For official use only

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

UNIFIED INSPECTION AND

MAINTENANCE OF GHAT SECTION

CAMTECH/2003/C/GHAT/1.0
SEPTEMBER - 2003

Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance

Maharajpur, GWALIOR - 474 020

CAMTECH/C/2003/GHAT/1.0 1

Unified Inspection
&
Maintenance
of Ghat Section

Unified Inspection and Maintenance of Ghat Section September - 2003

CAMTECH/C/2003/GHAT/1.0 2

Foreword

In this handbook on Ghat Section, CAMTECH has tried to furnish

details of typicality and complexity of Permanent Way in hilly terrain.
General details of track, bridge & works sites as well as their inspection
and maintenance are nicely brought out with several sketches and case
histories of various ghat sections.

Civil Engineering branch of CAMTECH has made excellent effort to

bring out this handbook.

I am sure that this book will certainly prove to be useful for field
engineers & staff of Indian Railways

CAMTECH/Gwalior C.B.Middha
Date : 10.9.2003 Executive Director

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Preface
The Ghat sections are the important, strategic and vital part of the Indian
Railway track having scattered and varying in character. The idea of bringing
out this handbook is to furnish information regarding inspection & maintenance
of track, bridges, tunnel & protection works typical to the ghat sections, at one
place for the Railway Maintenance Engineers.

This lesson plan does not supersede any existing instruction from
Railway Board, IRPWM, LWR Manual & RDSO on the subject.

I am grateful for the assistance given by Shri Anupam Sharma,

CTA/Civil, Shri Sunil Gupta, STA/Bridge and Shri Anil Dubey, STA/P.Way,
who went through the complete text, collected information, data etc. and done
text editing work. Nice data entry & formatting has done by Shri Ramesh
Bhojwani, Console Operator, CAMTECH.

We welcome any suggestion for addition and improvements from our

readers.

CAMTECH/Gwalior Manoj Agarwal

Date : 09.9.2003 Director/Civil

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CONTENTS

Chapter Description/Topic Page Nos.

No.
Foreword i

Preface ii

Content iii

Correction Slip iv

1.0 Introduction 01

2.0 Maintenance of SWR/LWR/CWR 06

3.0 Bridges 15

4.0 Tunnel & Cuttings 29

5.0 Protection work 43

6.0 Case studies 54

Note 74

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ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be

numbered as follows:

CAMTECH/2003/C/GHAT/1.0/CS. # XX date .....………….......

Where “XX” is the serial number of the concerned correction slip

(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. Date of Page no. and Item No. Remarks

of issue modified
C.Slip

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CHAPTER – 1

Ghat Sections in Indian Railways

INTRODUCTION

The hill railways of India are numerous, widely scattered and varying in character. India is a
sub-continent larger than the whole of Europe less Scandinavia and Russia. It is bounded on
the north by that greatest of mountain ranges, the Himalayas. The spurs of the Himalayas are
hundreds, and in some instances thousands, of miles long. There are, besides, notable
detached ranges such as the Nilgiris in southern India, and the Western Ghats overlooking the
west coast. Moreover, the tropical climate of a land in which there are many people who
come from more temperate climates is responsible for driving them to the welcome coolness
of the hills in the hot weather. Hence the need for railways to carry them to the hills.
Occasionally, however, the trade of the country has also to be transported over the mountain
ranges.

It is difficult to define a hill railway, and still more difficult to describe all those that might
claim this title; but this page will give you a general, idea of the various types of hill railway
in India. Classification may best be based first upon gauge and then upon geographical or
traffic conditions. The hill lines are built to four gauges: broad (five feet six inches), metre
(three feet three inches), two feet six inches and two feet. The term "ghat," which frequently
recurs on this page, means a hill, hill range, route through hills, or a pass. The mountain lines
given in the following table are of particular interest.

Railway System Section of Line Ruling Gradient

Broad Gauge
Central Railway Thal Ghat 1 in 37
Bhore Ghat 1 in 37
Metre Gauge
Southern Railway Nilgiri Line 1 in 12.5
2' 6 " gauge
Northern Railway Kangra Valley 1 in 25 (mostly 1 in 40)
Kalka-Simla 1 in 33
North East frontier Darjeeling-Himalayan 1 in 29 with short
Railway 2' gauge sections of 1 in 23.

The only extremely steep metre-gauge hill railway in the Deccan - the peninsula of India
proper - is the Nilgiri branch. It is also the one section of line in India worked on the Swiss
Abt rack system. This is necessitated by its long 1 in 12.5 gradients. The type of locomotive
used is Swiss built. As on similar grades elsewhere, the engine is always below its train
whether ascending or descending. The first part of the climb from the plains up to Conoor is
mainly along an almost continuously precipitous mountain face, involving rock galleries and
tunnels, as well as other heavy engineering works. The views from this part of the ascent over
the plains are magnificent. Above Conoor the gradient eases, and no rack is used.
Ootakamund, the summer headquarters of the Government of Madras, is reached just beyond
the summit of the line, which is 7,300 ft. above sea-level. This is one of the most attractive

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hill stations in India. Most of the others are perched precariously on steep hill slopes, but
Ootakamund is situated on a plateau, encircled by open rolling downs. Here English wild
flowers abound, and also many that are cultivated at home grow wild there, notably the Arum
lily, which in "Ooty" grows in the streams. Altogether it is probably one of the healthiest and
most pleasant spots in the whole of the East.

The longest of the narrow-gauge hill lines is the Kangra valley branch of the Northern
Railway. The gauge is 2 ft. 6 In., and, though the ruling grade over a part of its length is 1 in
50, it has a final ascent of some kms. at 1 in 25. The principal feature of this line is the heavy
bridging involved almost throughout; the aggregate length of the steel girder bridges is
11,000 ft. Among other bridges is the first steel arch in India, known as the Reond Arch. It
bridges a cleft in the hills 200 ft. deep with two 40 ft. approach spans and a single main span,
with a steel arch, 180 ft. long. This arch was made entirely in India. The delicate operation of
erection was successfully carried out by the Bridge Department. The scenery along this line is
most impressive, particularly in winter when the snow-clad Dhaula Dhar mountains appear to
be near at hand. As the Kangra Valley was the centre of the disastrous Dharamsala
earthquake some years ago, all structures on the line - which was constructed in year 1926-28
- are designed to resist shocks as far as possible.

Perhaps the best known and one of the most interesting of the Indian hill lines is the Kalka-
Simla Railway. It probably deserves a rather more detailed description than some of those
previously dealt. The Kalka-Simla derives importance from the fact that during the summer
months the Supreme Government of India, including Army Headquarters, and the
Government of the Punjab move from Delhi and Lahore respectively, to Simla in the
Himalayas. When this move was first introduced the only way from the plains to Simla was
by road. Since this was long before the days of motor-cars the tedium of the journey may
readily be imagined. A railway to Simla was, therefore, proposed, the line was completed
and opened to traffic In 1905. It was built by a company, but shortly after the opening it was
taken over by the State. It now forms part of Northern Railway system.

The railway runs from Kalka to Simla. Kalka, about 64 Kms. from Ambala on the Punjab
plains, stands at an elevation of 2,000 ft. above sea-level. The section from Ambala to Kalka
is broad gauge (5 ft. 6 ins.). The distance from Kalka to Simla by rail is 95 Kms.. There is a
rise between these two places of roughly 5,000 ft. The climb, however, is not continuous the
whole way. Over three stretches in the up direction height is lost in the form of counter
grades. The aggregate length of these three sections is about 13 Kms.

The gauge of the line is 2 ft. 6 in., the ruling grade is 1 in 33, and the minimum radius of the
curves 33.53 m. All curves of 42.68 m radius and sharper are provided with check rails. The
main line is now all laid with 60 lb and 75 lb. flat-footed rails, although many sidings still
exist with the old 41 lb. rails. For the greater part of its length the line hugs steep hillsides;
thus numerous retaining walls were necessary. There are no fewer than 102 tunnels on the
section, with an aggregate length of 8.5 Kms.; the longest is Barog Tunnel, which measures
3,752 ft. The majority of the tunnels are on curves; several are on reverse curves, notably the
Gumman Tunnel on the Gumman loops. In many tunnels, especially during the rains, the
leakage of water is a great trouble, causing rusted and "roaring" or corrugated rails.
Galvanized trays with down pipes are fitted in many places to keep the water away from the
rails and lead it into the side drains.

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There are few steel bridges on this railway. Since stone is available locally, small stone box
culverts and arch bridges are the rule. Where the line runs to the head of a valley and then
crosses to the other side, stone "galleries" have been built. These comprise tiers of arches one
above the other; in some instances as many as four tiers have been used. In view of the
position of each of these at the head of a valley it is necessarily built on a curve, often with a
radius of 120 ft. In 1935 an arch bridge near Simla, which required rebuilding, was replaced
by a steel trestle bridge. The whole of the rebuilding was done with no interruption to traffic,
and yet without resort to a temporary diversion of the line.

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The rainy season here is from May to September, the average rainfall for the last twenty years
during these months being fifty inches. This period is an anxious time, as the continual rain
frequently causes heavy slips of the precipitous hillsides with consequent interruption to
traffic and the ever present possibility of a train running into a slip. During this season many
extra patrolmen are engaged to ensure that any damage to the track is reported as soon as
possible.

There are nineteen stations on the line, each station being at the end of a block section. The
longest section is 7.2 Kms. the shortest is 2.4 Kms. Each station has two running lines, and
either a third loop or a relief siding.

The block working is by means of Neale's token instruments; these are in the station
buildings and are worked by the station-master on duty. Each station has a home signal and a
starter signal in either direction; the latter can be lowered only by a key released from the
token instrument when permission to proceed has been given by the station ahead. There is a
large square white board beyond the home signal which acts as a distant signal, warning the
driver that he is approaching a signal although it gives no indication of its position. In
accordance with the usual practice on the Northern Railway there are broad whitewashed
bands across the track 800 m from these boards. These serve as an additional warning to the
driver at night and also in stormy or foggy weather that he is approaching a signal.

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During the summer a service of rail motors is run. A Diesel-electric car built by Armstrong-
Whitworth was introduced. It has become popular with the public.

At present rail motors in use are two four-seaters and four large Drewry cars, with seating
accommodation for twelve, sixteen, and eighteen passengers.

***
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CHAPTER – 2

Maintenance of SWR/LWR/CWR

Short Welded Rails

Introduction :
The fish plated joints are the weak links in the continuity of track structure. The state of
maintenance of track and the quality of running depends largely on how the joints are
maintained. It has been estimated that 40% of the maintenance efforts in maintaining fish
plated track is towards maintenance of joints. The best way to maintain rail joint is to get rid
of fish plated joint and replace it by a welded joint.

This can be achieved by having long length of LWRs/CWRs. However where LWRs are not
feasible due to constraints (permitted locations etc.) SWRs is being adopted wherever
feasible. Thus on Indian Railways have very long lengths of track as short welded panels.

SWRs do undergo large thermal forces throughout its length due to variation in temperature
and hence the laying and maintenance instructions on SWRs have to be specified.

Role of Gangman in SWR

As the gangman is directly related to the maintenance of track his role is quite important in
maintaining the SWRs. Therefore he should be conversant with the behaviour of SWR due to
temperature variation and maintenance of the same following the specific instructions of
carrying out the work in SWRs within the specified temp. limits, maintenance of gaps and
observance of the behaviour of SWRs.

Definitions (IRPWM-Para 505) :

Short welded rails (SWR) is a welded rail which contracts and expands throughout its length.

OR

Short welded rails are the rails formed by welding standard lengths of rails (generally 3 rails)
which contracts (in winter) and expands (in summer) throughout its length due to the
temperature variations.

Length of short welded rails

Normally the length of SWR

In BG – 3 X 13M = 39 M
In MG – 3 X 12M = 36 M

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Various temperatures in SWR (IRPWM-Para 505-2) :

Rail temperature : Rail temperature is the temperature of the rail as recorded by an approved
type of thermometer at site.

This is differs from the ambient temperature, which is the temperature of air in the shade at
that place, as reported by the meterological department.

Rail temperature zones : The Indian Railways have been divided into four rail temp. zones.

Temp. Zones Limits of rail temp.

Zone – I 400 C to 500 C

Zone – II 510 C to 600 C
Zone – III 610 C to 700 C
Zone – IV 710 C to 760 C

Mean Annual Rail Temperature (IRPWM-Para 505-3) : Mean Annual Rail Temperature
(tm) is the average of the maximum & minimum rail temperature recorded during the year. t m
will be fixed locally wherever rail temperature records are available for a reasonable period
of 5 years. Where rail temperature records are not available tm can be read from rail
temperature map.

Installation Temperature (ti) (IRPWM-Para 505-4) : Installation Temperature (ti) is the

average rail temperature during the process of fastening the rails to the sleepers at the time of
installations of SWR.

Conditions of laying of SWR

Alignment : SWR shall not be laid on curves sharper than 500 M radius (Curves having
degree of curve more than 3.50) in both BG & MG.

Junction with insulated joints and point and crossings (IRPWM-Para 507-2) : SWR
shall not butt against insulated joints, heel of crossing and stock rail joints. Two standard
length rails (13M/12M) shall be interposed to isolate the SWR from such locations. These
standard length rails shall be anchored effectively to arrest movement in either direction.

Junction with standard length rails on wooden sleepers (IRPWM-Para 507-3): When
SWR track butts against track laid with standard length rail (13M for BG and 12 M for MG)
on wooden sleepers, the latter shall be adequately anchored for at least six rail lengths to
check the creep of rails. These six rail lengths shall have a sleeper density of M+7. Additional
shoulder ballast should also be provided.

SWR on Level Crossing :

SWR may be continued through the level crossing but no fish plated joint should fall on the
level crossing and within six (6) meters from the edge of level crossing on either approach.

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SWR on Bridges (IRPWM-Para 272-4) :

SWR may be continued over girders bridges with unballast decks up to 13.3 m opening if
length of SWR is symmetrical to the centre line of bridge and up to 6.1 m opening if the
length of SWR is unsymmetrical to the centre line of bridge.

