railway
application for track bed stabilization, track drainage,
erosion control, interface protection, construction over soft
soil, steep slope construction, mud pumping, etc.
 Its use is a necessity and cost effective for construction of
new formations & rehabilitate / strengthen the existing
formations for running of heavy axle loads.
 The specifications of Geosynthetics items specially
Geogrid for railway application are in evolving stage
worldwide.
 IR has gained some experience and RDSO has framed
provisional specifications. These should be tried as per site
conditions.
 Extended Field trials are necessary to validate & assess
specifications of geogrids for track bed strengthening.
Need for Use of Geo-Synthetics
New Constructions
• To construct ‘Dedicated Freight Corridors i.e.
Eastern Corridor & Western Corridor’ & ‘High
Speed Corridors to connect the major cities.’
• This requires construction of new stable track
formations suitable for heavy axle loads.
• It is difficult to adopt the present practice in DFC
& High speed which will increase the maintenance
cycles. Hence Railway formation should be
design using geo-synthetics.
 Specification of Geo-grid
SN Property Test Method Values

1 Polymer Polypropylene/Polyester or similar polymer

2. Mass per unit area IS: 14716 / 320 g/m2(minimum)

ASTM D: 3776
3. Aperture size Square opening of suitable size (suggested size 35mm to 60
mm) such that effective interlocking takes place with the
existing ballast particles. (Size to be decided by PCE
Zonal railway, as per site conditions.)
4. Roll width As per site requirement and width attachment to BCM

5. Roll Length 50 m (minimum)

Mechanical Properties
1. Ultimate Tensile Strength (MD) IS: 13162 part 5 & IS: 30 kN/m (minimum)
13325 /
Ultimate Tensile Strength (CD) ASTM D 6637 / 30 kN/m (minimum)
BS EN ISO: 10319
2. Strain at Ultimate Tensile Strength (MD) IS: 13162 part 5 & IS: 8 - 15%
13325 /
Strain at Ultimate Tensile Strength (CD) ASTM D 6637 / 8 - 15%
BS EN ISO: 10319
3. Creep limited strength for 15 years period at 30 0 ASTM D5262 / 15 kN/m (minimum)
C temperature (MD and CD) ASTM D6992 /
ISO 13431

Note: 1. Test method is only indicative which give procedure. However values will govern as
specified above.
2. Long term strength of geogrid with due consideration of creep effect is important as
geogrid is supposed to remain under track for long period say 20 years or more. Geotechnical
51 3. MD stands for Main Direction & CD stands for Cross Direction. Engg./RDSO