Track Tolerances 2020

TRACK GEOMETRY
TOLERANCES
&
measure of
Track Quality
WHY?
• Ideal Conditions cannot remain, when track is in service
• For Monitoring track geometry parameters
• To limit the disturbances in service
• To avoid Subjectivity
• For optimization of Maintenance Resources and
maintenance cycle
• To appreciate and control quality of inputs
• To optimize safety and Comfort Worthiness of Track,
and
• To prolong service life of vital & expensive asset
TRACK GEOMETRY STANDARDS
Laying standards
Maintenance Standards
Safety
Comfort
Cost effective
 Need-based maintenance inputs (no over/under maintenance)
METHODOLOGY FOR SETTING
STANDARDS
Statistical Analysis – (Track Geometry Quality components)
Economic Considerations / Maintainability
Correlation With Vehicle Ride

RIDE QUALITY CORRELATION
C & M Report No. 1 for Introducing trains at speeds
beyond 110 km/h (1969).
SD Based Studies considered in 59th TSC.
Transmark U.K. Studies on IR for Higher Speeds
(1995), Inertial Recordings of Track Parameters to
generate absolute profiles and correlation between
different parameters and ride quality.
TM-109 report of RDSO.
CS-149 & 150 to IRPWM
RIDE QUALITY CORRELATION
Between Track Parameters & Ride quality
Unevenness Vs Vertical Acceleration
Vs Vertical Ride Index
Alignment Vs Lateral Acceleration

Vs Lateral Ride Index
RIDING QUALITY STANDARDS (3 RD
CRITERIA COMMITTEE)
Acceleration
Ride Index
Stock Lateral Vertical
Preferable Limiting Preferable Limiting Preferable Limiting
Coaches 3.25 3.50 0.30 g 0.35 g 0.30 g 0.35 g

EMU & DMU 3.25 4.00 0.30 g 0.35 g 0.30 g 0.35 g
Locomotives 3.75 4.00 0.35 g 0.35 g 0.30 g 0.35 g
Wagons 4.25 4.50 Not specified Not specified
Break down
crane 4.25 4.50 - 0.5 g - 0.5 g
Departmental
vehicles 4.25 4.50 0.55 g 0.6 g 0.55 g 0.6 g
Q = actual track quality
Q0 = the initial quality
b = deteriorate rate coefficient
t = time
MAINTENANCE LIMITS
Categorization under three categories
Track requiring planned maintenance
Track requiring need based maintenance
Track requiring urgent maintenance
TRACK STANDARDS
Maintenance Inputs
New Track Tolerance (NTL)
Level of Maintenance
Maintenance Tolerance (TML)
Index Tolerance (PML)
Service Tolerance (NBML)

Deterioration
Slow Down Tolerance (UML)
Safety Tolerance
Time
TRACK STANDARDS
Classification
• New track tolerances (NTL)
• Maintenance tolerances (TML)
• Index or planning for maintenance tolerances (PML)
• Service tolerances (NBML)
• Slow down tolerances (UML)
• Safety tolerances
TRACK TOLERANCE ON I.R.
 New Track Tolerances: (NTL)
 Para 316 (2) (a) of IRPWM – Peak Based
 Floating condition
 Item 786 of 59th TSC
 Para 316 (2) (b) of IRPWM – SD Based & Peak Based
 Measurement by TRC
 Maintenance Tolerances: (TML)
 Table 3.1 of IRTMM
 RDSO’s report No.TM-115
Index Tolerances:
RDSO’s report No.TM-109
IRPWM para 607(2) – Planned Maintenance Limits
(PML)
for alignment and unevenness
Service Tolerances:
C&M-1 (Rly. Bd. Letter no.71/W6/HS/1 dt. 21-10-71)
IRPWM para 607(2) – Need Based Maintenance Limits
(NBML)
for alignment, unevenness, Gauge & Twist
SLOW-DOWN & SAFETY TOLERANCES
Slow Down Tolerances:
IRPWM para 607(2) – Urgent Maintenance Limit
(UML)
for acceleration, Gauge & Twist
Safety Tolerances:
Para 607(3) of IRPWM
 RAIL WHEEL interaction is a complex phenomena
 Safety Tolerances for maintenance of track alone can not be prescribed in
ISOLATION
 Tolerances in para 607(2), 607(3) and elsewhere are with a view to
maintain track geometry for
good riding comfort NO SAFETY TOLERANCE