No fish plated joint should be located on the girder or within 6 m from either side abutment.
Rail free fastenings such as rail screws, dog spikes or rail free clips shall be used. So that
relative movement between rail & sleepers may take place.

Maintenance of short welded rails :

General :

a) Ensuring of correct gaps at the fish plated joints appropriate to the rail temperature.

b) Availability of sufficient and well compacted ballast at all times.

c) Maintenance operations of SWR should be confined to the temperatures as close to the

mean rail temperature as possible.

d) Creep should be checked and necessary action should be taken to arrest the creep.

e) Watch on abnormal contraction in winter to guard against bending or shearing of fish

bolts and expansion in summer to guard against buckling of track.

f) Special attention should be given to the location vulnerable to buckling like short
stretches of wooden sleepers between SWR.

g) Lubrication of rail joints should be done at the time when the temperature is moderate or
near the mean rail temperature.

h) While doing lubrication of rail joints, one plate should be tackled at a time and it should
be ensured that at no time during the operation there is less than one fish plate and three
fish bolts connecting the two rails.

Regular Maintenance Operations (IRPWM-Para 509-1):

Regular track maintenance including all operations involving packing, lifting, aligning, local
adjustment of curves, screening of ballast other than deep screening and scattered renewal of
sleepers may be carried out without restriction when the rail temperature is below tm+250C in
case of zone I & II and tm+200C in case of zone I & II. However, on curves of less than 875
m radius on BG and less than 600 m radius in MG or yielding formation, the above
temperature limit shall be restricted to tm+150C in case of zone I & II and tm + 100C in case
of zone III & IV.

(IRPWM-Para 509-2) - If the above maintenance operations have to be undertaken at

temperature more than tm+ 250C in case of zone I & II and tm + 250C in case of zone III and
IV then not more than 30 sleeper spaces in one continuous stretch shall be opened, leaving at

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least 30 fully boxed sleeper spaces between adjacent lengths which are opened out. Before
the end of day’s work it shall be ensured that the ballast is boxed up properly.

(IRPWM-Para 509-3) - During the months of extreme summer for attention to the run down
track even if the temperature is less than tm+250C in zone I & II and tm + 200 C in zone III and
IV then more than 30 sleeper spaces in one continuous stretches shall be opened, leaving at
least 30 fully boxed sleeper spaces between adjacent lengths which are opened up. If joint
gaps are not available at time of opening of the track even when the rail temperature is less
than tm+25 C in zone I & II and tm+20 C in zone III & IV, nor more than 30 sleepers in one
continuous stretch should be opened leaving at least 30 boxed sleeper spaces between
adjacent lengths which are opened up.

Special maintenance in SWR (IRPWM-Para 509-4) :

Major lifting, major alignment of track, deep screening and renewal of sleepers in
continuous length: These work shall be done under suitable precautions and normally when
rail temperature is below tm+150C in case of zone I & II and tm + 100C in the case of zone III
and IV. If it becomes necessary to undertake such work at rail temperature exceeding the
above values then adequate speed restriction shall be imposed.

Use of Joggled Fish Plates and Clamps (IRPWM-Para 509-5):

Adequate no. of joggled fish plates with special clamps shall be provided to the gangs for use
in emergencies.

If any rail/weld fracture is noticed by gangman he should protect the track and the fractured
rail/weld should be supported by providing a wooden block and then same shall be fastened
by using joggled fish plates and clamps. Then only the traffic may be passed at restricted
speed from the failure spot. He should then immediately inform about the same to the nearest
SM, Gangman and JE/SE (P.Way) of the section.

(IRPWM-Para 509-6) : In case of any fracture in the weld or in the rail, the portion of rail
with fracture is cut, and removed for a length of not less than 4 m to carry out the re-welding
duly introducing a rail piece of equivalent length. This should also be ensured that no weld
lies closer than 4 m from the fish plated joint.

Causes of Buckling in SWR

1) In adequate resistance due to deficiency of ballast

2) In effective and missing fastenings.

3) Carrying out work of laying and maintenance at a temperature out side the specified
range specially in summer.

4) Excessive creep, jammed joints, sum kinks in track.

5) Failure to lubricate the joints in time.

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Vulnerable locations : Track prone to buckling in SWR

1) Wooden sleeper stretches between metal sleepers, approaches of LC, bridges and
yards etc.

2) Old track butting with new track.

3) Junction point of free rail track and SWR track.

4) Location of deficient ballast specially on shoulders.

Symptoms of Buckling :

1) Sun kinks in track

2) Absence of gaps in joints in the morning hours in hot weather.

3) High percentage of hollow/loose sleepers in continuous length.

Precautions to avoid buckling :

1) Provide proper expansion gaps in joints.

2) Keyman should inspect during extreme hot and cold by adjusting his duty hours.

3) No track work beyond specified temperature range.

4) Strengthening of track by provision of extra ballast over the shoulders, increasing the
sleeper density, provision of anti creep fastenings replacement and tightening of
missing and loose fittings.

Action in case of buckling :

By Gangman :

When tendency of buckling or actual buckling is detected, suspend the traffic and protect the
track. Inform the nearest Station Master and Mate of the gang. Do not leave the site
unmanned and unprotected.

By Supervisory staff :

1) Temperature of rail brought by pouring the water.

2) In case of fish plated & SWR Track, a gentle reverse curve may be given in the rear of the
buckled track to ease out the stresses.

3) Buckled rail then cut from two places not less than 6.5 m apart, rectify the misalignment
occurred due to buckling and close the gap by correct closure.

Gap Survey in SWR and rectification : Gap survey and rectification of gaps is carried out
once in a year before end of February i.e. before on set of summer by the JE/SE (P.Way). The
role of gangmen in this case is not significant and hence not described here.

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Long Welded Rail (LWR)

1. Prerequisites for proper functioning of LWR

 Initial laying work of LWR must be of high standard

 Maintenance of LWR/CWR track by the trained personals possessing valid
competency certificates issued by DETs/ZTCs.

2. Normally the work of regular track maintenance i.e. packing, minor lifting, alignment
correction, shallow screening, renewal of fastenings, casual renewal of sleepers and
periodical maintenance of SEJ & buffer rails are being carried out by the direct
supervision of keymen/mate. These works are done under the normal working of the
trains. Some unforeseen works i.e. emergency repairs of rails fracture and stabilization of
track in case of tendency of buckling are also attended by the gang staff, immediately of
their occurrences.

While working with LWR track following precautions should be observed by the gang
staff.

Rail temperature measurement

Continuous rail temperature recording should be done with the approved type of rail
thermometer. Rail thermometer should be tested periodically in the JE/SEs (P.Way) work
shop for its correctness.

‘td’ of the LWR

Every staff should know the ‘td’ of his LWR/CWR and working range of ‘td’ + 100C to
‘td-300C should be clearly marked on the rail thermometer taken on the site of work.

Working hour

a) All regular maintenance works should be completed well before the onset of summer i.e.
before 31st March of every year and should be confined to the hours when rail
temperature is in between of ‘td’ + 100C to ‘td-300C.
b) When during the work rail temperature exceeds ‘td’ + 100C stop the work and put back
the ballast by boxing and try to compact the ballast by the hand rammers.
c) If rail temperature further exceeds ‘td’ + 200C, then the following speed restriction should
be imposed for the period of consolidation.

Concrete sleeper track

a) 50 Kmph for BG/40 Kmph for MG- if shoulder & crib ballast compaction has been done.
b) 30 Kmph for BG/20 Kmph for MG – if ballast compaction has not bee done.
c) Other than concrete sleeper track.

50 Kmph for BG/40 Kmph for MG.

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Ballast

a) Maintain well compacted proper ballast section at all times.

b) Keep special watch on Pedestrian & cattle crossing, curves, approach of LC & bridges.
c) Deficiency of shoulder ballast from the center of track between the rails over a width not
exceeding 600/350 mm & depth not more than 100/75 m in BG & MG respectively.

Correction of alignment

Should be such that lifting of track is not done due to wrong planting of crow bars. Angle of
crow bars should not be more than 300 from the vertical.

Lifting of track

Lifting of track shall be done in stages, not more than 50 mm in concrete sleepers & 25 mm
in other sleepers track in one stage with the adequate time gap between two stages for proper
consolidation.

Opening of track ballast for manual maintenance

1. Not more than 30 sleepers spaces should be opened continuously with atleast 30 fully
boxed sleepers in between in adjacent opening.

2. ‘In between’ length can be opened after passage of traffic for atleast
- 24 hours in case of BG-having more than 10 GMT.
- 2 days in case of other routes of BG & all routes of MG.

3. Upto 100 sleepers spaces can be opened continuously under the direct supervision of PWI
and during the period of year when min. & max. rail temperature is in between ‘td’ + 300C
to ‘td’ + 100C and the fastening conditions satisfactory & no sign of unusual behaviour in
SEJ.

Casual renewal of sleepers :

1. Not more than one sleeper at a time in 30 consecutive sleepers.

2. If consecutive sleepers required to be renewed, renew second sleeper after renewal &
packing the first sleeper.

Casual renewal of fastenings

1. Not requiring lifting of rails – one in 15 sleepers.

2. Requiring lifting of rails – one in 30 sleepers.

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Maintenance of SEJ

1. SEJ, shall be checked, packed, aligned once in a fortnight by mate.

2. Oiling & greasing of tongue & stock rails and tightening of fastenings shall be done
simultaneously once in fortnight by keyman.

3. Gap of SEJ shall be observed by keyman during his daily routine inspection and any
abnormal movement shall be reported.

4. If centre to centre spacing of two central sleepers of SEJ differ by more than 700 + 10
mm, immediate rectification is necessary.

Maintenance of buffer rails

1. Type of sleepers under buffer rails

- PRC sleepers with – J clips
- Wooden sleepers with – M.S. canted bearing plates and rail screws.

2. Expansion gap in each buffer rail joints 7.5 mm at ‘td’ range.

3. All fish bolts holes in buffer rails should be chamfered.

4. If buffer rails are provided between track and LWR, then conventional track for three rail
length should be box anchored.

5. Fish bolts of buffer rails should be kept tight at all times.

6. Buffer rails are laid with rail free fastenings.

7. Extra shoulder ballast width of 500 mm & heaping of ballast up to 100 mm should be
provided in buffer rail lengths.

8. Maintenance of rails shall be of high standards.

9. Lubrication of buffer rail joints should be done in temp. range between ‘td’ - 150C to ‘td’ +
150C and average gap value 3 to 12 mm.

Action in case of rail fracture :

1. In case of rail weld fracture in LWR track, emergency repairs should be carried out by the
gang staff.

2. Suspend traffic and protect the track as per rules.

3. Clamp the fractured rail by using one meter long fish plates or joggled fish plates as
required and restore traffic with stop dead and 10 kmph for first train and 20 kmph for
subsequent trains.

4. Use rail piece of suitable size, if gap at fracture is more than 30 mm.

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5. Man the site by deputing the flagman till the permanent repairs carried out by JE/SE
(P.Way).

Action in case of buckling / Tendency towards buckling

1. If abnormal kinks are noticed in the track, check the track sleepers for loose packing.

2. If tendency of buckling or buckling of track get established, suspend traffic and protect
the track and inform to the concerned staff.

3. In case of tendency of buckling, stabilise the track by heaping the ballast on the shoulders
up to the bottom of rail head, taking the ballast from the inter sleepers spaces between the
rails.

Trackman will stay at the site, till the permanent repairs is carried out by the JE/SE
(P.Way).

***
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CHAPTER – 3

Bridges

Necessity for inspection

The first steps to any maintenance programme is inspection. The purpose of

inspection of a bridge can be identified as follows :

(a) To provide assurance that the bridge is structurally safe and fit for its designed
use. This relates to the gradual deterioration of the bridge with time or to an
accidental occurrence such as earthquake, overloading, derailment etc.

(b) To identify actual and potential sources of trouble at the earliest possible
stage.

(c) To record systematically and periodically the state of the structure. This
enables one to know the time when defects occurred and to identify any
significant structural changes.

(d) To provide feed-back of information to designers and custodians of bridges on

those features which are likely to give maintenance problems and to which
necessary attention is best given during design and construction stages ; and

(e) To provide necessary information on which decision will be made for carrying
out maintenance repairs, strengthening or replacement of the structure.

Inspection lays the foundation of the entire maintenance programme. If

inspection or maintenance is neglected or it is done at too long an interval or
performed with insufficient effort, the consequences may lead to :

a) Loss of aesthetic appearance .

b) Loss of function, serviceability and possibly of safety.

c) Loss of material value of the structure resulting in reduced service life.

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Inspection of bridges1
Following are the guide lines and general procedure for Inspection of different
type of Bridges

Arch Bridges

Most of the arch bridges are old but they usually have such a reserve of
strength that they have been able to carry the present day traffic with increased axle
loads and longitudinal forces, without much signs of distress.

Cracks in abutments and piers

These cracks indicate uneven settlement of foundations. These are of serious

nature. In the worst conditions, such cracks extend through the arch barrel and are
seen as longitudinal cracks (cracks parallel to the direction of traffic) in the arch
barrel.

CRACKS IN PIER AND ABUTMENTS

EXTENDING TO ARCH BARREL

Cracks associated with spandrel wall

In cases of brick masonry bridge where spandrel walls are constructed

monolithically with the arch barrel, longitudinal cracks sometimes appear under the
inside edge of spandrel wall on the intrados. Such cracks are not considered serious,
but they must be kept under observation.

CRACKS IN SPANDREL
WALL DUE TO WEAKNESS IN
ARCH RING

1
Please refer report no. BS-48, Sept.2002 of RDSO/B&S Dte./Lucknow on “Guidelines for Inspection,
Maintenance and Rehabilitation of concrete Bridges”.

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LONGITUDINAL CRACKS UNDER

SPANDREL WALL

If such cracks show tendency to widen with time, then the problem can be traced to
excessive back pressure on the spandrel wall arising out of ineffective drainage or excessive
surcharge load from the track. Many times, track level on the arch is raised bit by bit and new
masonry courses are added on the spandrel wall without giving thought to the adequacy of
spandrel wall cross section. This is also a cause for such cracks.

Blockage of drainage and excessive surcharge may also lead to sliding forward of the
spandrel wall.

