IMPROVED

SEJ(LAYING,
MAINTENANCE &
INSPECTION.)
BY:- Harpal Singh (SSE/PWAY/RPJ)

INTRODUCTION
On Indian Railways IRS design switch expansion joints were laid on both
ends of LWR in lieu of Buffer rails. These SEJs are failing frequently as there
were many cases of fracture of Stock rail/Tongue rail which is affecting
Safety of running trains

DRAW BACK OF
CONVENTIONAL SEJ
Stock rail fracture takes place at its reduction of section and due to involvement of bend.
Stock rail give up at about 20 40 mm away from the point of section reduction (throat) and 700

mm from its tail end which is left unsecured against longitudinal movement. The broken piece
keeps moving away by hammering of playing wheels and discontinuity with wider gap in track
especially in winter.
Hammering and breakage of bearing plates.
Chipping on throat of Stock rail & Tongue rail.
Level difference at throat of Tongue rail & Stock rail.
Spacing of sleepers at mid of SEJ 700 mm.
In case of fracture it is very difficult to carry out emergency repair.
Not suitable to for laying on curves sharper than 0.5 deg.
Rivets of MS flat which was provided to Stock rail are loosened and unusual sound heard while

running of trains.

CONVENTIONAL SEJ

REQUIREMENTS OF IDEAL
SEJ
To avoid bends in design of the Stock rail and Tongue rail.
To avoid any fractures in the bent portion of Stock rail & Tongue rail.
Suitable to lay on curves sharper than 0.5 deg. and up to 4.0 deg.
Suitability to higher axle loads.
Suitability for higher speeds.
In case of fracture part of Stock rail piece shall not move from its original

position due to longitudinal forces.

TYPES OF IMPROVED SEJ

SEJ with one gap
Developed by M/s Rahee Industries
Ltd, Calcutta.

SEJ with two gaps

Developed
by
M/s
Bina
Metalway,
Jamshedpur. & M/s Chintuparni Engg.
Works, Barabanki.

ADVANTAGES OF
IMPROVED
SEJ
Advantages of SEJ with one

Advantages of Two gap SEJ

gap :

The maximum gap is 57 mm which lead to lesser impact under

No bends in tongue and stock

It gives the field staff better control in providing correct nominal

rail.
Only 5 sleepers of standard

SEJ on PSC assembly are used.

Check rails guard against

excessive play of worn out

wheels.
Design suitable up to 200mm

max. gap.

passing wheels as compared to gap of 74 mm in IRS type.

gap at the time of installation/ replacement of SEJ.
The minimum head width of tongue rail is more than 61% of full

rail head width (44.75mm) as against 35% of head width

(25.5mm) in conventional type.
The wear prone areas of heads of stock and tongue rails are

pearlitised through a special process to achieve a hardness of 320

BHN
Maximum head thickness of stock rail is 89.5 mm as compared to

72 mm in IRS type of SEJ which in turn increases wheel support.

Status of stock rail is static as compared to moving type in IRS

type of SEJ.
It is suitable to be laid in curves in steps of

1,1.5,2,2.5,3,3.5,4 by supplying pre curved stock rails.

The tongue rail being slender can be curved at site by the field

staff.

COMPARISON BEETWEEN NORMAL SEJ

AND MODIFIED SEJ
S.No

Features

Normal SEJ

Modified SEJ

Merits

Bend in rails

1 in 8

No bend

No breakage

Sleeper spacing at
increases stability

Mid of SEJ

700 mm

600 mm

Designed for

80 mm/120 mm

180 mm

Less wheel Impact in large gap

Head thickness of
Tongue rail

25.5 mm

42 mm

Increase life

Head thickness of
Stock rail

72 mm

86 mm

More wheel support

Status of Stock rail

Unsecured

Secured

Safety ensured

Suitability to lay on curves

Limited up to 0.5
deg.

Can be laid up to 4.0

deg.

Scope for use

Provision of 1 in 20 can`t in
SEJ sleeper

Not provided

Provided

Built up twist avoided

Failure rate

Very high

For last five years no

failure is reported

Decreases maintenance cost

INSTALLATION OF MODIFIED
SEJ
Preparatory works.
Installation works.
Reference marks and gap measurements.
Routine maintenance of Modified SEJ.
Special maintenance.
Unusual occurrences.
Inspection and records.

PREPARATORY WORKS
Details plan of LWR track showing exact location of SEJ to be decided.
Distance between the ends of adjoining LWR between in which Modified SEJ

to be laid shall be equal to length of Modified SEJ-2x13 m.

Material required as follows : Material required for one set of Modified SEJ as per drawing.
Sufficient number of 6.5 m long ultrasonically tested closure rails of same section.
Rail cutting equipment.
Sufficient number of 1 m fishplates with suitable clamps.
Equipment for protection work.
Sufficient manpower with tools.

INSTALLATION WORKS
Impose SR of 30 KMPH on the particular KM where SEJ to be inserted.
SEJ shall be pre-assembled as per drawing on PSC sleepers and kept ready beside of

proposed location with suitable arrangement to shift on to track.

Minimum 1 hr. block to be obtained and both ends of rail shall be cut as per marking.
The existing PSC sleepers and rails to be removed.
Ballast shall be leveled.
Pre-assembled SEJ to be inserted in track & joined with suitable fish plate & clamps.
Ballast shall be recouped and track shall be attended to correct line and level.
Welding of both ends to be done as per availability of block.
SEJ gap to be adjusted as per LWR manual during distressing temperature.

REFERENCE MARK AND

MEASUREMENT
Pillars shall be erected at Centre of SEJ and reference marks shall be

marked on these pillars on either side of track during distressing.

SEJ gap to be provided 40 mm.
Marking on pillars be shall be in form of saw marks.
A string shall be stretched across track over the saw marks of reference for

measuring SEJ gap with respect to tip of Tongue rail/Edge of Stock rail.

ROUTINE MAINTENANCE & SPECIAL

MAINTENANCE
All fastening shall be complete and well secured.
Fastening shall be renewed on not more than one rail seal at a time.
Once in fortnight the SEJ shall be checked, packed and aligned if necessary.
Oiling and Greasing of Tongue rail & Stock rail shall be carried out once in

fortnight.
During daily patrolling, the Key man shall keep special watch on the SEJ.
SEJ gap to be adjusted during distressing which shall be carried out as per

provisions laid in LWR manual.

UNUSUAL OCCURRENCES
If another SEJ is not available for replacement, both damaged SEJ rail and

undamaged SEJ rail on opposite side shall be replaced by closure rail and
connected to LWR/SWR with suitable clamps and fishplates.
New SEJ to be installed.

INSPECTION & RECORDS

Inspection shall be carried out on every fortnight during the two coldest

and hottest months of the year during minimum and maximum

temperatures at supervisory level and senior level.
Alternatively once in two months during other months at supervisory level.
Recording of inspection notes as per preformat given in LWR manual.
Compliance of observations of deficiencies is also entered in the inspection

register.

THANK YOU