 Standard Deviation Based Tolerances
 NTL, PML, NBML
 For alignment & unevenness only
 For Speed ≤ 100 km/h
 For Speed > 100 km/h ≤ 110 km/h
 Peak Based Tolerances
 Al & UN (for NTL & NBML), Acceleration (for UML)
 For Speed ≤ 100 km/h
 For Speed > 100 km/h ≤ 110 km/h
 Gauge & Twist (NBML & UML)
 + Maintenance Tolerances (TML)
TRACK STANDARDS
Classification
NEW TRACK TOLERANCE
Best in terms of track quality.
Useful for controlling quality of track renewal, and
track relaying.
Practically achievable.
Track Standards
TRACK LAYING STANDARDS AS PER IRPWM (PARA-316) 59TH TSC-786
TO BE RECORDED 3 MONTHS AFTER THE SPEED IS RAISED TO
NORMAL
(a) Gauge Sleeper to sleeper variation + 2 mm
(b) Expansion gap Over average gap worked out by recording 20 successive gaps + 2 mm
(c) Joints Low joints not permitted
High joints not more than 2 mm
Square-ness of joints on straight + 10 mm
(d) Spacing of Sleepers With respect to theoretical spacing + 20 mm

(e) Cross level To be recorded on every 4th sleeper + 3 mm
(f) Alignment On straight on 10 m Chord + 2 mm
Variation over theoretical versine 5 mm

On curves of Radius more than 600 m (On 20 m Chord)
Variation over theoretical versine 10 mm

On curves of Radius less than 600 m (On 20 m Chord)
(g) Longitudinal level Variation in longitudinal level with reference to approved 50 mm
longitudinal sections.
GAUGE ON CURVES – BG – NEW
TRACK
(PARA 403 OF IRPWM)
Sl. No. Radius in meters Gauge
Straight including curves of -5mm. to

1. radius up to 350 m and more +3mm.
2. For curves of radius less than Up to +10mm.

350 m
NEW TRACK STANDARDS (IRPWM PARA 316(2)(B)
(I)) CS-149
SD value for
Parameter Speed upto Speed above
100 km/h 100 km/h and upto 160 km/h
UN-1
2.0 mm 1.4 mm
(9.0 m)
UN-2 - 1.9 mm
(18.0 m)
AL-1
1.4 mm 1.1 mm
(9.0 m)
AL-2
- 1.3 mm
(15.0 m)
NEW TRACK STANDARDS (IRPWM PARA 316(2)(B)
(II)) CS-149
Peak values for
Parameter Speed upto Speed above
100 km/h 100 km/h and upto 160 km/h
UN-1
6.0 mm 4.0 mm
(9.0 m)
UN-2 - 6.0 mm
(18.0 m)
AL-1 4.0* mm 3.0* mm

(9.0 m) * from design versine for curves * from design versine for curves
AL-2 4.0* mm
-
(15.0 m) * from design versine for curves
TRACK STANDARDS
Classification
MAINTENANCE TOLERANCES
For assessing efficacy of maintenance operation.
Next best tolerances, after new track tolerances, to which
the track should be brought after maintenance
input.
Theoretically depends on age of track structure,
cumulative GMT carried, method of maintenance.
Level of track quality attainable after each
maintenance cycle goes on reducing due to wear &
tear of track components with time.
MAINTENANCE TOLERANCE
(TABLE 3.1 OF IRTMM)
Acceptance criteria for Tamping of track
Parameter <10 peaks Any peak
Alignment ±4mm ±6mm
X-Level ±6mm --
Unevenness ±6mm ±10mm
Note-
(i) At least 4 stretches of 25 sleepers per km of tamped track
should be recorded
(ii) The versine and SE of curves for at least 10 stations should
be recorded
TRACK STANDARDS
Classification
INDEX TOLERANCES (PML)
Tolerances at which planning for maintenance
should be undertaken.
For applying timely correction
PLANNED MAINTENANCE LIMITS (PML)
For Alignment & Unevenness (affects Ride Quality)
based on SD values only (no peak limits)
SD values, if exceeded,
 Analyze track geometry condition
 Consider for planned maintenance
Meant for Guidance to plan
Through maintenance of track
In a complete block section, when majority of track exceed PML
By track machines only.
MAINTAINABILITY CONSIDERATION (PML)
Generally not more than 50% of track to fall beyond
this limit
Practically both Left and Right side values for both
Alignment and Uneven-ness would be above
prescribed limits
Therefore 70% of track on CFD is taken for selected
sections to work out SD values
95 percentile value amongst these is taken for PML,
to discard abnormally high value.
PLANNED MAINTENANCE LIMIT (PML)
(IRPWM PARA 607(2)(A) CS-149
SD value for
Parame Speed above Speed above Speed above
ter Speed upto 100 km/h and 110 km/h and 130 km/h and
100 km/h upto 110 km/h upto 130 km/h upto 160 km/h
UN-1 5.0 mm 3.8 mm 3.3 mm 2.9 mm
(9.0 m)
UN-2 - 5.4 mm 5.1 mm 4.4 mm