EARTH PRESSURE & SURCHARGE

Spandrel wall

SLIDING FORWARD OF
SPANDREL WALL

Amount of sliding ARCH BARREL

PIER

Excessive back pressure on spandrel walls can also lead to bulging and/ or tilting of
the spandrel walls. The drainage of the arch should never be sought to be improved by
drilling holes through the arch barrel as it may lead to shaking of the barrel masonry and
weakening of the arch bridge.

Cracks on the face of the arch bridge

This type of distress is sometimes noticed in the vicinity of crown of the arch
and can be traced to

1. Weathering of stones/ bricks.

2. Excessive loading
3. Inadequate cushion over the crown.

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As per IRS Arch Bridge Code, a minimum cushion of 900 mm is

recommended over the crown of the arch. Cushion is the vertical distance between the
bottom of the sleeper and the top of the arch. Lesser cushion results in transfer of
heavier impact on the crown which may result in cracking and crushing of the
masonry in the vicinity of the crown. Existing cushion may be reduced while
changing the metal or wooden sleepers over the bridge with concrete sleepers.

Leaching out of lime/ cement mortar in the barrel.

This condition is many times noticed in the arch barrel where water trapped in
the full above the arch seeps through the joints. In such cases, the remedy lies in
grouping the joints and improving the drainage through the weep holes in the spandrel
wall.

Loosening of key stone and voussoirs of arch

This can happen on account of the tilting of abutment or pier because of

excessive horizontal thrust. This is also likely to occur where more of dynamic forces
are transmitted on account of lesser cushion.

Transverse cracks in the arch intrados

These cracks are very serious in nature. These cracks have a tendency to
progress in diagonal/ zigzag directions in stone masonry arches along the mortar
joints. These cracks indicate serious weakness in the arch and need proper
investigation and adoption of appropriate strengthening measures.

Concrete Bridges

RCC/ Concrete bridge, composite girders and concrete deck bridges are now
being widely adopted on Indian Railway. But suitable guidelines in respect of
inspection, investigation, repairs and remedial measures in respects of these bridges
are not known to the field staff. There is misconception that such bridges last for long
and need little care and maintenance. However, scenario is totally different after
reports of signs of distress have been observed in some of the RCC/ Concrete bridge
built up in 1960’s and 1970’s. Even in case of newly constructed box girders,
Composite girders, no inspection and maintenance is being carried out by field
officers/ staff, which has become a matter of serious concern.

Concrete component may show following signs of visual damage which

should be looked for-

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Cracks

 Examine the defects very carefully.

 In case of any cracks do record the following observations.

i) Location.
ii) Width and Length of crack.
iii) Type and pattern of cracking.
iv) Whether active or dormant.
v) Behaviour under load i.e. whether crack gets closed after passage of trains
or otherwise.

CRACKS AT INTERFACES CRACKS IN CONCRETE

OF PRECAST AND CAST GIRDERS
IN PLACE CONCRETE
ELEMENTS

 Draw sketch for each particular crack to be shown.

 Mark the crack with dated tell tales both in concrete structure as well as in
diagrams on registers.
 Analysis of each crack.

Spalling and Scaling

i) Record the area, depth and location of spalling.

ii) Also critically record, your observation on condition of reinforcement whether

exposed or not.

iii) Record the location and area affected by scaling.

iv) Critically record the level of scaling whether light, medium or severe.

Disintegration

i) Location where disintegration of concrete is taking place.

ii) Analyze the reasons for this.

iii) Do take a sample for lab test.

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iv) Assess the existing strength & disintegration of concrete by non-destructive

tests.

Rust Streaks and Leaching

i) Record the location on rust streaks.

ii) Analyze the reason and simulate it with the reinforcement or cable profile.

iii) Any deposit, salt or lime deposit ; white in colour on concrete surface indicate
leaching.

iv) Analyze the reasons of the leaching.

Please examine the locations critically for these specific defects.

Prestressed Concrete Bridge

Prestressed concrete bridges are now being widely adopted on Indian railway
network, suitable guidelines in respect of inspection, investigation, repair & remedial
measures have not received the required attention for prestressed concrete bridges.
This may be partly due to the misconception that such bridges last for long and need
little care and maintenance. However, the scenario is different after reports of signs if
distress observed in some of the prestressed concrete bridges built in 1960’s and
1970’s.

Functional life of such bridges is observed to be getting adversely affected

due to factors such as aggressive environment, atmospheric pollution, quality of
materials, workmanship etc. A bridge is expected to have a usable life of 80 to 100
years. During the last 15 years, the number of prestressed concrete bridges requiring
major repairs has increased substantially especially on road network. Few important
road bridges have also collapsed incurring loss of material as well as of human life.
Therefore inspection and maintenance of bridges has to be treated as a regular
ongoing requirement and not a necessity to be undertaken only in the case where the
bridge is damaged.

EQUIPMENT REQUIRED FOR INSPECTION

Following equipment are required for thorough Inspection of various element of

bridges.

List of Equipment for Steel Bridges

1. Pocket tape (3 to 5 m long)

2. Chipping Hammer
3. Plumb bob
4. Straight edge (at least 2 m long)
5. 30 metre steel tape
6. Feeler gauge set (.1 to 5mm)

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7. Log line with 20 kg lead ball to kept at bridge side to measure depth of water
8. Thermameter for measuring temperature
9. Elcometer to ascertain paint film thicknesses (Dry film thickness) etc.
10. Wire brush
11. Mirror (10 x 15 cm) to see hidden places/ part of bridges
12. Magnifying glass 100mm dia. to identify minor cracks
13. Crack meter to ascertain various configuration of cracks etc.
14. Chalk water proof pencil, pen of paint for marking concrete or steel
15. Centre punch to mark any correct/ reference point
16. Caliper (Inside & outside to measure correct gaps/ thickness of various parts
of bridge.
17. Torch light (of 5 cell).
18. Screw drivers - to scrap/ mark a certain point etc.
19. Paint & paint brush for repainting areas damaged during inspection.
20. Gauge cum level
21. Nylon chord to check camber/ straight edge etc.
22. 15 cm. steel scale
23. Inspection hammer (350 - 450 gm)
24. Rivet testing hammer (110 gms)

Optional (where required)

25. Binocular - to see distant objects

26. Camera,
27. Dumpy level set - to check camber etc.

Some additional equipment

01. Ladders
02. Scaffolding
03. Boats or Barges
04. Echo sounders (to assess the depth of water)
05. Dye penetrants (to detect cracks specially in welded girders)

Equipment Required for Inspection of Concrete Bridge

SR INSTRUMENTS PURPOSE
1 30M Steel tape For taking measurements such as clear span, overall
length of girder, etc.

2 Straight edge For checking deformation, distortion, buckling and

(1M Long) bulging of structure

3 Feeler Gauge For measuring width of cracks and cavity

(0.1 to 5mm)
4 Measuring For measuring invisible minute crack width by
microscope magnification scale.

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5 Nylon chord or Piano For measuring camber of PSC girder.

wire with clamp and
2 nos. 10kg. weight
6 15 cms steel scale For measuring depth of spalled concrete and gap
between parts.

7 Mirror (10 x 15 Cm) For inspecting parts in any awkward location by

reflection method and to lit object in dark location by
directing sun rays.
8 Magnifying glass For identifying very fine cracks in member/ welds
(100mm dia) which may not be visible for naked eyes.
9. Torch light (5 cell)/ Used along with mirror for identification of fine cracks
Flash light in dark locations.
10 Plumb bob For checking verticality of member , pier and abutment
etc.
11 Inspection cum For checking hollow pocket or honey comb in masonry
chipping hammer and concrete structure including PSC girder by tapping
and for examining the extent of corrosion, adherence of
paint and removing loose disintegrated material during
inspection.
12 Thermometer For recording temperature at the time of measuring
camber and for purpose of setting bearings at desired
inclination.
13 Spirit level For checking cross level of track on bridge or bed
block. Also for setting of girders on bearing.
14 Chalk marker, plaster To mark the cracks on concrete structure and make tel-
of Paris, Red Paint, tale for observing crack.
Plain glass
15 Binoculars For inspection of bridge components which are at
inaccessible location tall piers, arches in viaducts, etc.
prior to closer examination.
16 Camera with flash For taking photograph of cracks, spalled concrete or
any distressed portion for clarity and record.
17 Pocket knife For removing scaled or weathered surface of concrete
for inspection.
18 Dial Gauge For measurement of deflection in case of load testing
or to measure depth of cavity.
19 Schmidt's rebound For assessing the strength of concrete structure for
hammer for concrete soundness as NDT method.
20 Concrete cover meter For assessing the cover availability to reinforcement in
(R meter) existing concrete structure or diameter of steel bar or
spacing.
21 Ultrasonic pulse To identify uniform dense concrete structure or hollow/
velocity test honey comb inside the concrete structures and to
determine presence of discontinuity, crack etc.
22 Windsor probe test To evaluate the hardness of concrete by probing and
penetration, which will help in assessing compressive
strength of concrete.

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23 CORE drilling test To determine actual strength of concrete in structure.

24 Scaffolding/ To provide close accessibility to structure for
Inspection cradle inspection of girder, sub structure etc.

CHECK LIST FOR INSPECTION OF BRIDGES

This has been oftenly noticed that in the process of bridge inspection so many items
either skipped or untouched. In due course of inspection following items must be inspected
and recorded in a descriptive manner and brought to the notice of suitable authority.

Foundation and Flooring

(a) Scour over foundation A1, P1, P2, ......... A2.

(b) Quantity of filing - Boulders/ Earthwork.
(c) Availability/ Requirement of flooring.
(c) Repair to curtain wall/ Drop walls.
(e) Obstruction to waterway if any.

Substructure

(a) Condition of masonry A1, P1, P2 ....... A2.

(b) Cracks/ Hollow masonry requiring grouting.
(c) Pointing of masonry joints.
(d) Leaning of abutments/ piers along the track and transverse to track.
(e) Condition of wing walls and return walls.
(f) Provision/ Cleaning of weep holes.
(g) Masonry below bed blocks.
(h) Condition of jacketted masonry.

Protection works

(a) Marking of HFL, Danger levels etc.

(b) Protection of banks upto HFL.
(c) Top level of guide bunds and their slope.
(d) Condition of flood protection works like RAT (RAW) etc. if, any.
(e) Condition of boulder pitching with pointing & slope in case of a burried
abutment.

Bed Block

(a) General condition of bed blocks in A1, P1, P2,............. A2.

(b) Epoxy grouting/ pointing of bed blocks needed or not.
(c) Condition of Ballast wall-repairs, if any.

Bearings

(a) Cleaning around bearing area.

(b) Greasing of bearing with date.
(c) Gap in guide/ location strips of sliding bearing.

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(d) Condition of rollers of bearing.

(e) Inclination of rocker bearing along with ambient temp.
(f) Seating of bearing properly.
(g) Distance between adjacent span girders/ girder and ballast wall.
(h) Condition of anchor/ holding down bolts.
(i) Location and condition of elastomeric bearing.

Super Structure

Steel - Span No. 1,2,3 ............ etc.

(a) Condition of painting along with last date of painting.

(b) Corrosion of members with details.
(c) Position of loose/ missing rivets.
(d) Distorted members, if any with measurements.
(e) Actual camber at various points where applicable along with theoretical
camber.
(f) Cracks in welds or plates along with their location.
(g) Upto date GMT carried by the girder.
(h) Provision of Man and Trolley refuges and their condition.
(i) Any special repairs required to be done.

Arch Bridges

(a) Span and shape of the arch.

(b) General condition of masonry.
(c) Cracks-type and location-Longitudinal cracks.
Diagonal cracks
Transverse cracks.
(d) Separation of arch ring near the parapets from the main barrel.
(e) Shape and condition of parapet walls.
(f) Condition of spandrel walls and location of weep holes.
(g) Clear earth cushion over the crown of arch ...... mm.
(h) Condition of joints with extended portion with slab etc.
(i) Load test done on .......... crown deflection ........... mm spread at springing
level .......... mm

Concrete Slab

(a) Condition of concrete in general span 1,2, ............ etc.

(b) Cracks requiring grouting.
(c) Location of spalled concrete, if any.
(d) Rust streaks, cracks etc - location with date.
(e) Extent of exposed reinforcements.
(f) Provision of wearing course on top of slab and its conditions.
(g) Clear cushion of ballast/ earth and ballast.
(h) Condition near anchorages of PSC slabs.
(I) Condition of drainage hole in deck slab.
(j) Condition of ballast (caked up/ clear).

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Concrete Girders

(a) Condition of concrete in general span 1,2............. etc.

(b) Cracks if any at
 near mid span
 near support
 near junction of main girder and diaphragms
 in diaphragms.
(c) Cracks requiring epoxy grouting along with details of location, size etc.
(d) Spalled concrete with details of location. extent etc.
(e) Condition of concrete in soffit of deck slab.
(f) Junction of concrete slab and steel girders in composite girders.
(g) Inside portion of box girders - cracks condition of concrete etc.
(h) Rust streaks, crack etc. - location with details.
(i) Condition of concrete surface around prestressed cables with reference to
cable profile.
(j) Condition of concrete near end blocks and condition of anchorages.
(k) Actual camber compared with original camber.
(l) Condition of drainage holes in the deck slab.
(m) Provision of wearing course on top slab and its conditions.
(n) Clear cushion of ballast/ earth and ballast.
(o) Condition of concrete in deck slab.
(p) Special repairs required if any.

Pipe culverts and other small openings.

(a) Alignment of the pipe.
(b) Slope and level of the pipe.
(c) Clearing of the water way.
(d) Condition of face wall and wing wall.
(e) Flooring on the approaches.
(f) Clear earth cushion available over the crown of the pipe.

Track Structure

Open Decks

(a) Eccentricity of track with respect to centre of girder span 1,2,........ etc.
(b) Guard rails, their conditions and fittings.
(c) Clearance and level of guard rails.
(d) End anchoring of guard rails with wooden blocks on the approaches of A1,
and A2.
(e) Condition of footpath plates and their fixing.
(f) Location of fish plated joints and SEJs with respect to abutment and piers.
(g) Condition of sleepers and No. of sleeper requiring renewal.
(h) Spacing between sleepers and their squareness.
(i) Thickness of bridge timbers excluding gouging done for rivet heads.
(j) Level of rail at different location in cambered girder.

