04 - Part A - Track

Specifications RVNL
4 – SPECIFICATIONS FOR PERMANENT WAY WORKS
1. SCOPE OF WORK
1.1 SCOPE:
1.1.1 This specification deals with the requirements for the manufacture,
supply, assembly, installation, testing and commissioning of Permanent
Way Works.
1.1.2 The successful tenderer shall be required to interface closely with the
Employer, Engineer, other contractors and other officials of Indian
Railways.
1.1.3 Permanent Way works involved for the proposed double line can briefly
be described as under:
Laying and Linking of new track between the Stations mentioned

in the Bid Documents including Remodelling of Station Yards, Laying of
Loops and other Safety requirements like Sand Humps, alterations to the
existing manned and unmanned level crossings to suit to the provisions
of proposed new track.
1.1.4 Nature of works:
The Permanent Way works to be executed can broadly be grouped as

under:
(a) Setting out the line and level of track for the proposed line
and establishing working, bench marks and alignment
references, taking the details from bench marks and
alignment references established by the Employer / by the
same or other Contractor earlier in main lines, and in
station yards including for loops, turnouts, cross over roads,
derailing switches, sand humps etc.
(b) Supply of ballast along the track in mid section and in yards
and running out this ballast to the top of formation and
compacting of ballast with mechanical means.
(c) Supply of 1 in 12 & 1 in 8 ½ Turnouts with CMS crossings

including lead rails, derailing switches, Switch Expansion
Joints, Glued joints etc.
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(d) Supply of rails for item (d) above, and all rail & sleeper
fastenings required for the above works and for installation
of track in main lines and yards.
(e) All transportation, handling, stacking materials, watching,

protection of the above listed material from the
manufacturer‟s works to the sites of use, including rails.
(f) Assembling and laying of new track, turnouts, switch

expansion joints, glued joints, derailing switches etc., on
newly made up formation with/without traffic blocks.
(g) Dismantling / Replacing existing turnouts where necessary

with plain track on running lines at stations under block.
(h) Insertion of new turnouts on main line and running lines

where necessary under block.
(i) Slewing and lifting / lowering of track as required with /

without blocks.
(j) Packing of PSC sleepers including lifting and lining of track,

turnouts, etc., as required.
(k) Welding of rail joints by Flash Butt/ SKV process for

Conversion of free rails to LWR/CWR/SWR /10-Rail panels.
(l) De-stressing of LWRs/CWRs, gap adjustments for SWRs

and Free Rails.
(m) Fabrication of check rails for Level Crossings, shifting of

gate leaves, W & W/L boards etc.
(n) Installation of P.Way components for all level crossings

including shifting of existing gates posts, fencing etc for the
new line.
(o) Installation of P.Way components for shifting of level

crossings in yards for both the lines including provision of
gate posts, fencing etc.,
(p) Laying of guard rails on bridges including at bridge

approaches.
(q) Erection of all type of Boards / Indicators
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(r) All other miscellaneous works.
(s) Making and supply of „As Built‟ drawings for the new assets
created.
Note: (1) The above are not an exhaustive list comprising of all
works to be done under this contract. Major works only
have been listed for guidance.
(2) The finished earth work in formation either in bank or cutting

with / without blanket shall not be used for transport of
materials, specially heavy materials like ballast and P.Way
components. Right from the beginning, this particular
stipulation should be kept in view, while planning
transportation & handling of Ballast, P.Way components
and track linking.
2.0 Standards:
2.1 Permanent Way components and assemblies should comply with the
requirements and Standards given in the latest Drawings and
Specifications of RDSO. It shall be the responsibility of the contractor to
adopt the latest version of the technical specifications with all correction
slips issued by RDSO / LKO from time to time.
2.1.1 ABBREVIATIONS
Trackwork Abbreviations
CWR Continuously Welded Rail
EVA Ethyl Vinyl Acetate
FC Flange way Clearance
HDPE High Density Polyethylene
HH Head Hardened
GIRJ Glued Insulated Rail Joint
LWR Long Welded Rail
SEJ Switch Expansion Joint
P&C Point & Crossing
Standards Abbreviations
UIC International Union of Railways
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Other Abbreviations
HTS High Tensile Strength
RDSO Research Design and Standards
Organisation
ETU Electric traction unit
2.1.2 Standard Specifications - Codes
1. International Union of Railways Standard Codes (UIC)