(18.0 m)
AL-1 3.3 mm 2.5 mm 2.5 mm 1.9 mm

(9.0 m)
AL-2 - 4.1 mm 3.5 mm 2.5 mm

(15.0 m)
GAUGE AS PER PARA 224 (2)(E)(V) OF IRPWM
• Variation of Gauge due to
 Age and condition of the Rail, Sleepers, and fastenings
• Limits of Gauge are specified
 in floating condition;
 for guidance regarding condition of Track;
 from passenger comfort perspective.
 Provided that generally a uniform gauge is maintained
over long lengths.
GAUGE AS PER PARA 224 (2)(E)(V) OF IRPWM
• In case of exceedences to plan suitable maintenance
action based on last TRC/OMS results)
• On straight – 6 mm to + 6 mm
• On curve with
 Radius 440 m or more – 6 mm to +15 mm
 Radius less than 440 m upto +20 mm
• Reference Gauge = 1676 mm (nominal gauge)
TWIST AS PER PARA 224 (2)(F)(XII) OF IRPWM
• Track geometry maintenance for comfortable ride
at sectional speed.
• Limits of Twist are specified
 in floating condition;
 for guidance regarding condition of Track;
 from passenger comfort perspective.
 On a base of 3.0 m
TWIST AS PER PARA 224 (2)(F)(XII) OF IRPWM
• In case of exceedences to plan suitable maintenance
action based on last TRC/OMS results)
• On straight & Curved Track 3.5 mm/m

(other than transition)
• On transition of curve 2.1 mm/m

(Local Defects above designed value)
TRACK STANDARDS
Classification
SERVICE TOLERANCES (NBML)
Standards upto which track parameters may deteriorate
during service.
Limiting standards of track parameters:
 for maximum permissible speed to have the minimum acceptable level
of riding comfort.
Track should be attended as soon as these limits are reached.
(Most important tolerances for maintenance Engineer)
Marked by *** under MI column in Km wise TRC output.
NEED BASED MAINTENANCE LIMITS (NBML)
Purpose
For applying timely correction
Before existing defect size (just below NBML) grows to
the level of UML (before next monitoring)
UML requires traffic to slow down
Allowable time for attention depends on
Magnitude of defect; and
Various other factors affecting track geometry
deterioration
 Sectional speed, axle load, traffic volume etc.
MAINTAINABILITY CONSIDERATION (NBML)
For both Alignment and Uneven-ness not more than
10% of track shall fall beyond this limit
Practically both Left and Right side values for both
Alignment and Uneven-ness would be above
prescribed limits
Therefore 95% of track on CFD is taken for selected
sections to work out SD values
95 percentile value amongst these is taken for
NBML, to discard abnormally high value.
NEED BASED MAINTENANCE LIMIT
(NBML)
IRPWM PARA 607(2)
Speed upto 100 km/h
Parameter
SD Value (mm) Peak value (mm)
UN-1
(9.0 m)
6.8 20
UN-2
(18.0 m)
- -
AL-1
(9.0 m)
4.9 15
AL-2
(15.0 m)
- -
(NBML)
IRPWM PARA 607(2)
Speed above 100 km/h and upto 110
Parameter km/h
UN-1
(9.0 m)
5.5 17
UN-2
(18.0 m)
7.5 23
AL-1
(9.0 m)
3.9 12
AL-2
(15.0 m)
6.7 20
(NBML)
IRPWM PARA 607(2)
Speed above 110 km/h and upto 130 km/h
Parameter
UN-1
(9.0 m)
4.9 15
UN-2
(18.0 m)
7.4 22
AL-1
(9.0 m)
3.6 11
AL-2
(15.0 m)
5.3 16
(NBML)
IRPWM PARA 607(2)
Speed above 130 km/h and upto 160 km/h
Parameter
UN-1
(9.0 m)
4.4 13
UN-2
(18.0 m)
6.6 20
AL-1
(9.0 m)
3.6 11
AL-2
(15.0 m)
4.9 15
(NBML)
IRPWM PARA 607(2)
• The limits for alignment are variation from average
versine for curves.
• For maintenance/realignment of curve
 Para 421 remains applicable
ROC PROVISIONS (PARA 421, IRPWM)
ROC PROVISIONS (PARA 421, IRPWM)
• In case the above limit is exceeded,