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(k) Provision of hook bolts and their condition.

(l) Oiling of hook bolts and their plates markings.
(m) Condition of top flange plates under sleeper seats.
(n) Track parameters (Gauge level and alignment)
(o) Level portion on approaches of the bridge (length).
(p) Ballast retainers on approaches and condition and adequacy of rails, sleepers,
fittings and ballast.
(q) Proper placement of speed restriction boards, if any on both the approaches.
(r) Proper placement of Name boards, Bridge tablets and other markings.
(s) Provision of steps in the embankments at approaches of bridges.
(t) Location and condition of height gauges in case of RUBs.

Ballasted Decks

(a) Eccentricity of track with respect to centre line of bridge in span no 1,2,
........... etc.
(b) Guard rails, their condition and fittings.
(c) Clearance and level of guard rails.
(d) End anchoring of guard rails with wooden block on the approaches of A1 and
A2.
(e) Location of joints with respect to abutments and pier.
(f) Type of sleepers and their conditions.
(g) Clear ballast cushion available.
(h) Track parameters. (Gauge level and alignment)
(i) Level portion on approaches of bridge.
(j) Ballast retainers on approaches and condition of track and fittings.
(k) Proper placement of speed restriction boards, if any, on both the approaches.
(l) Proper placement of Name boards, Bridge Tablets and other markings.
(m) Provision of steps in the embankments at approaches of bridge.
(n) Location and condition of height gauges in case of RUBs.

Symptoms and remedial measures of problems in bridge structure :

Some of the common symptoms and remedial measures thereof are listed below :

I Foundation :

Nature of problem Remedial measures

(a) Settlement :
Moderate Packing under superstructure
Severe Stabilise by piles around foundation; Do
micro piling or root piling or rebuild.
(b) Scour
Moderate Protect by flooring dump boulders around
piers in the scoured portion.
Severe Protect by piles around the foundation

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II Substructure :

Weathering of masonry :
Joints – Superficial Pointing
- Deep Grouting with
a) Cement
b) Epoxy
Leaching of lime mortar Cement grouting
Masonry units Guniting
Cracks Grouting with
a) Cement
b) B) Epoxy Jacketting
Leaning/bulging Drain backfill
Soil anchoring/Rock anchoring
Jacketting
Rebuilding
Shaken/cracked bed blocks Recast bed blocks
i) Cast in situ
ii) Precast and bond
Hollow left in masonry due to defective Cement grouting
workmanship

III) Superstructure

(a) Arches
Weathering Pointing
Grouting with
a) Cement
b) Epoxy* Guniting
Cracks in arch Pointing
Grouting with
a) Cement
b) Epoxy* Inturning of arch, Rebuild
Cracks/pulges in parapet/spandrel wall Draining the backfill
Providing ties
Rebuilding
(b) RCC/PSC girders and slabs
Cracks Grouting with Epoxy
Spalling Guniting
(c) Steel girders
Defective material (e.g. early steel) Replace
Corrosion
Moderate Painting, metallising
Severe Strengtheing and painting/metallising
Cracks Strengthen
Loose rivets Replace rivets
Loss of camber Strengthen

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IV Special cases

Inadequate section of pier of abutment Jacketting

Additional waterway Additional opening raising the soffit of
girders after regrading

***

Go to index

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CHAPTER – 4

Tunnels & Cuttings

TUNNELS

Inspection by Engineering Inspectors

The Permanent Way Inspector shall inspect every tunnel on his section once a year during the
prescribed month after the monsoon season but where specified by the CE. The structural part
shall be inspected by the Works Inspector.

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Item to be covered in the inspection

The inspection shall cover :

1. Tunnel approaches and cuttings.

2. Portals at either end
3. Tunnel walls, lining and roofing (lined and unlined)
4. Drainage
5. Refuges
6. Ventilation shafts/Adits
7. The section in relation to moving dimensions
8. The track and
9. Lighting equipment and special tools with the maintenance gang.

Record inspection

1. The inspector/inspectors shall record the results of their inspection a manuscript register
which shall contain particulars of date of inspection, condition of tunnel and approaches
at the time of inspection and repairs carried out during the year. Two or three sheets may
be allotted for each tunnel with the tunnel number, its length and kilometreage. The
register should be in the form shown. Annexure - A

2. The inspector/inspectors should promptly attend to the repair required.

3. The inspector shall submit to the Assistant Engineer by the prescribed date a list of
important defects with a certificate in duplicate to the effect.

“I certify that I have personally carried out tunnel inspection of my section in accordance
with standing orders for the year ending ………….. and append herewith a list of
important defects”.

4. The Assistant Engineer shall issue such orders as deemed necessary to the inspector and
counter sign and forward one copy of the certificate of inspection to the Divisional
Engineer with remarks if any.

5. The inspector shall accompany the Assistant Engineer on the latter’s Annual inspection of
tunnels.

Inspection by Assistant Engineer

1. The Assistant Engineer shall inspect every tunnel on the sub division once a year before
the monsoon during the prescribed months and record the results in ink in the tunnel
inspection register, Form Annexure A.

2. The tunnels, the condition of which warrant special attention should be inspected more
frequently.

3. The instructions and index as Annexure A should be prefixed to each tunnel inspection
register. Two or three sheets should be allotted for each tunnel so that a register may

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contain record of inspection over 10 to 15 years. The register should be printed using the
standard proforma.

4. The inspection shall be detailed and cover all aspects, entries being made under each of
the heads given in the register.

5. The Assistant Engineer should make an extract of all remarks concerning repairs
required, send these to the Inspector/Inspectors with explicit instructions and ensure
expeditious compliance.

6. On completion of his annual tunnel inspection, the Assistant Engineer shall certify at the
end of the register as follows :

“I certify that I have inspected all the tunnels shown in register during the year ending
……….. and have issued detailed orders in writing to the Inspectors concerned except the
following on which the Divisional/Sr. Divisional Engineer’s orders are solicited”. These
registers should be in the Divisional/ Sr. Divisional Engineer’s office by specified date.

By Divisional / Sr. Divisional Engineer

1. The Divisional / Sr. Divisional Engineers shall carefully scrutinise the Assistant Engineer
tunnel inspection register and inspect such tunnels as called for his inspection. He shall
record his orders regarding the points which require a decision by him and initial against
every entry of tunnel in the registers in token of scrutiny. He should endorse on each
register, below the Assistant Engineer certificate, as follows :

“I have personally scrutinised this register and have issued orders regarding all essential
points requiring a decision by me. The following points are submitted to the Territorial
Head of the Department at Head Quarters for order”.

2. The Divisional / Sr. Divisional Engineer should extract the items of inspection register
requiring attention and send it to the Assistant Engineer who should intimate the same to
the inspector concerned for expeditious compliance.

3. The register should be forwarded to the Territorial Head of the Department at Head
Quarters who will examine each register, issue orders regarding matters referred to him,
endorsing the registers to the effect and return them to the Divisional / Sr. Divisional
Engineer, subsequent action taken on the notes should be entered in the registers by the
Assistant Engineer.

Mobile staging for inspection

Requisite stagings mounted on the mobile units, such as open wagon, dip lorry or rail motor,
shall be used to carry out thorough inspection of the sides and roof of the tunnels. These
should be kept at suitable points for urgent use as required.

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Details of tunnel inspection

The details of inspection to be carried out are as follows :

1. Tunnel approaches and cutting : Normally the tunnel approaches will be in deep
cuttings. The inspection of these cuttings should be carried out as detailed in paras 1010
to 1012 later in this chapter.

2. Portals at either end : During inspection it should be checked as to whether there are
any signs of slips in the slopes above the portals; whether the masonry is in any way
cracked, shaken or bulging and signs of movement are apparent. “Catch-water drains
above the portals should drain away and not be allowed to percolate into the tunnel or
behind the portal masonry.

Trees leaning or hanging on the slopes above the portals should be cut and cleared. Loose
boulders, if any should be removed.

3. Section of tunnel in relation to moving dimensions : It should be checked as to whether

the dimensions of the tunnel section on straight and curves conform to the diagrams given
in the Schedule of dimensions. Stagings mounted on mobile units will be helpful to check
the profile.

4. Tunnel walls and roofing :

a) Lined section : During inspection it should be ascertained whether the lining is in a

satisfactory condition. Seepage through joints in the masonry should be looked for.

Doubtful masonry should be tapped to detect ‘drummy’ places.

Cracks in the masonry should be marked by red paint, dated telltales placed at their
extremities and serially numbered to detect extension.

Pointing of the masonry should be examined for its condition.

b) Unlined Sections : The unlined portions should be examined to find out whether they are
sound.

Doubtful places, such as loose projections should be tapped and identified.

c) Drainage : The drainage arrangements inside the tunnel and upto the outfall should be
inspected. It should be ensured that the side drains are adequate and function satisfactory.
The drains should be periodically cleaned.

d) Tunnel refuges : It should be checked up as to whether these are well maintained and
free of vegetation and other growth.

e) Ventilation shafts/Adits : It should be ascertained whether these are adequate and

maintained free of vegetation and other growth. For tunnels more than 200m long, level
of pollution and temperature condition should be enquired from the gang and keyman

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working in that location of tunnel keeping in view passenger comfort and working
conditions for working inside the tunnel.

f) Lighting equipment and special tools : The lighting equipment and special tools where
supplied should be in a state of good repair. Sufficient spare tools should be stocked.

g) The track : The track should be examined for good line and level including for corrosion,
inside the tunnels.

Level pillars and reference marks indicating the correct level and alignment shall be
checked periodically. Renewals should be carried out as and when required on high
priority.

Leakage in tunnels and methods of correction :

General

1. Water leakage occurs in most of the old tunnels. It is one of the most aggravating and
difficult problems detrimental to tunnel linings and contributing to muddy track.

2. Water leakage usually occurs near the portals or where the depth of cover is less.
Underground streams or springs may contribute to leakage anywhere in the tunnel. Water
following an impervious strata of material may also seep out.

3. Leaks generally occur at construction joints; cracks that have developed in the lining,
honey combed of concrete and joints of brick or stone lining. Seepage in brick lined
tunnels may be examined carefully as they may cover extensive area.

4. Weep holes often fail to function because of their small diameter or their being blocked
by mineral deposits or talus piling up at the back of the wall. This holds up the water
behind the lining which is relieved by the development of seepage and lead to leakage
through the tunnel lining. Old shaft used in construction may be source of seepage of
water.

Correction of leakage in tunnels :

1. For masonry lined tunnels it is best to bring the water through proper drains into the ditch
rather than try to seal the water at the back of the tunnel ling. Attempts should be made to
open existing weep holes and drains. However, where this is not feasible, new weep holes
and drains should be made.

Holes should be drilled through the tunnel lining at the wet areas to tap the water.

2. The holes should be drilled as near the drain level as possible, depending on the height of
the seepage pints and spaced at suitable intervals.

3. Construction joints or cracks where seepage is light may be sealed by chipping the crack
in the form of a “V” and caulking with lead wool and by guniting.

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4. Where seepage in joints or cracks is too great to seal or a definite leak occurs, water
should be carried in recessed drain to the side drain level. A series of holes should be
drilled in the recessed drain channel through the tunnel lining of offer an easy path of
escape of water. The face of the drain may be of brick or shotcrete.

5. Very often, leaks around the portals are due to poor drainage over the portal. This may be
due to clogged portal drains and/or weathered material forming a catch basin over the
portal over the portal. Generally it is best to open portal drains and clear the drainage
ditches above the portal.

Works connected with the maintenance of tunnels

All works in tunnels should be carried out under the protection of engineering signals. The
inspector concerned shall be responsible for the safety of trains and of the men and
equipment.

Mobile testing units shall be used under block protection.

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DEEP CUTTINGS
General

Deep cuttings exists on the approach of tunnels and in ghat sections. At deep cuttings, traffic
may be interrupted by slips or boulders dropping from the hill sides.

Inspection register of vulnerable cuttings :

Each Divisional Engineer/Sr. Divisional Engineer should identify the vulnerable cuttings in
the various sections. A register for these cutting should be maintained in the suitable
proforma given at page no. 42 (Annexure –B). Separate page will be maintained for each
cutting.

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Inspection of Deep Cuttings :

1. Immediately after the monsoon, the PWI should inspect each cutting and record his
observation in the register which should be sent to the AEN for his examination well
before the next monsoon to enable for planning of remedial measures that he may like to
take in the intervening period.

2. Each vulnerable cutting should be inspected before the onset of rains as in the case of
bridges and tunnels by the AEN concerned and he should record his remarks in the
register which should then be sent to the PWI for taking appropriate action. Action taken
by the PWI should recorded in the register and the same returned to the AEN for his
perusal before the onset of the monsoon. Date by which these registers should be returned
to the AEN for his perusal to enable that adequate action has been taken should also be
specified by the Divisional Engineer depending upon the time when the monsoon starts in
a particular section.

3. During monsoon, frequent inspection of vulnerable cuttings may be carried out as

required keeping in view the past history and the vulnerability of the cuttings.

Points to be noted during inspection of cuttings

1. During the inspection of cuttings, the inspecting official should look for signs of upheaval
in the regular slope surface of cuttings which would indicate that there are water pocket
underneath the cutting slopes.

2. The official should examine weather catch water drains have been provided to intercept
water from running down the hill side and getting into the cutting. He should see that the
catch water drains are clear of all obstructions and ensure that there are no depressions in
the longitudinal level of these drains which could collect storm water and may cause
slips. He should check that the catch water drains have a good longitudinal slope towards
the out-fall.

3. He should examine carefully for any loose boulders on top of cutting and side slopes
which are likely to fall and are in precarious position.

4. He should examine :

 The condition of rubble pitching on the slopes, if any.

 The condition of retaining walls and the weep holes.
 The condition of side drains and see that they are not choked up.

5. He should see whether any tree is precariously perched on the top of cutting and slopes.

Action to be taken in the case of boulder drops.

1. In case of boulder drops, the boulder may be removed by jacking. If the boulder cannot be
moved by jacks or levers, blasting will be necessary.