UIC Code 860 - 0 Technical Specification for the supply of Rails
UIC Code 861-3 Standard 60 kg/m Rail Profiles
Types : UIC 60 and 60 E
UIC Code 864 – 2 Technical Specifications for Supply of Steel

Track Bolts
UIC Code 864 – 3 Technical Specifications for the supply of
spring steel washers for use in Permanent
Way.
UIC Code 864 – 4 Technical Specification for supply of Fishplates
or sections for Fishplates made of rolled steel
UIC Code 864 – 5 Technical Specification for the Supply of Rail
Seat Pads
UIC Code 864 – 8 Rolled Profiles for Fishplates 60 kg/m Rails
UIC Code 866 - 0 Technical Specification for the supply of cast
manganese steel crossings for switch and
crossing works.
2. International Organisation for Standardisation (ISO)
1. ISO 1113 Information Processing – Representation of
the 7 bit coded character set on punched tape
2. ISO 1191 Plastics – Polyethylenes and Polypropylenes
in dilute solution – Determinaion of viscosity
number and of limited viscosity number
3. Indian Standards (IS)
IS 456 ( 2000) Code of Practice for Plain and Reinforced
Concrete
IS 800 (1984) Code of Practice for General Construction in
Steel
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4. European Standards (EN)
EN 1561 Founding – Grey Cast Iron
EN 1562 Founding – Malleable Cast Irons
EN 1563 Founding – Spheroidal Graphite Cast Irons
5. German Standard (DIN)
DIN 53455 Testing of Plastics – Tensile Test
DIN 53479 Testing of Plastics and Elastomers –
Determination of Density
DIN 53508 Testing of rubber - Accelerated ageing
6. International Electrotechnical Commission (IEC)

IEC 60093 Method of testing for volume resistivity and
surface resistivity of solid electrical insulating
materials (Formerly DIN 53482)
7. Indian Railway Standards
IRS T–1 Fish Plate.
IRS T-10 Switches, crossings and SEJs

IRS T–12 Rails.
IRS T–19 Fusion welding of rails by Alumino-thermic

process.
IRS T–23 Fish bolts and nuts.
IRS T–28 High Tensile steel fish bolts and nuts.
IRS T–29 CMS crossings.

IRS T–31 ERC Clips
IRS T–37 GR sole plate
IRS T–39 PSC sleepers for plain track.
IRS T–44 GFN – 66 liners

IRS T -45 PSC sleepers for turnouts
IRS T – 46 SGCI inserts
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Standard Specifications – Manuals
Indian Railways Engineering Code.

Indian Railways Schedule of Dimension BG 2004
Indian Railways Permanent Way Manual (IRPWM).
Indian Railways Track Manuals.
Indian Railways Bridge Manual
Indian Railways Manual for Flash Butt Welding of Rails.
Indian Railways Manual for Alumino- thermic welding by SKV process.
Indian Railways Manual for Ultra Sonic Testing of Rails and Welds.
Indian Railways Manual for LWR.
Indian Railways Track Machine Manual.
Indian Railways Manual for fabrication, installation and maintenance of
Glued Insulated Rail Joints.
Indian Railways Manual CE-1000 – guidelines on handling of rails – July
2000- issued by RDSO.
Indian Railways General and South Central Railway‟s Subsidiary Rules.
2.2.1 The works shall be carried out as per the Standard Specifications laid
down for each item read with provisions made in the above manuals and
Codes.
2.2.2 The relevant technical specifications and manuals etc. of Indian Railways
have been mentioned in clause 2.1 above. However, it shall be the
responsibility of the contractor to adopt the latest revision of relevant
technical specification/manuals with all correction slips and alterations.
The contractor shall be responsible for collecting the relevant technical
specifications from Indian Railways at his own cost and shall submit them
to the Engineer for his approval before starting of work.
2.2.3 The relevant RDSO‟s Specifications and Drawings for each of the
Permanent Way Component and Assembly shall be followed for the
Permanent Way works. It shall be the responsibility of the contractor to
adopt latest RDSO Drawings and Specifications with all correction slips
and alterations. The contractor shall be responsible for collecting the
relevant Specification and drawings for each of the Permanent Way
component and assembly from RDSO at his own cost and submit them to
the Engineer for his approval before starting of work.
2.2.4 For the supply of goods or material or performing any work or test, when
reference is made in the contract to a specific standard(s),
specification(s) or code(s), the provisions of the latest current edition or
revision of the relevant standard(s), specification(s) and code(s) in effect
shall apply, unless otherwise expressly stated in the Contract. Where
such standard(s), specification(s) or the code(s) are notional, or relate to
a particular country or region, other authoritative standards which ensure
an equal or higher quality than the standards and codes specified will be
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accepted subject to the Engineer‟s prior review and written approval.
Differences between the standards specified and the proposed
alternative standards must be fully described in writing by the contractor
and submitted to the Engineer at least 28 days prior to the date when the
contractor desires the Engineer‟s approval. In the event the Engineer
determines that such proposed deviation does not ensure equal or higher
quality or does not serve the requirements, the contractor shall comply
with the standards specified in the documents.
2.3 GENERAL CRITERIA AND TRACK PARAMETERS
2.3.1 All connected works of supply, installation, testing and commissioning of