• Local adjustments may be resorted to, in cases
where the variation of versine between adjacent
stations is only at few locations, at the earliest
possible.
• If more than 20% stations are having versine
variation above the limits prescribed
• Complete realignment of the curve should be
planned within a month.
TRACK STANDARDS
Classification
URGENT MAINTENANCE LIMITS (UML)
Laid down in terms of
Accelerations Limit on comfort considerations; and
Peak values for Gauge and Twist
Wherever acceleration peak exceeds UML
Permitted speed to be reduced to lower speed level;
(restored only after attending the track)
More studies are required to lay down in terms of
peak values for other parameters
URGENT MAINTENANCE LIMIT (UML)
PARA 607(2) OF IRPWM
The permitted speed reduced to a suitable lower
speed level keeping in view aforesaid criteria.
Lateral & Vertical

Speed Band
Acceleration Peak
Above 130 km/h 0.30g
Above 110 km/h and upto 130 km/h. 0.30g
Above 100 km/h and upto 110 km/h. 0.25g
Above up to 100 km/h 0.20g

TRACK STANDARDS
Classification
SAFETY TOLERANCES
Limits beyond which dangerous/unsafe conditions arise for
movement of rolling stocks.
Track geometry, if maintained within tolerances for ride
comfort, will automatically ensures safety
 Safety tolerances would be very slack compared service tolerances for
minimum ride comfort.
Unsafe conditions not only depends on condition of track but
also on type of vehicle, their riding characteristics & their
maintenance standards.
Not specified on IR even on world railways.
NO SAFETY TOLERANCE
IRPWM PARA 607 (3)
Para 607(3) The stability of trains against derailment, depends
upon several factors such as track geometry, vehicle characteristics
& state of their maintenance and speed of the particular vehicle at
relevant point of time etc. Rail wheel interaction is thus, a complex
phenomenon and therefore, safety tolerances for track alone
cannot be prescribed in isolation. With this in view, safety
tolerances for maintenance of track have not been prescribed on
Indian Railways. Each derailment case, therefore, needs careful
examination of all available evidence, in respect of Track, Rolling
Stock, speed and other factors considered relevant, to arrive at the
cause.
The provision and tolerances mentioned in Para 607(1) and 607(2)
and elsewhere in this Manual are with a view to maintain track
geometry for good riding comfort.
Summery
SUMMERY OF PML, NBML, AND UML
(SPEED UPTO 100 km/h)
Planned NeedBased
UrgentMaintenance
SN Parameter Maintenance MaintenanceLimit
Limit(UML)
Limit(PML) (NBML)
1 Unevenness
SD-6.8 mm
1.1 UN-1 SD-5.0 mm
PeaK-20 m
Vertical and lateral
1.2 UN-2 - -
acceleration peak of
2 Alignment
0.30g
SD-4.9 mm
2.1 AL-1 SD-3.3 mm
Peak -15 mm
2.2 AL-2 -
3 Gauge
3.1 Meangaugeover200msectionovernominal gauge
(a) Straight - -8 mm to +10 mm -10 mm to + 12 mm
(b) Curve with radius 440m or more - -5mm to +14mm -7mm to +17mm
Curve with radius less than 440m (Permissible
(c) - -5mm to +18mm -7mm to +20mm
speed as per relevant para of IRPWM)
3.2 Isolateddefects–Nominal trackgaugetopeakvalue
(c) - -6mm to +22mm -8mm to +25mm
4. Twist(TW-1) 5 mm/m 7 mm/m
(SPEED ABOVE 100 km/h and upto 110 km/h)
Planned NeedBased Urgent
SN Parameter Maintenance MaintenanceLimit MaintenanceLimit
Limit (PML) (NBML) (UML)
1 Unevenness
SD-5.5 mm
1.1 UN-1 SD-3.8 mm
PeaK-17 m
SD-7.5mm
1.2 UN-2 SD-5.4mm Vertical and lateral
Peak-23mm
2 Alignment
0.30g
SD-3.9 mm
2.1 AL-1 SD-2.5 mm
Peak -12 mm
SD-6.7mm
2.2 AL-2 SD-4.1mm
Peak-20mm
3 Gauge
(c) - -5mm to +18mm -7mm to +20mm
(c) - -6mm to +22mm -8mm to +25mm
4. Twist (TW-1) 4 mm/m 7 mm/m
Planned Need Based
Urgent Maintenance
SN Parameter Maintenance Maintenance Limit
Limit (UML)
Limit (PML) (NBML)
1 Unevenness
SD-4.9 mm
1.1 UN-1 SD-3.3 mm
PeaK-15m
SD-7.4mm
Peak-22mm
2 Alignment
0.25g
SD-3.6 mm
2.1 AL-1 SD-2.5 mm
Peak -11 mm
SD-5.3mm
2.2 AL-2 SD-3.5mm
Peak-16mm
3 Gauge
(c) - -5mm to +18mm -7mm to +20mm
(c) - -6mm to +22mm -8mm to +25mm
4. Twist (TW-1) 4 mm/m 6 mm/m
Planned NeedBased
UrgentMaintenance
SN Parameter Maintenance Maintenance
Limit (UML)
Limit (PML) Limit (NBML)
1 Unevenness
SD-4.4 mm
1.1 UN-1 SD-2.9 mm
PeaK-13 m
SD-6.6mm
Peak-20mm
2 Alignment
0.20g
SD-3.6 mm
2.1 AL-1 SD-1.9 mm
Peak -11 mm
SD-4.9mm
2.2 AL-2 SD-2.5mm
Peak-15mm
3 Gauge
© - -5mm to +18mm -7mm to +20mm
© - -6mm to +22mm -8mm to +25mm
4. Twist (TW-1) 3.5 mm/m 5 mm/m
MEASUREMENT OF GAUGE AND TWIST
In floating condition
Gauge – para 224(2)(e)(v); and
Twist – para 224(2)(f)(xii)
For low speeds – 224(2)(f)(xiii)
(work-sites, yard lines etc.)
GAUGE – PARA 224(2)(e)(v)
The limits of gauge in floating condition
For guidance regarding track condition from comfort perspective
BroadGauge(ReferenceGauge=1,676mm)
a) On straight -6 mm to +6 mm
b) On curves with radius 440 m or more -6 mm to +15 mm
c) On curves with radius less than 440 m Up to + 20 mm
Generally a uniform gauge can be maintained over long lengths
In case of exceedences the results of last TRC/OMS
analyzed for planning suitable maintenance action
TWIST – PARA 224(2)(f)(xii)
Twist in Floating Condition:
For guidance regarding condition of track from passenger
comfort perspective, shall be as under (on a base of 3.0 m)
On straight and curved track, other than transition –
3.5 mm/m
On transition of curve
2.1 mm/m (Local defects above Designed value)
In case of exceedences
Results of last TRC/OMS analyzed for planning suitable
maintenance action.
FOR LOW SPEEDS – 224(2)(f)(xiii)
For maintenance of track (where speeds are low)
Worksites, yard lines etc.
For guidance of field officials.
In floating condition
PeakValueof Peakvalueof
Speed
Unevenness Twistinmm Gauge
(Km/h)
(at3.6mchord) (at3.0mchord)
45 22 mm 18 mm -10 to +27 mm
30 24 mm 21 mm -10 to +27 mm
15 33 mm 25 mm -12 to +27 mm
Thank You