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2. Inspectors who will handle blasting equipment should be conversant with the methods of
blasting and should be familiar with all safety precautions to be observed for the custody
and use of explosives.

3. The following equipment should be kept at the Head quarters of each inspector in whose
section such vulnerable cutting exist:

 Jacks in good working condition,

 Jumping steel bars 1"dia and 5'long.
 Charging rods and
 Suitable stock of explosives, fuses and detonators at specified places.

Action to be taken after inspection of cutting

1. Action should be taken to remove boulders in a planned manner as referred to in para

above.

2. Action should be taken to clear and repair catch water drains and side drains as necessary.

3. Trees perched at top and side slopes of cuttings should be removed.

4. Provision of retaining walls as necessary to be made.

Guarding of vulnerable cuttings

Stationary watchmen should be posted round the clock at nominated vulnerable cuttings
during the monsoon period in accordance with para 1014 of Indian Railway Permanent Way
Manual 1986.

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Annexure – A
Sheet no. – 1
TUNNEL INSPECTION REGISTER

Instructions to be printed in the register details of inspection.

Detailed inspection of tunnel includes examination of –

1. Tunnel approaches and cutting – To ascertain whether there are any signs of slips or loose
boulder falling on the track.

2. Portals at either end : To ascertain whether there are any signs of slips in the slopes above
the portals, whether the masonry is in any way cracked, shaken or bulging and signs of
movement are apparent.

Whether the catch water drains above the portals drain way and no allow the water to
percolate into the tunnels or behind the portal masonry.

3. Section of tunnel in relation to moving dimensions :

To as certain whether the dimensions of the tunnel section on straights and curves
conform the diagrams given in the schedule of dimensions.

4. Tunnel walls and roofings –

 Lined Section – To ascertain whether the lining is in a satisfactory condition.

Doubtful masonry should be tapped to detect drummy places.

Point of the masonry should be examined for its condition.

 Unlined sections – To ascertain whether the unlined portions are in sound condition.

Doubtful places such as loose projections, should be tapped to detect hollow sounding
portions or loose rock.

5. Drainage : To ascertain whether side drains are adequate and function satisfactorily.

6. Refuges : To ascertain whether these are well maintained and free of vegetation and other
growth.

7. Ventilation shafts/Adits : To ascertain whether these are adequate and maintained free of
vegetation and other growth.

8. Lighting equipment and special tools : To ascertain whether the lighting equipment and
special tools where supplied are in a state of good repair.

9. The track : To ascertain whether it is in good line and level, including the approaches.
Rails, sleepers and fastenings should be particularly examined for corrosion.

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Entries in tunnel inspection register

1. Entries should be made under each of the heads 1 to 8 mentioned under “Inspection of
tunnels”.

2. Under each head the first entry should state whether the previous year’s notes have been
attended to.

3. Entries in the column “condition of tunnels at the time of inspection” should be in the
nature of statements. A defects once mentioned should not be omitted in future years
unless it has been eliminated by rebuilding or repair in which case a note should be made
to that effect.

4. In the column “Action taken” the remarks should be in the form that orders have been
issued e.g.

 Permanent Way Inspector instructed to renew rails;

 Permanent Way Inspector/Works Inspector instructed to grout cracks.
 Bridge inspector instructed to put in steel support stagings.

5. No tunnel in which the lining is shaken, crushed, bulging, deteriorating or shows signs of
movement or in which any of the unlined portion is loose, should be described as
“sound”.

6. A tunnel is to be noted “requiring special repairs” when any part of it has to be relined or
undergo heavy repairs.

Annexure – A
Sheet no. 2
TUNNEL INSPECTION REGISTER

An index to be opened in the register giving the tunnel No. and Page No. etc.

INDEX

Page No. Kilometreage (Mileage) Tunnel No.

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Annexure – A
Sheet no. 3
DETAILS OF TUNNEL

Separate pages should be allotted for each tunnel and the following details should be
furnished for each one of them.

Tunnel No.__________________ Section ___________ Between stations _____________

Total length _________________ Kilometreage __________________________________

Year of construction ___________

Curve/Straight ________________ Details of construction _________________________

Brief particulars of soil met with ______________________________________________

Portions lined and thickness of lining ___________________________________________

Brief particulars of ventilation _________________________________________________

Brief particulars of lighting (if any) _____________________________________________

Brief particulars of drainage __________________________________________________

Minimum height above rail level along centre line of track/s _______________ milimetres.

Minimum distance from centre line of track/s ___________ milimetres.

Reference to Plan _________________________________________________________.

Previous History of Tunnel

Here all the records, such as details of damage to the tunnels and the repairs, if carried out
with cost, special care to be taken in the maintenance of tunnel etc. are to be shown.

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Annexure – A
Sheet no. 4
Extract of page of tunnel inspection register

Details of Year 2001-2002 Year 2002-2003

inspection Details of Condition Action Details of Condition Action
inspection at the time taken and inspection at the time taken and
inspection initials inspection initials
1 2 3 4 5 6 7
1. Tunnel
approach &
cutting.
2. Condition of
portals

3. Tunnel walls
& roofing.
Comment
about tunnel
conforming
to moving
dimension

4. Drainage
inside tunnel
and out fall

5. Condition of
tunnel
refuges &
ventilation
shafts.

6. Tracks in
the tunnel.

7. Lighting
equipment
& tools

8. Any other
items

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Annexure – B

Proforma of the Register of vulnerable cuttings

Name of section __________________ and reference to authority for nominating

it as vulnerable _______________________ No._______________ Date ______________

No. of Kilometre Max Degree of Type of Past History

cutting From/To depth/side curvature if strata of cutting
slopes any

Date of Remarks Date of Remarks Date of Remarks Action taken

inspection of PWI inspection of AEN inspection of DEN by PWI

***

Go to index

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CHAPTER – 5

Protection Works
Protection works :

Protection works are appurtenances provided to protect the bridge and its approaches from
damage during high flood conditions; these are

1. Flooring
2. Curtain and drop walls
3. Pitching
4. Toe walls
5. Guide bunds
6. Marginal bunds
7. Spurs/groynes
8. Aprons
9. Sausage/rectangular crates

Maintaining these works in proper conditions is as important as maintenance of the bridge

structure itself.

Treatment of formation
Classification of formation requiring treatment :

Formation requiring treatment shall be categorised as under :

(a) Very bad : Where either speed restrictions are imposed on this account or number of
normal attentions to track in a year is more than 12.

(b) Bad : Where the number of normal attentions to track is between 6 to 12 in a year.

Nature of formation problems :

In such stretches, the track levels get disturbed frequently causing problems in track
maintenance. These problems are attributable to :

(a) Excessive or uneven settlement of banks.

(b) Slope and the failure of soil leading to slips, heaving beyond the toe, creep or bulging
of slopes.

(c) Ballast penetration and mud pumping of poor sub grade material.

(d) Swelling and shrinkage of expansive soils in fills such as black cotton soil.

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Site investigations : The following data should be collected for determining the type of
treatment to the formation :

a) History of the affected section :

 Period when constructed;

 Method of construction;
 Date of opening to traffic;
 Subsoil bank settlements;
 Slips if any; and
 Speed restrictions on formation account.

b) Site details :

 Bank heights;
 Depth of cutting;
 Nature of existing slopes (Turfed or not with or without berms);
 Drainage conditions;
 Stagnation of water;
 Condition and proximity of borrow pits;
 Signs of movement and bulging in the slopes;
 Ground water level and its position during rains

c) Number of attentions to track : The particulars of the number of attentions to track should
be obtained from gang charts for the last five years, to get an idea about track
maintainability. Man-days utilised for maintenance per Km. Should also be collected vis-
à-vis men required for normal maintenance.

d) Ballast penetration profiles : These profiles should be obtained at regular intervals of one
telegraph post/O.H.E. mast, to indicate the extent of ballast penetration and condition of
ballast (loose, caked, mixed with cinder/sand moorum etc.)

e) Exact nature of present troubles : The exact nature of the present trouble should be
identified whether it is due to :

 Bulging of ballast between cribs or at the cess.

 Mud pumping
 Slope movement
 Slope failure etc.

Soil investigations and testing :

Soil investigation :

(a) Undisturbed soil samples should generally be collected at every telegraph post/O.H.E.
mast. Undisturbed soil samples in 100 mm, sampling tubes should be collected from the
following places as necessary :

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 From the formation below the depth upto which the ballast has penetrated.
 From inside the bank along the probable circle through which the slip has occurred,
where the bank has been found to be structurally unstable.
 From various depths below the ground level at the toe of the bank, where base
failures/settlements have occurred.
 From two sections in the slipped portion and one section at the toe adjoining the site
where slip has not occurred in the past.

(b) Two cross sections of the bank in both the sections should also be taken by means of
precise levelling.

(c) In addition to this, disturbed soil samples should also be at regular intervals of a telegraph
post/O.H.E. mast, to determine the index properties of the formation soil.

(d) Soil testing : Selected undisturbed/disturbed soil samples should be tested at the soil
mechanics Laboratory, to determine the following properties.

 Index properties viz., grain size analysis and Atterrberg limits (i.e. L.L., P.L., S.L.).
 Natural moisture content and natural dry density.
 Optimum moisture content and optimum dry density.
 Shear property.
 Differential free swell.

For banks which are structurally weak/unstable, the shear property of the soil sample is very
important and sufficient number of samples must be tested so as to get an accurate idea of the
shear strength of the bank soil and soil strata below ground level.

Remedial measures suggested : Based on the site investigations and soil testing relevant
remedial measures to be formulated. Some of the remedial measures suggested for the
formation troubles generally encountered are listed below :

For banks where settlement has occurred, consolidation test should also be carried out.

a) Track level variations due to Suggested treatment (any one or in

conjunction)
1 Inadequate drainage due to high cess, Improve side drainage by lowering the
dirty ballast. cess and screening of ballast.
2 Weakening of soil at formation top on  Cationic bituminous emulsion below
contact with rain water resulting in ballast.
mud pumping.  Provision of moorum/sand blanket of
20-30 cm. depth below ballast.
 Laying of geotextiles.
3 Strength failure below ballast causing  Provision of 30-60 cm. deep blanket
heaving of cess or between sleepers. below ballast.
 Provision of sub-ballast.

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4 Seasonal variation in moisture in  Treatment with lime slurry pressure

formation top in expansive soils injection.
causing alternate heaving shrinkage of  Moorum blanket 30-45 cm. with
formation. moorum lining.
5 Gradual subsidence of the bank core  Cement grouting in ballast pockets if
under live loads due to inadequate ballast pockets are permeable.
initial compaction/consolidation of  Sand or boulder drains.
embankment.
6 Gradual consolidation of earth below  Lime piling in sub-soil.
embankment  Sand drains in sub-soil.
7 Creep of formation soil Easing of side slopes.
8 Coal ash pockets due to treatment of  Sand drains below deepest level of
previous slips coal ash.
 Cement pressure grouting.

b) Instability of Bank/Cutting slopes Treatment

due to
1 Inadequate side slopes causing bank Flattening slopes and provision of berms,
slips after prolonged rains. improvement in drainage.
2 Consolidation/settlements of sub-soil Provision of sand drains of expedite
causing bank slips. consolidation.
3 Hydro-static pressure built up under  Draining out of ballast pockets by sand
live loads in ballast pockets contain or boulder drains.
water causing bank slips.  Cement sand pressure grouting of
ballast pockets.
4 Creep of soil Reducing stresses by provision of side
berms or flattening the slopes.
5 Swelling of over consolidated clay side Flattening side slopes.
slopes in cuttings causing loss of shear
strength and slipping.
6 Erosion of banks Provision of turfing, mats, etc.
R.D.S.O’s help, wherever necessary may be taken for formulating the remedial
measures.

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General Checklist for Slope Protection and Preparedness

1. Slopes Visually inspect all sloped areas for signs of gullying, surface cracks,
slumping etc. Also inspect patios, retaining walls, garden walls, etc. for signs of
cracking or rotation. Such signs might be indications of slope movement. If you
notice any problems, have the site inspected by a geo-technical engineer.

2. Bare Ground Make sure your yard does not have large bare areas which could be
sources for mudflows during a storm event. The fall is a good time to put down mulch
and establish native plants; it may be possible to vegetate these bare areas before the
storm season.

3. Storm Drains Visually inspect nearby storm drains, before the storm season and after
every rain; if the storm drains are obstructed, clear the material from the drain.

4. Blufftop Inspections Visually inspect all blufftop retaining walls, wall drains, surface
drains, culverts, ditches, etc. for obstructions or other signs of malfunction, before the
storm season, and after every storm.

5. Inspect Irrigation Systems Visually inspect all irrigation systems and surface
waterlines for signs of leaking and to insure that water is not being directed
immediately at or over an area which could become unstable.

6. Shut-Offs for Irrigation Systems There should be an easy way to shut-off all
irrigation systems. They should be shut-down during periods of high rain. Even if
systems operate with moisture sensors, there should be a manual valve override.

7. Sand Bags and Plastic If there are small areas which could be affected by excess
rainfall, consider stockpiling sand bags and plastic sheeting to divert water. Plastic
can suffocate vegetation and create standing pools of water, and should not be left in
place for long periods of time. Plastic used over several months should be inspected
and maintained after every rain.

8. Long-term Site Stability If it is in a landslide prone area and has not been inspected
for geologic stability, it may be prudent to hire consultant a geologist or geotechnical
engineer to survey the site and prepare a stabilization plan, possibly recommending
temporary and permanent protection measures.

9. Gutters and Runoff Storm water runoff from impermeable surfaces (e.g., roofs,
driveways, and patios) should be directed into a collection system to avoid soil
saturation and potential slope failure.

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Flooring

Flooring is provided in bridges with shallow foundations so as to prevent scour. At either end
of the flooring on upstream and downstream side, curtain walls and drop walls are provided
to prevent disturbance to the flooring itself. There have been instances in which neglect of
flooring has led to failure of bridges. Since such flooring is generally provided in smaller
bridges, it is more likely to be neglected. There are cases in which the flooring has
completely vanished through the ravages of flood/time. In such cases, the inspecting official
should take care not to write the remarks “NIL” under the column “flooring” provided in the
Bridge Register without cross checking the original drawings.