Permanent Way works for the proposed line should confirm to the
General Specifications for a sanctioned speed of 160 kmph for Group „A‟
route, 130 kmph for Group „B‟ route and Upto 100 kmph for other Routes
on Indian Railways.
2.3.2 General Criteria:
The installation of Permanent Way work shall comply with the provisions
of Indian Railway Schedule of Dimensions for Broad Gauge 2004, Indian
Railways Permanent Way Manual, other Manuals, RDSO‟s
Specifications and Drawings and the Broad Gauge Track Parameters.
Some of the salient features are listed below:-
Particulars Details
1 Gauge 1676 mm (B.G)
2. Standard of loading Modified B.G -1987
3. (A) Rail profile- Main Line 60 Kg 1st quality, 880 UTS rails
or 52 Kg. 1st quality 880 UTS
rails depending upon the route.
(B) Loop Lines and sidings.

52 Kg 1st or 2nd quality, 880
(C)Guard Rail on Bridges.
or 710 UTS rails.,
(D)Check Rail on Level
Crossings
Note :1 Released 52 kg. rails if
available, will be issued for
being used as Guard rails on
Bridges and Check Rails at
Level Crossings.
2. Rails required for track in
main line, loops in station yards
and sidings will be given by the
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Employer free of cost.
3. Rails required for
manufacture of turnouts
including lead rails, SEJs,
derailing switches, glued rail
joints shall be procured by the
Contractor at his cost.
4. Type of sleeper Mono block 60 kg. PSC sleepers
for track.
On ballasted decks of bridges
and bridge approaches, Mono
Block 60 kg. PSC sleepers with
arrangements for fixing guard
rails.
At level crossings Mono Block
60 kg. PSC sleepers with
arrangements for fixing Check
Rails.
.
5. Sleeper density Main line – As per Para No.244
(3) (a) of IRPWM
Loop line – 1310 nos./km
6. Ballast cushion Main line – 300 mm
Loop line – 250 mm
7. Rail lengths and rail end fittings. Free 13 m / 26 m long rails for
Fish plated track.
SWR of 3 x 13 m rail panels with
fish plates at ends.
LWR 1 km. long panel with
switch expansion joints at ends.
CWR 3 km. long panel with
switch expansion joints at ends.
8. Maximum cant 165 mm
9. Maximum cant deficiency Generally 75 mm
For nominated stock 100 mm
10 Maximum cant excess Generally 75 mm
For nominated stock 100 mm
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11 Maximum cant gradient Generally 1 in 720 or flatter.