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TRACK GEOMETRY

Economic Considerations / Maintainability

Correlation With Vehicle Ride

Alignment Vs Lateral Acceleration

Coaches 3.25 3.50 0.30 g 0.35 g 0.30 g 0.35 g

Locomotives 3.75 4.00 0.35 g 0.35 g 0.30 g 0.35 g

Wagons 4.25 4.50 Not specified Not specified

Maintenance Tolerance (TML)

Index Tolerance (PML)

Service Tolerance (NBML)

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

good riding comfort NO SAFETY TOLERANCE

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

(d) Spacing of Sleepers With respect to theoretical spacing + 20 mm

Variation over theoretical versine 5 mm

Variation over theoretical versine 10 mm

Straight including curves of -5mm. to

2. For curves of radius less than Up to +10mm.

AL-1 4.0* mm 3.0* mm

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

UN-2 - 5.4 mm 5.1 mm 4.4 mm

AL-1 3.3 mm 2.5 mm 2.5 mm 1.9 mm

AL-2 - 4.1 mm 3.5 mm 2.5 mm

• On straight & Curved Track 3.5 mm/m

• On transition of curve 2.1 mm/m

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

• In case the above limit is exceeded,

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

Lateral & Vertical

Above up to 100 km/h 0.20g

• Maintenance tolerances (TML)

• Index or planning for maintenance tolerances (PML)

• Service tolerances (NBML)

• Slow down tolerances (UML)

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