Generally heavy scour is observed on the downstream side of drop wall. It is necessary to
repair this scour by dumping of loose boulders is seen to be quite ineffective in majority of
such cases wherever water impinges at such locations at high velocity and the loose boulders
are carried away to downstream locations.

Curtain wall, drop wall and flooring

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Pitching

Stone pitching is some times provided on approach banks constructed in the khadir of alluvial
rivers to prevent erosion of a bank. Pitching is also provided on guide bunds and spurs for the
same purpose. Pitching acts like on armour on the earthen bank. It is necessary to inspect this
pitching and rectify the defects as any neglect of this may lead to failure of approach
banks/guide bunds, etc. in high floods.

Toe wall is an important component of pitching and if the toe wall gets damaged, pitching is
likely to slip into the water. Providing a proper foundation to the toe wall is important.

In a number of small and big bridges (because of improper excavation of borrow pits while
constructing the line) a stream starts flowing parallel tot he bank on bridge approaches. To
protect the bank from scouring, a toe wall is provided at the bottom of bank pitching. This toe
wall needs to be inspected properly and kept in good condition.

X-Section of pitching

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Guide bunds

These appurtenances are provided generally in alluvial rivers to train the river stream through
the bridge. On many of the bigger and longer guide bunds a siding is laid to work ballast
trains used for transporting boulders. The track of the siding must be maintained in proper
condition.

Disturbances tot he pitching stone in the slope of guide bunds indicate possibility of further
damage during subsequent monsoon and should be carefully noted.

It is necessary to take longitudinal levels and also levels for plotting cross section to ascertain
whether there had been any sinking of these works. Sinking of guide bunds is dangerous and
may lead to overtopping of floods and consequent failure during floods.

Guide bunds constructed on clayey soils need special attention as regards scouring at the
base. Scouring may cause a vertical cut below the toe of guide bund which may ultimately
result in failure of guide bund by slipping. Therefore whenever water keeps on standing at the
toe of the guide bund it is necessary to take soundings and plot the profile of the guide bunds.
This is particularly possible at mole heads.

Guide bund and apron

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Aprons

Apron is provided beyond the toe of slope of guide bund so that when the bed scour occurs
the scoured face will be protected by launching of apron stone. As the river attacks the edge
of the guide bund and carries away the sand below it, the apron stone drops down and forms a
protective covering to the under water slope. This is known as launching of apron.

Sausage/rectangular crates

6 mm  to 8
mm 
MS Round @
100 c/c

Wire crates

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Rock Bolting and Grouting

Rock bolts are used to tie unstable or potentially unstable rock structures into the slope.
There are static and tensioned rock bolts:

 Tensioned rock bolts should be used only where a force is needed to counteract the
forces making the structure unstable.
 In most cases static bolts should be used.

The logic behind a static bolt is that if the structure is safe enough to drill into and install
rock bolts, it already has an inherent factor of safety. If the stability of the structure is
adversely affected in the future the static bolt will automatically go into tension with the
exact amount of force and in the exact location that it should.

***
Go to index

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CHAPTER – 6

Case Studies
Maintenance of Track in Ghat Section (KSR Section)

Salient Features

Track

1 Length 96.60 Km.

2 Gauge 762 mm (2’-6”)
3 Ruling gradient 1 in 33.33 (3%)
4 Total no. of curves 919 nos.
5 Max. degree of curve 480
6 Max. super elevation 65 mm
7 No. of tunnels 102 (8 Kms., 8% of the section)
8 Longest tunnel 1143.61 M (Barog tunnel)
9 Total length of tunnels 7.653 Km. (8% of the section)
10 No. of bridges 889 nos.
11 Longest bridges Br. No. 226 (68.58 M, Arch Galleries)
12 Total length of curved track 67.68 Km. (70% of total section)
13 Altitude above MSL Kalka : 656 M
Shimla : 2076 M
14 No. of stations including Kalka, Shimla. 19

Track structures

1 Rails 60 R 96.60 Km.

60BSS/62BSS FF 2.66 Km.
75R/75LBS ISR 31.93 Km
2 Sleeper wooden 3.30 Km.
Steel trough 93.24 Km.
3 Sleeper density M+4
4 LWR 1.18 Km.
5 SWR 2.12 Km.
6 S.R. (FP) 93.25 Km.
7 Ballast cushion Stone, 125 MM
8 GMT 0.46 up & 0.44 DN, Total = 0.90 GMT

2. About the section :

The 96.60 km. Long section was opened for traffic on Nov. 9, 1903 having been constructed
in record period of 3 years, this is an engineering feat of highest skill comprising of 102
tunnels, 889 bridges, innumerable cuttings with curves sharper upto 480 covering nearly 70%
of alignment.

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The 96.6 Km. Hill section is amongst the most spectacular Narrow Gauge lines in the world.
This Kalka-Shimla NG section has been described by the Guinness Book of Rail Facts and
Feats as “ The greatest Narrow engineered in India”. It rises by 1420 M between in Kalka
(656 M) and Shimla (2076 M) with an average gradient of 1 in 67. The ruling gradient is 1 in
33.33.

3. Inspection

The inspection are being conducted as per para 107, 124 and 139, 139A of IRPWM by AEN,
PWI-I/C and PWI-section respectively in concordance with CE circular no. 219 (P.Way).

Special instruction : ODC TRAIL RUN is conducted once a year over the entire section, to
check any infringement to moving trains by fixed structures like tunnels, retaining walls and
platforms etc., as per paras 221 of IRPWM.

4. Maintenance

Regular

(I) Post Monsoon attention : Systematic through packing, over hauling of track and
lubrication of rail joints is being carried out during post monsoon attention as per
P.Way manual.

(II) Pre-monsoon attention : During April & May cleaning of catch water drains, and
water ways of bridges is under taken along with picking up slackes. Four days a week
are given to work and two days are given systematic maintenance viz. Changing of
worn out/defective rails, unserviceable sleeper and realignment of curves etc.

(III) Attention during monsoon : Cleaning of side drains, catch water drains and water
ways of bridges, deweeding of retaining walls and bridges along with picking up
slacks.

Incidental

(I) Replacement of defective rails/welds detected during USFD testing and detected by
keyman during visual examination of rails.

(II) Replacement of U/S sleepers and track fittings.

(III) Repair to cess, where in Hill side shows the signs of settlement.

Special

(I) Maintenance of proper check rail clearance at curves.

(II) Frequent attention to track in tunnels as track deteriorates at faster rate due to seepage.

(III) Fixing of wooden struts to maintain proper clearance in track and fixed structures i.e.
retaining walls etc.

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5. Problems and remedial measures :

(I) Falling of trees on track : Pine trees falls on the track during monsoon and tempters
weather on an average 10-12 times a year.

(II) Falling of heavy boulders : During heavy rains erosions of sleep slopes takes place
which gives way to heavy boulders to roll down. Boulders are cut into pieces with the
help of chisels and hammers in order to clear the track.

(III) Hill slips : Heavy slips and major subsidence of track occurs due to :

a) Heavy rains causes sleeper slopes of soil mass to slip.

b) Erosion of soil caused by water oozing out of the slopes. Hill slips is a very
common phenomenon during monsoon on KSR section. Some times the section is
closed for more than 12 hrs. due to hill slips. Extra labour is called from others
section to clear the debris.

(IV) Snow fall : Snow fall occurs normally in December and January, in Shimla and up to
Shoghi station occasionally snow is removed manually and/or with wedge shaped
cutter fitted to the cow catchers of the locomotive.

6. Pre-monsoon attention :

(I) Felling trees : A survey is conducted before onset of monsoon for trees which are
likely to fall on the track. These trees are felled down after taking necessary safety
precautions.

(II) Felling boulders : Similarly boulders which are likely to fall down are detected and
there boulders are felled down after taking necessary safety precautions.

(III) As already discussed in para 4(II) catch water drains, side drains and water ways of
bridges are cleaned thoroughly in April and May.

7. Post Monsoon attention :

Run down stretches of track are attended to bring the section in good shape. One cycle
of through packing over hauling is given from one end to another end of beat as
detailed in para 203 (2) of IRPWM.

Attention during Monsoon : Same as para 4 (ii).

Tunnels : There are 102 tunnels on KSR section. The longest tunnel is BAROG tunnel
(1143.61 M), which is located between KMTI & BOF. The track in this tunnel is laid with
LWR.

Inspections : All tunnels are inspected once a year by AEN after monsoon. Defects noted are
attended by IOW or bridge branch as the case may be. In most of the tunnels seepage of

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water is the main problem. Seepage water is collected in water collecting trays and brought
down through pipes along the tunnel walls.

Due to seepage, track deteriorates frequently which is attended from time to time. As no
lighting arrangements is there so, maintenance of track and repair to tunnels is done with the
help of LPG patromaxs, locally made mashals, torches etc. mirrors are also used for
reflecting sun-rays into tunnels which gives a very good natural light during sunny days, it
help in maintenance operation to a great extent.

Bridges : There are 889 bridges on KSR section. Most of the bridges are arch gallery type
constructed with stone masonry. Longest bridge No. is 226 having length 68.58 mts. (Arch
gallery 4 steps).

Occurrence of floods:

(i) Br. No. 127 was totally washed away by flash floods in the year 1992.

(ii) Br. No. 77 was over-flooded in 1992 and again in 1999 by flash floods. Recently this
bridge have been supplemented with (4 X 2) Hume pipes.

(iii) Br. No. 712 was washed away by flash floods in 1995 and it was rebuilt in 1996.

Past Incidences :

(i) Slope failures/ Hill Slip

(ii) Accidents : During the last 3 years, there is no accident occurred on P.Way account.

Patrolling : Normal monsoon patrolling is done from 15 June to 15 Sept. during night.
During day time, of there is adequate no of gangmen are deputed on monsoon patrolling by
gangmate on his beat. KOTI-GMM block section is infested with wild animals sometimes
hardships are being faced in patrolling this block section due to fear of wild animals (leopard
etc.).

Gang working : Gang working time during winter season – 8 to 12.30 hours and 13.00 to
17.00 hours and during summer season, 7.30 hours to 12 hours and 13.30 hours to 17.30
hours.

During gang working portable whistle boards are exhibited on either side at a distance of 400
mts. to make the drivers aware that the gang is working ahead. Driver would start whistling to
make the gang alert and cautions of the approaching train.

Keeping in view the hilly terrain and inaccessible by road the gang beats are kept 4 to 5 kms.,
so that in case of any event of unusual, gang could reach at site without loosing by time.

Safety equipment : In addition to other safety equipment as in plain section 2 nos. fuse
signals are given to each gang, monsoon patrollers and keyman.

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Curves : There are 919 curves on KSR section covering 67.68 kms. i.e. about 70% of total
track is on curve sharpest curves are of 480 (36.57 m radius). More than 30% of track is on
curves sharper than 400. All curves on this section are transitioned. The gauge is kept upto 16
mm slack on curves.

Maximum cant deficiency - 40 mm

Maximum super Elevation - 65 mm
Check rail - Provided on curves sharper than 36
Check rail clearance - 71to 75 mm

Maintenance problems on curves :

1. Check rail on curves are subjected to severe strain and check blocks tends to loose.
2. Movement of track due to temperature variation.

Recurring activities :

- Check rails are lubricated once a week to reduce wear and tear.
- Provision of wooden struts to check the lateral movement.
- Checking of versine by JE/SE (P.Way) fortnightly and adjusting the curves locally.
- Tightening of check rail bolts and keeping correct clearance.

Drainage system : Properly lined side drain are provided to run off the rain water quickly,
side drains are lined to avoid percolation of water due to natural slopes, there is smooth flow
of rain water.

Side slope protection : Catch water drains have been provided. Retaining wall and breast
walls have been provided where slopes are steep. Boulders catch on u/s of the
bridges/culverts have been provided to arrest the boulder fall from the side slope. Boulder
catch are provided above the sumps in half round shape.

Permanent speed restrictions : The MSS of the section is 25 kmph for pass trains and 30
kmph for rail motor cars (booked speed – 22.5 kmph and 25 kmph respectively).

1. 8 kmph for shunting in yard due to sharp curve over all stations of the section.
2. 10 kmph on decending gradients due to limited brake power for all goods trains of
goods loads exceeding 857.35 quintals with less than eight four wheelers.

Working of Trollies/Lorries and material trains :

1. Push trollies are worked on proper line clear like trains.

2. Materials lorries are worked under block protection.
3. Material trains : P.Way materials and building materials are transported from Kalka to
various station/block sections on KSR section, through BKC8S/FR set.

Trolley Refuges : Man refuges are provided in tunnels and on long bridges.

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PROBLEMS OF TRACK MAINTENANCE IN KARJAT-LONAVLA GHAT

SECTION OF CENTRAL RAILWAY

Brief history of section

The KARJAT-LONAVLA ghat section is passes through the most difficult ranges of
“Sahyadri” in Western Ghats”. This ghat section, commonly known as “Bore Ghat” or
“South East Ghat” extends from Karjat (kms.99.7 Ex. Mumbai) at an elevation of 52 m.
above MSL to Lonavla (Kms.127.76 Ex. Mumbai) 622 m above MSL. Thus an altitude of
570 m is negotiated in just 28 kms. with a ruling gradient of 1 in 37 between Palasdhari and
Lonavla which even today is the steepest section for main Broad Gauge Railway line in the
whole world. The section between Karjat and Palasdhari (kms.102.69 Ex. Mumbai) is semi
ghat section (length 3 km.) with gradient upto 1 in 100. The ghat section is 28 kms. long on
triple line.

The line was opened for traffic in May 1868 on single line. Doubling was completed in 1929
and third ghat line constructed in March 84. The length of Up, Middle and Dn lines is 28.54,
27.57 and 27.18 km respectively between Karjat and Lonavla. (Total track kms.82.29 kms.)

General details of ghat section

Track structure

Entire track is now on PSC Sleepers with 52/60 kg. rails.

62 kg. rail with SWP = 39.47 kms. (47.8%)

52 kg. rail with SWP = 38.72 kms. (47.1%)
60 kg. rail with free rails = 04.10 kms. (5.1%)

Total = 82.29 kms.