1 in 360 in very exceptional
circumstances only.
12 Rate of change of cant/cant 35 mm / sec
deficiency
13 Turnouts in yards: Where passenger trains ply both
on main lines and loops : 1 in 12
Turnout with curved switches
and CMS crossings laid on PSC
sleepers on fan shaped layout.
Loops and sidings where
passenger trains do not ply :1 in
8.5 turnout with curved switches
and CMS crossings laid on PSC
sleepers on fan shaped layout.
Note: 1 in 8 ½ symmetrical split
type turnout may also be used
on loops where passenger trains
ply.
Derailing switch 60 / 52 kg on 60
kg. PSC sleepers.
14 Track Laying Standards
(a) Gauge – Sleeper to Sleeper + 2 mm
variation
(b) Expansion gap average gap + 2 mm
worked out by recording 20
successive gaps.
(c) Joints :
Low joints not permitted.
High Joints not more than + 2 mm
Squareness of joints on straight. +/- 10 mm
(b) Spacing of sleepers
With respect to theoretical +/- 20 mm
spacing not differing by more
than
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(e) Cross Level

To be recorded on every 4th +/- 3 mm
sleeper not more than.
Twist not more than 1.5 mm / m
(f) Alignment
Variation in alignment, on +/- 2 mm
straights on 10 m chord not more
than.
Variation over theoretical
versines on 20 m chord, not
more than
On curves of radius more than 5 mm
600 m
On curves of radius less than
600 M. 10 mm
(g) Longitudinal Level :

Variation in longitudinal level with 50 mm
reference to approved
longitudinal section prepared
before the start of the work not
more than
2.4 INTERFACES:
Interfaces are required to ensure that work is done in a sound manner
without affecting or being affected by requirements of other consultants /
contractors and railway operations.
2.4.1 Commissioning of this line requires close coordination among various JV

partners / sub-contractors executing the works in this section, Engineer,
Employer and the Railway authorities. The contractor shall therefore plan
all his works requiring interfacing, like works in station yards etc.,
meticulously, in consultation and coordination with all concerned parties,
in advance, for expeditious execution, without causing any delay either to
his works or those of others.
2.4.2 The contractor shall strictly adhere to the work plan made for works
requiring interfacing. Any delay either on his part or on the part of other
agencies and other bottlenecks that could affect the pace of works shall
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be informed to the Engineer in time so as to enable him to take corrective
steps.
2.4.3 If, in the opinion of Engineer, the delay in execution of works requiring
interfacing is on account of failures of the contractor, and the contractor is
not taking adequate steps to the satisfaction of Engineer for smooth
execution of such works, then the Engineer shall have the right to take
necessary steps to organize and streamline such works, including
excluding the requisite portion of work from the scope of the contractor
and getting the same executed by other agencies, at the risk and cost of
the contractor, in the over all interest of completion of project.
3. INSTALLATION AND CONSTRUCTION SCHEDULE
3.1 REQUIREMENTS:
3.1.1 General Requirements:
1. The Contractor shall comply with all Enactments in executing the

works, including but not limited to all statutory provisions on
occupational health and safety.
2. The Contractor shall co-ordinate with other designated Contractors in
the execution of the Works.
3. The Contractor shall also co-operate with all relevant authorities in the
execution of the works and comply with the instructions issued by
them.
4. The installation of all machinery and equipment shall be undertaken at
all times by suitably trained and competent employees of the
contractor, to the satisfaction of the Engineer.
5. Only appropriate tools, plants, machinery and equipment and vehicles
shall be used for execution of works.
6. The works of consolidation of ballast before laying of track, installation
of track, aligning and packing of track, regulation of ballast profile,
installation of turnouts, aligning and packing of turnouts shall be done
using suitable mechanical means. Approval of the Engineer should be
taken for the type of machinery and the methodology proposed to be
deployed / adopted for these works.
7. The contractor shall, prior to starting any installation and construction
work, identify any possible hazards, and implement measures for
eliminating and / or controlling such potential hazards, in line with safe
working practices.
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8. The Contractor shall ensure that all areas of work are sufficiently
illuminated for the works to be undertaken and that a safe system of
work is employed for all activities.
9. The contractor shall operate a suitable system for the control of
persons entering or working on the site. The system shall include as a
minimum -
 Register of all employees
 Register of all visitors
In addition to the above, the Contractor should also maintain a

register of all his employees containing the following information :
 Personal identification with photograph and signature / thumb
impression
 Levels of competence
 Date of joining
 Date of discharge
10. The Contractor shall co-operate, at all times, with the Engineer and
other designated Contractors to ensure that the site is protected from
unauthorised admission, either wilfully or otherwise.
11. The Contractor shall make due provisions for safe access to and
egress from the site of works for his staff and sub contractors. This
access shall be maintained such that it is free of all hazards and is in
a safe condition throughout the duration of the works.
12. As the work of installation of track as plain track or in yards, where
other connected works like installation of loops, turnouts etc. are to
be done in the extreme vicinity of running rail system involving safety
of trains and passengers, contractor should adhere to all the safety
related instructions issued to him directly or through the Engineer /
Employer or South Central Railway Personnel from time to time.
Contractor should take immediate action in implementing these
instructions. No extra payment will be made for such works
undertaken by the Contractor.
3.1.2 Specific Requirements:
The installation and construction work pertaining to this contract shall
include, but not be limited to the following. All these works shall be done
by the contractor and got approved from the Engineer.
 Survey on site and review of the technical requirements shown in this
specification and the Employer‟s drawings.
 Finalisation of the assembly, installation and construction programme.
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 Production of the calculation sheets and installation drawings for site
installation.
 Procurement, handling, storage of materials, Permanent Way
components and assemblies and there further transport to the sites as
required including all handling.
 Installation in accordance with the finalised installation drawings.
 Co-ordination with other designated contractors.
 Submission of the installation reports and records.
 Testing and commissioning as per finalised protocol and programme.
 Production of as built drawings, documents, calculation sheets, and
records.
3.1.3 Construction and Installation Plan:

3.1.3.1 The contractor shall undertake installation work in stages as per the
detailed installation programme. Installation, testing and
commissioning of later stages shall have no impact on revenue
operations of earlier stages.
3.1.3.2 As a minimum, the detailed construction and installation plan shall
include but not be limited to, installation details and methods of all
activities, equipment and tools to be used for installation, safety
issues, supervision, temporary land occupation needed and the
vehicles to be used for transportation of material and installation.
3.1.4 Temporary Works:

3.1.4.1 The design and drawings of Temporary works proposed to be used
shall be submitted by the Contractor to the Engineer for approval and
got approved.
3.1.4.2 All temporary works shall be removed on completion of permanent
works, or as directed by the Engineer.
3.1.4.3 Temporary works shall be clearly distinguishable from permanent
works.
3.1.5 Site Supervision and Safety Issues:
3.1.5.1 The contractor shall set up a site supervision system, which shall be
part of the overall safety assurance system and quality management
system.
3.1.5.2 Health and Safety requirements at site shall be properly complied with.
3.1.5.3 As the work of installation of track as plain track or in yards, where
other connected works like installation of loops, turnouts etc. are to be
done in the extreme vicinity of running rail system involving safety of
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trains and passengers, contractor should adhere to all the safety
related instructions issued to him directly or through the Engineer /
Employer, or South Central Railway Personnel from time to time.
Contractor should take immediate action in implementing these
instructions. No extra payment will be made for such works
undertaken by the Contractor.
3.1.6 Quality Management:
3.1.6.1 The Contractor shall adopt an appropriate quality management
system to ensure that the System performance requirements as
specified in this Particular Specification are achieved.
3.1.6.2 The Contractor shall provide sufficient number of suitably experienced
supervisors and skilled workers to ensure that the progress and
quality of the work, both on site and in the Contractor‟s workshops,
are maintained to the satisfaction of the Engineer.
3.1.6.3 Key Supervisors shall have a minimum of three years previous
experience in a supervisory capacity on similar projects.
3.1.6.4 The supervisors shall work on a full time basis during the entire
installation process.
3.1.6.5 The Engineer may undertake, at any time, checks on the proficiency
of the Contractor's staff, their licensing and all associated
documentation. Should any of the Contractor‟s staff be found
incompetent by the Engineer or unlicensed, they shall be removed
from the site till their competence has been established.
3.1.7 Workmanship:
3.1.7.1 The style and procedure of workmanship shall be appropriate and
consistent throughout the works.
3.1.7.2 Unless otherwise specified, the Engineer shall decide the final colours
for all paintwork and other finishes to be applied to any part of the
works, which shall confirm to the practice of Indian Railways.
3.2 PROGRAMME REQUIREMENTS