Gradients

The length of steepest grades of section are as follows :

Grade Length of track

1 in 50 9.30 kms.
1 in 40 23.10 kms.
1 in 37 10.80 kms.

Curves

The max degree of curvature is 5.75 degree. The 52.72 km (68.4%) track length is laid curves
out of 82.29 kms. of track length. Out of this 28.9 % track is laid on curves sharper than 4
degree. 13.74 kms. of curved track length is inside the tunnels.

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Tunnels

There are total 52 tunnels with total length of tunnels equal to 14.7 kms. The largest tunnel is
tunnel no. 25 C, which is 2.156 kms. long and was longest on IR till construction of Karbude
Tunnel no. 35 of Konkan Railway which is 6.506 kms. long. Total 21.9% of track runs inside
the tunnels in Ghat Section.

Bridges

There are total 161 bridges in Ghat section. 9 bridges are major and 152 are minor bridges.
The longest bridges is 6 X 24.4 girder viaduct bridging semi circular valley between Nagnath
and Monkey hill on third ghat line.

Catch siding

There are 6 catch sidings at 4 locations as follows :

Road Khandala Monkey hill Thakurwadi Nagnath

Up 629.72 M 580.12 M - 900 M
Dn 693.42 M - - -
Mid 693.42 M 580.12 M 1223.16 M -
Steepest grade 1/7 1/5 1/4 1/4

Maintenance problems

Maintenance problems are of two types, one associated with track and other with the fall of
boulders/land slides during monsoon.

Scanning of loose boulders

This is very important activity carried out in ghat section during the month of Feb. and March
before monsoon. All the hill slopes are examined for loose boulders by hill side tunnel gangs
which consists of local villagers who are familiar with hill climbing and mountaineering. All
the loose boulders and also the boulders suspected to becomes loose during course of
monsoon are identified paint marked on hill top as well as on nearest location adjacent to
track. The date of scanning is also mentioned in paint marking. The scanning is completed by
end of March. On an average 200 to 250 boulders are detected as loose boulder every year.

Working on boulders special

After completion of scanning work, a date wise programme is prepared for dropping of loose
boulders by AEN in consultation with TRD department joint blocks are planned on one or
two lines, or some time even all the three lines depending on proximity of lines and height of
loose boulder to be dropped. Generally, the program is of one month duration in the month of
April/May. The program is approved by DRM and two diesel powers are provided for
working of boulder special train. The boulder special train consist of emergency van loaded
with P.Way material, explosive material for blasting, a special coach, on which air
compressor is installed which drives the pneumatics tools like drilling machine and pavement
breaker, wiring coach of TRD department containing emergency OHE material. During the
block, loose boulders which are paint marked on hill slopes/top are dropped by hill side gang.

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The boulder which is dropped may infringe the track or even damage the OHE wire or OHE
mast. The dropped boulders are cleared from site by blasting, if size is large or by rolling if
size is small. The damaged OHE wire/mast, if any, are restored by OHE emergency wiring
train.

Monsoon patrolling/patrolling of vulnerable locations

The entire ghat section is patrolled from 15 June to 15 Oct. from 16.00 hrs. to 8.00 hrs. in 2
shifts by a set of 2 patrolman. All Up and Dn trains on all three roads are given protection of
monsoon patrolmen. The section is divided in to beats of 6 to 7 kms. on each road and
patrolmen in pair are deputed for patrolling.

Apart from regular patrolling, the static watchmen are deputed at certain locations which are
declared as vulnerable due to their previous history of land slides/boulder falls. These
vulnerable locations are 17 nos. manned round the clock in 3 shifts and provided with
emergency phone arrangement.

Problems of track maintenance

Wear of rail

Due to sharp curves and steep gradients, more tractive force is exerted by moving trains on
rails, especially in ascending direction. This causes heavy wear on gauge face of outside rail
which has been observed up to 10 to 12 mm. The amount of side wear in outside rail depends
on degree of curvature. On the curves sharper than 4.5 degree the wear is about 1 mm to 1.5
mm, in a year in case 90 UTS rails. The wear is about 0.8 to 1 mm per year, on curve upto 4.5
degree. Due to excessive side wear, the rails are required to be interchanged every 5 years
and required to be renewed every 10 years on sharp curves. Hence, the criteria for renewal of
rails is not on GMT/service life basis but on condition basis. Greasing of gauge face on sharp
curves is done on every alternative day to control the wear, but grease becomes ineffective
due to sanding done by bankers and front engines of goods trains to control the stalling of
loads.

Flattening of inner rail table

Flattening of rail table takes place on inner rail on sharp curves. This is due to large vertical
stresses caused by heavy goods trains which experiences cant excess. Vertical wear also takes
place due to paste formed out of grease applied to gauge face and sanding done by the drivers
to control the stalling. The burrs are formed on top table which causes tight gauge.

Wheel burns/wheel scabbing

There are large cases of stalling of goods trains in ascending direction due to steep gradients.
After the load is stalled, the driver tries to start the train by sanding. The tractive force is
applied but longitudinal movement is not effected. This causes wheel slipping, leading to
wheel burns in rail. The problem is more prominent in monsoon season when friction
between rail and wheel is considerably reduced. In descending direction the drivers try to
control the speeds by continuous applications of brakes. Sudden application of brakes from
high speeds, at times causes wheels to lock and slide. This also causes wheel burns in the rail.
On descending direction wheel burns are found at all the locations of stop signal provided for

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catch sidings at Khandala, Monkey Hill and Nagnath on Up and Middle road. The depth of
wheel burns varies from 0.5 to 4 mm. the multiple wheel burns gets converted into scabbing
which needs immediate replacement. The wheel burns/scabbing not only creates hammering
action equal to the rail joint but also keeps on increasing in size and shape. The rail is prone
to fracture due to this defect. The 90 UTS and 110 UTS rails are more fracture prone due to
wheel burns/scabbing. On an average 300 to 350 scabbed rails are required to replace every
year.

Corrosion of rail

The heavy corrosion of rails is taking place inside the tunnel due to continuous damp
conditions caused and seepage. The total length of tunnels is 14.7 kms and 21.90% of track is
inside the tunnels. The corrosion is also taking place on the approaches of stop signals where
the grease/waste oil are falling from engine on the track. These corrosion prone conditions
are also causing seizure of pandrol clips and corrosion of metal liners leading to their
premature renewals. Average life of fittings is found to be 3 to 4 years under such corrosive
conditions.

Maintenance of joints

To avoid elbow kinks at joints on curve sharper than 4 degree, the mid staggering of joints
has been done. It also avoids the wastage of cutting almost each panel of inner rail which
might be required to keep the joint square during inter changing the rails. The maintenance of
joints after the mid staggering is very important to avoid the formation of twist due to low
joints. The joint sleeper spacing has been changed to 32.5 cm for better maintenance, since
normal spacing of sleepers lead sot hogged/battered joint causing more hammering action.

The normal rubber pads and liners were working out, leading to the notching in joint PSC
sleepers below the rail seat. This problem is controlled by provision of 10 mm thick rubber
pad and cut liner which are modified locally. The J clips are provided on all joints but are
found less effective due to poor toe load.

Lubrication of all the fish plated joints is carried out every year in the month of
December/January and broken fish plates, bolts etc. found during visual inspections are
replaced. Total 78.9 kms. (95%) track in ghat section is converted to SWR out 82.3 kms.
leaving only 4.1 kms. on single rails which is also planned for conversion to SWR. As per
provisions of IRPWM, SWR can not be provided on curves with radius sharper than 500m.
but considering the difficulties in maintenance of fish plated joints the FP track has been
converted to SWR. Since it's conversion, which started in 1991, the behaviour of thermal
stresses is experienced. A report has been forwarded to RDSO for approval of existing SWR.

Maintenance of curves

The curves gets disturbed at their transitions, particularly, when reverse curves are continued.
The versines portion to transition portion gets accumulated of versines in transition leads to
the sharpness of curve in transition portion in ghat section. As this is portion, where the cant
is also reduced from max. to zero in case of front transition end, it creates deficiency of cant
for transition portion and results in excess wear on this part of curve. Due to this problem, the
more amount of slew is always there, which is difficult to provide, due to tunnels cuttings,
OHE structures or bridges. Hence the curves are always realigned either in smoothening

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mode or by compounding method in design mode. The local adjustment of versine,

increasing of cess ballast and lubrication of gauge face of outer rail on each curve is being
done to maintain the curves in proper shape. Greasing of gauge face on curves sharper than
4.5 degree is done on every alternate day.

The rail seat of MBC sleepers on inner rail on sharp curves are developing the notches with
depth varying from 5 to 10 mm at some locations. These notches are developed after the
rubber pad is crushed. This necessitates premature replacement of sleepers & rubber pads.
This problem is due to heavy radial and vertical forces due to movement of heavy goods
trains.

The M.S.Liners are also found to be heavily worn out at outer rail side. This wear is
occurring due to lateral forces on outer rail by fast moving passenger trains. The MS liners
are replaced regularly and cant is properly maintained.

Running of material train

Dip lorrying is not permitted in the ghat section and all the material has to be moved by the
material train. Even the building materials required for construction works also has to be
taken by material train only. Since traffic blocks are common between Engineering and OHE
dept, the material train requires diesel power if power block is also imposed along with traffic
block. Generally requirement of blocks for engineering and OHE works is planned in
advance so that material train is working smoothly. All the ballast supply is not possible due
to non-availability of approach roads.

Recommendations and suggestions

1. Use of wide gauge sleepers on sharp curves to control the gauge face side wear of outer
rail.

2. Conversion of balance fish plated track into SWR for better maintenance.

3. Mid-staggering of joints on sharp curves.

4. Provision of 10 mm thick rubber pad, modified liners, J clips and joint PSC sleeper
spacing at 32.5 cms on fish-plated joints.

5. Cropping and pulling of rails at battered and hogged rail joints.

6. Intermediate round of boulder scanning to ascertain the loose boulders which might have
been developed after heavy rainfall and their systematic dropping.

7. Protection of hill slopes by new methods like rock-bolting, Netlon grid or Geogrids and
construction of retaining walls along the track susceptible to land slides. The initial cost
of such works will appear to be very high but considering savings respect of traffic
dislocations during unusual like boulder-falls/landslides it will be much cheaper in long
run.

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SOUTH EASTERN RAILWAY

HISTORY OF GHAT SECTION

1 K.K.Line KOTTAVALASA & KIRANDUL line opened for traffic

the year 1968.
2 Name of the zonal South Eastern Railway
railway in which line is
construction
3 Name of the Division Waltair
4 Total length of line 445 Km.
5 Total length of ghat 60 km.
section

The line was constructed primarily to transport iron ore from Biladilla mines in M.P. to
Visakhapatnam port for export to JAPAN. At present Iron ore transported to Visakhapatnam
Steel Plant and also to some other Industries.

Salient features of Anantagiri ghat section

1 Total length of ghat 60 km. From km. 32/0 to 92/0 between BDVF-SMLG
section station.
2 Total no. of curves in 182 nos. of curves out of which 162 nos. are of 80.
ghat section.
3 Ruling gradient in ghat 1 in 60 falling continuously for loaded traffic.
section
4 Total no. of tunnels 44 nos.
5 Total no. of major 20 nos.
bridges
6 Locos in use WAG 5B
7 No. of wagons run on BOX ‘N’ 56 nos. = 4800 Ld.
this line. BOY 52 nos. 4800 Ld.
8 No. of rakes per day Loaded 12 rakes.
Empty 12 rakes.
9 Speed of section 45 kmph. for BOX ‘N’
40 kmph for BOY.

In rising gradient direction the speed is allowed up to maximum permissible considering cant
deficiencies.

The line is electrified and trains run with 3 electric locos 6200 H.P. Three locos are required
to negociate the up gradient of 1 in 60 in empty and in down direction for a load of 4800
M.T. to control the 56 wagons in the falling gradient.

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Track structure in Anantgiri ghat section

1 Rails 60 kg. 90 UTS and 60 kg. 110 UTS rails & H.H.rails
2 Sleepers 60 kg. P.S.C. with elastic fastenings to M+7 density and
rolled steel sleepers with elastic fastenings to M+7
density. They are with rigid fastenings.
3 Station yards All the main line points and crossings are laid with 60
kg. P.S.C fan-shaped layouts with C.M.S. crossings
and heat treated crossing.
Slip sidings are laid with spring loaded points.
Enroute catch sidings are provided.
4 Jurisdiction of S.E. From Km. 3/11 to km. 60/14 Fx. KTV to Ex. CMDP.
5 Jurisdiction of J.E. From Km. 32/11 to Km. 60/14 RDVR to ex. CMDP.
6 No. of P.Way supervisors Four
7 No. of gangs Four
8 No. of station yards RDVR, SLPM and TXD
9 Total length of track in ghat Km. 32/0 to km. 60/14 (28.48)
section
10 Total no. of curves 86 nos. (length 21.00 km.)
11 No. of girder bridges 12 Twelve (length 0.60 km.)
12 No. of tunnels 2 + 24 (length 6.86 km.)
13 Total length of straight track 7.48 Km.

Inspection problems in ghat section

1. Foot plate and last vehicle inspections are carried out as per the schedule and defects
noticed are rectified for safe passage of traffic.

2. Inspection of section by push trolley in ghat section is the main problem as the push
trolley inspection is to be carried out by taking line clear or by blocking the section.

3. Inspection of curves could be done as per the scheduled programme and attended to
rectification of defects where curves require local adjustment/re-alignment.

4. Inspection of points and crossings, level crossing and tunnels are carried out as per the
schedule and defects noticed are rectified as required.

5. Inspection of gangs routine work in ghat section is carried as per schedule.

Since it is very typical Ghat section the problems are faced in completing the schedule of
inspection.

1. The track in ghat section is also subjected to heavy creep, leading series of consecutive
jammed joints which develops bursting forces acting radially outward which almost
equal to thermal forces in rail.

Such a contraction of force leads to increase the positive angle of attach of leading outer
wheel on outer rail. This is the cause of heavy lateral and angular wear of outer rail.

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The effect of angularity can be seen by the presence of continuous grazing marks on
inside face of check rails.

2. Load distribution: The load distribution of wagon if not even causes twist in the under
frame of the wagon. Which reduces the twist negotiable of the wagon. Such uneven
loading on one side of wagon both side bearer clearances were zero and the other side
bearer clearances were upto 50 mm such unevenly loaded wagon is highly prone to
derailment.

Sudden retardation and acceleration has a tendency to lift off the trollies due to buffing
forces. This situation can attain dangerous dimension in sharp curves.

3. Gauge : On P.S.C. track it results in ERCs gradually loosing toe load and liners getting
worked out. On steel sleepers the holes are getting elongated and clip bolts are getting
sheared. As a remedial measure the steel clips are inter changed to hold the gauge, and
clip bolts are regularly greased or replaced.

4. Wear on rails: Due to lateral forces the gauge face of the outer rail is getting premature
worn-out. Remedial actions are taken by greasing the gauge face of the outer rails by
greasing by P & M lubricators and by hand greasing by deputing additional man
Eveready. When wear reaches beyond the tolerance the outer rails are interchanged and
later the rails are renewed when both the gauge faces are worn-out.

Inner rails getting flattened and wheels are grazing on the face of the check rails and
resulting the bolts are getting slant or loose. Additional men are deputed to tighten the
bolts or replace the broken, slant bolts frequently.

5. Creep: Creep is causing numerous problems due to constant falling gradient for the heavy
loaded traffic. Creep anchors are provided to arrest creep. Creep posts are provided at
500 mts. intervals to identify the creep and to take timely action.

During monsoon all most all the gang staff in ghat section are deputed for patrolling the
track as such normal maintenance during monsoon could not be attended.

Due to running of ‘N’ box loaded traffic the track structure is getting frequently
distributed and additional attention is paid to maintain the track to the safe standards by
deputing additional men power.

(I) Constant falling gradient of 1 in 60 for loaded traffic as such creep is excessive
and requiring frequent attention.

(II) Due to lateral thrust track fittings are frequently getting loose. Additional men
power is utilised to rectify.

(III) Additional men power is utilised for hand greasing due to excessive wear.

(IV) Maintenance is done only on need base as per the defects noticed during foot
plate inspection/last vehicle inspection.

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SPECIAL INSTRUCTIONS FOR KALKA-SHIMLA SECTION/1993

Relevency : All General Rules, Subsidiary Rules and Ghat Rules apply to the working of
Kalka - Shimla section except those modified or superseded by these special instructions.

Definition : The Motor-propelled vehicle of the Assistant Engineer, Shimla, weight more
than 4 quintals is there, to be treated as a Train like other Rail Motors.

Train Working :

(a) A copy of the approved special instructions in accordance with which trains and stations
are to be worked is given to these instructions.

(b) Running through of trains : At the following stations of which the diagrams do not show
which is the main line for the purpose of the running through of trains and rail motors,
running through is to be arranged on the line shown below against each of these stations
names :

Stations Up trains or rail motors Down trains or rail motors

Summer hill No.1 No.2
Jatogh No.1 No.2
Taradevi No.2 No.1
Salogra No.2 No.1
Solon brewary No.1 No.2
Barog No.1 No.2
Kumarhatti No.1 No.2
Sonwara No.1 No.2
Jabli No.1 No.2

Control of train running : Control, when operative, will entirely regulate all train-running.
When control is inoperative station masters will take on the responsibility of regulating train-
running.

(a) Potato Trains : Down goods trains composed of less than the equivalent of 8 four
wheelers with a weight of 750 quintals or over must not run at a speed of more than 14
kmph and in order to allow brakes to air cool, these trains must halt for 5 minutes each at
Dharampure (Himachal) and Koti and for 9 minutes each at Jabli, Gumman and Taksal.

(b) The pinning down or fastening of hand-brakes of vehicles of a running train for the
purpose of controlling it is forbidden, except in case of emergency.

(c) Two diesel engines in working are not to be attached to any train, except in case of an
emergency due to an accident, in which case the second engine is to be attached in rear of
the train with the vacuum-pipe connected.

(d) The speed of a train with a dead engine must not exceed 15 kmph.

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Pushing trains :

(a) In case of accidents or other emergencies a passenger train, a relief train, and a train with
empty coaching stock may be pushed outside station limits over descending as well as
accending gradients.

(b) The speed of a train which is being pushed must not exceed 8 kmph. if the leading vehicle
is a brake-van the guard must keep a sharp look out and be prepared to apply the vacuum
brake. If the leading vehicle is not a brake-van the train shall move only at walking speed
and the guard must walk ahead of the train, exhibit hand signal to the Driver, and be
prepared to place detonators on the line, if necessary.

(c) If a train is being pushed outside station limits at night the leading vehicle must show two
red lights in the direction in which the train is moving and a red tail light must be placed
on the engine.

(d) A train which is being pushed, must, when approaching a station, be stopped at the white
board from where is must be slowly piloted upto the outer signal by the guard provided
conditions for reception are fulfilled, the outer signal will then be lowered for the train to
be pushed into the station.

(e) Train lighting in tunnels :During day the switch for the lights in carriages must be turned
on by the guard only for the following tunnels :

Tunnel No.3 Tunnel No.41

Tunnel No.10 Tunnel No.44
Tunnel No.18 Tunnel No.51
Tunnel No.30 Tunnel No.54
Tunnel No.33 Tunnel No.91
Tunnel No.38 Tunnel No.103
Tunnel No.40

Placing of fog signals :

(a) When it is necessary for fog signals to be place outside the outer signal they must be
placed opposite the white board.

(b) When a station master anticipates that it will be necessary to use fog signals for a special
rail motor, he must give as much prior notice as possible to control, or if control is
inoperative, to the station master of the station immediately in the rear in the direction
from which the special is to arrive. Control or the Station Master concerned, as the case
may be, will, on receipt of such a message arrange to stop the rail motor at the station in
rear for delivery of the memo advising that fog signals are likely to be used at the station
ahead, to the rail official accompanying the party or to the member of the party if there is
no railway official.

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Failure of engine electric search light :

When the engine search light fails the following instructions are to be observed.

(a) Passenger train :

(i) When the weather is fair, the train may proceed at 8 kmph., whistling frequently
until the engine is changed.

In the case of search light failing when a train passes through a long tunnel for
which the search light is normally put on, the Driver may pass through the tunnel
at a reduced speed of 8 kmph and whistling frequently.

(ii) Rainy or foggy weather : The train must wait at the station where the search light
has failed until a goods train or a relief engine arrives to take the place of the
engine with a search light out of order.

If the search light fails between stations, the train may proceed at the speed of 8
kmph, whistling frequently until it reaches the station ahead.

(b) Goods train (including light engine) : The train must be stabled till day light.
However the train should clear the block section at a speed of 8 kmph, whistling
frequently.

Marshalling of trains :

(a) Bogie stock must be marshalled together and placed next to the engine. If both bogie and
4 wheeler vehicles are attached to the same trains, the 4 wheeler stock must be placed in
rear of the bogie stock. Loaded bogie and 4 wheeled vehicles must be marshalled in front
of empty bogie and 4 wheeled vehicles respectively.

(b) Bogie vehicles loaded with goods, when attached to passenger to mixed trains, must be
placed immediately behind the engine.

(c) Not more than one bogie or two four wheeler vehicles may be attached outside a bogie
Brake van. No vehicle shall be attached outside a four wheeler brake-van.

(d) A powder-van must not be attached to a mail or passenger train or to any goods train
carrying any commodity of an inflammable nature or to a train that has a composition
bogies, excluding the brake-van and powder-van.

When attached to a goods train, the van must be run with one 4-wheeled vehicle between
it and the rear brake-van and at least an equivalent of four 4 wheelers between it and the
engine.

When attached to a troop train, special orders will be given in the train notice with regard
to the position of the powder van in the composition of the train.
In no circumstances is a powder van to be marshalled outside the brake van of any train.

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(e) A dead engine may only be attached to a train with a composition of the equivalent of not
less than eight 4-wheelers, of which there must be two loaded bogies. The two loaded
bogies, must be placed between the train engine and the dead engine. The crew must ride
in the cab of the dead engine and assist the Driver to control the trains with the engine
hand brake.

(f) Passenger trains, consisting of bogie stock, must be marshalled as follows :

Up trains : Engine, second class, First & second class, composite first class, second class,
luggage van and brake van.

Down trains : Engine, luggage van, second class, First class, first & second class,
composite, second class, brake van.

A saloon required to be attached to a passenger train should marshalled in rear of the first
and second class composite.

Loads of trains : Instructions contained in working time table & other instructions issued
from time to time be adhered to.

Overload on trains :

(a) Maximum load for trains hauled by ZDM-3 DSL. Power is as under : It should be strictly
followed :
Up trains : 1075 quintals
Down trains : 1200 quintals

In no circumstances whatever is an overload to be given to a down potato train (Refer para

4(a) of these instructions).

A driver who finds that his engine is, for any reason, unable to haul the full load of a train, is
authorised to request a station master to cut off a goods vehicle (other than the brake van) at
the station concerned, giving his reasons in writing to the station master. The vehicle selected
to be detached should normally be the lightest vehicle and a full load wagon in preference to
a T.R. or C.R. van.

Tunnels bells and telephones : The following tunnels are provided with a bell or telephone
for use by Drivers to call attention of the station immediately ahead of the tunnel when held
up outside signals.

Koti (Tunnel no. 10) bell at he Jabli end of the tunnel.

Barog (Tunnel no. 33) Telephone at the Kalka end of the tunnel.
Station masters, Koti and Barog, must frequently test these to ensure that they are in good
working order.

Beats of engineering staff : The beats of the engineering staff are given in appendix ‘C’.

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Special instructions for Kalka-Shimla section

1. All the stations on KLK-SML section are provided with the following essentials :

(i) Only one approach signal in each direction which is called ‘outer’ signal.
(ii) One starter in each direction common for all running lines.
(iii) A speed board on either side to restrict the speed of approaching trains to 10 kmph.
(iv) A caution white board on either side at a prescribed distance from the outer signal.

2. Conditions for granting ‘Line Clear’.

The line shall not be considered clear and ‘Line Clear’ shall not be given unless:-

(i) The whole of the last preceding train has arrived complete.
(ii) The outer signal has been put back to ‘ON’ position behind the said train; and
(iii) The line is clear upto the outer most facing point at the end of the station nearest to
the expected train.

3. Conditions for taking “OFF” outer signal :

The outer signal may be taken ‘OFF’ if

The line on which the train is intended to be received is clear and free from obstruction, upto
the close of the switches of the outermost trailing points, the route is correctly set and facing
points are locked.

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Maintenance problems in ghat section

Due to heavy iron loads the wear of rails on inner rails on 8 degree curves was very heavy
and the top of rail width reaching up to 125 mm and the lateral wear was maximum was up to
13 mm. due to heavy hammering action series of battered joints are formed. Batter reaching
up to 10 mm to 15 mm. Wheel grazing marks are seen on fish plate coller causing in heavy
failure of fish plates shearing/snapping of fish bolts and rail failures particular at joints. Due
to weak rail joints creep is developing fast. Due to all the above reasons sleepers are going
out of square even on straight track. Spreading of gauge is one of the numerous problem on
wooden and CST 9 sleepers causing more anxiety and the services of entire gangs was
utilised for gauging the wooden sleepers and squaring CST 9 sleepers.

After introduction of steel rolled sleepers with 7 holes to fix the check rails the problems of
additional maintenance to check rails is solved but the fastening used for fixing the running
rail could not prevent creeping of rails. ‘T’ headed bolts to drawing no. T 1074/1 (130 mm
long) getting bent towards running rail at an angle of 30 degree and above and resulting in the
other fastenings are getting loose and allowing the creep. Due to this reason extra men are
deputed to attend the fastenings.

After introducing the PSC sleepers designed to fix check rails ‘T’ headed bolts are fixed to
check rails at an intervals of 60 cm to 65 cm with the running rails. due to many holes in
check rails at close intervals and rigidity in fastening the check rails itself are getting broken.

During monsoon and post mansoon periods heavy slips are taking place with boulders and
mud and the traffic was blocked for continuously for a period of 15 to 20 days. During the
period all the sectional gangs are deputed for clearing the slips etc. This was causing loss of
man days for maintenance works. Even now this problem is there to some extent even after
protection works in the section.

Gauge spreading : On PSC sleepers it will result in ERC’s gradually loosing toe load and
liners getting worked out. On steel sleepers the holes are getting elongated and clip bolts are
getting sheared. As a remedial measure the steel clips are inter changed to hold the gauge,
and clip bolts are regularly greased or replaced.

Wear on rails: Due to lateral forces the gauge face of the outer rail is getting premature
worn-out. Remedial actions are taken by greasing the gauge face of the outer rails by greasing
by P & M lubricators and by hand greasing by deputing additional men everyday. When
wear reaches beyond the tolerances and outer rails are interchanged and the rails are renewed
when both the gauge faces are wornout.

Inner rails getting flattened and wheels are gazing on the face of the check rails and resulting
in bolts are getting slant or loose. Additional men are deputed to tighten the bolts or replace
the broken, allan bolts frequently.

Creep: Creep is causing numerous problems due to constant falling gradient for the heavy
loaded traffic. Creep anchors are provided to arrest the creep and to take timely action.

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Due to running of ‘N’ BOX loaded traffic the track structure is getting frequently disturbed
and additional attention is given paid to maintain the track to the safe standards by deputing
additional men power.

(I) Constant falling gradient of 1 in 60 for loaded traffic, as such creep is excessive and
requiring frequent attention.

(II) Due to lateral thrust track fittings are getting loose frequently. Additional men power
is utilised to rectify.

(III) Additional men power is utilised for hand greasing due to excessive wear.

Maintenance is done only on need base as per the defects noticed during foot plate
inspection/last vehicle inspection.

***
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 NOTES 

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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 & comments, please write to us :

Contact person : Director (Civil)

Postal Address : Centre for Advanced

Maintenance Technology,
Maharajpur, Gwalior (M.P.)
Pin code – 474 020

Phone : (0751) - 2470869, 2470803

Fax : (0751) - 2470841

Unified Inspection and Maintenance of Ghat Section September - 2003