In addition to the requirements specified in the General Conditions of
contract and Specifications, the contractor shall program the works in
accordance with a pre-determined sequence to meet various key
dates and Access dates so as to meet the target dates. The program
shall be prepared by the contractor and finalized in consultation with
the Engineer. The same may be summarized as under:
3.2.1 Establish work site and get shared access to work jointly for the
relevant works. All the civil works may not be complete at the same
time and may be completed in stages to facilitate the track laying
operation.
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3.2.2. Partial completion of track work to provide shared access for the
works of other agencies. Completion of track work, which can be,
completed without non-interlocking of the station yards.
3.2.3 Completion of track works jointly with Signalling work and Facility
works for additions and alterations to station Yards with or without
non-interlocked working after CRS sanction in Phases.
3.2.4. Completion of Acceptance tests after completing necessary testing
and integrated testing in phases.
3.2.5. Commissioning of works after meeting all the requirements of
operation and maintenance. (In Phases)
3.2.6.1 Final commissioning of the system.
3.3 SITE FACILITIES FOR THE ENGINEER

3.3.1 General
The Contractor shall provide at appropriate locations, as decided by
the Engineer, for the use of the Engineer, office accommodation,
equipment, communication and drawing facilities throughout the
period the works are under progress and also for the defects liability
period, as the Engineer may require. The details of the
accommodation and other facilities are given in Part II (Employer‟s
Requirement) of Bidding Document.
3.3.2 Survey Equipment and Other Tools
The contractor should provide the survey equipment and other
accessories as per the instructions of Engineer as and when required.
He should also provide all necessary tools and help as required by the
Engineer for checking the works, whenever required.
4 MATERIAL AND WORKMANSHIP: GENERAL
4.1 INTRODUCTION
4.1.1 This Materials and Workmanship Specification for Track works shall be
read in conjunction with all the documents forming part of the Contract.
4.1.2 No permanent Works shall be carried out until all methods and
materials have been approved by the Engineer in charge.
4.1.3 Unless noted otherwise in the Contract, all components and materials
shall be handled, transported and stored, in accordance with the
manufacturer‟s recommendations with prior approval of Engineer.
4.1.4 The test results of each test to be carried out as per Employer‟s
requirement shall be recorded and submitted in a format approved by
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the Engineer and shall include graphical presentation of results as well
as numerical base data wherever required.
4.1.5 Drawings, records, reports, documents, proforma etc. shall be
submitted in both hard copy and electronic copy.
4.2 ABBREVIATIONS, STANDARDS, TESTING AND INSPECTIONS,

PACKAGING, SHIPPING AND STORAGE
4.2.1 Abbreviations, Standards, have already been dealt under Sub paras of
Para No 2.1 above.
4.2.2 TESTING AND INSPECTION
4.2.2.1All materials and components proposed to be supplied by the Contractor

under this contract shall be tested and inspected in accordance with the
procedures laid down in the Drawings, Specifications and Codes of
Practice before despatch to site, at the manufacturers works itself.
4.2.2.2 Subsequently, before use for installation, all the materials and
components shall be inspected by the Engineer.
4.3 PACKAGING, SHIPPING AND STORAGE
i) All materials, components or assemblies shall be packed and

shipped, to avoid damage to them during handling and transport.
ii) All materials shall be stored and protected in neat, well maintained
stacks, bundles or enclosed stores with clearly visible markings.
iii) Materials shall be so stored as to ensure no deterioration due to
water or any other reason.
iv) All material storage arrangements shall be with prior approval of
the Engineer
v) The materials and equipment having specific provisions of
packaging & storage shall be packed and stored in accordance
with their technical specifications in addition to that described
above.
vi) All materials, components and assemblies shall be offered for
Engineer‟s inspection at Contractor's storage depots before
installation. The material classified as damaged by Engineer shall
not be used for the work; they should be replaced within a
reasonable time.
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5.0 MATERIAL & WORKMANSHIP : MATERIALS AND COMPONENTS
5.1 RAILS
5.1.1 Rail Sections
Rail sections shall comply with Table below:-
Item Rail type Rail profile
Standard rails on main line, all UIC 60, IRS T-12-96, UIC 861-3
SEJs, glued insulated joints, all 880 Grade
turnouts and derailing switches on
main lines.
Standard rails on loop lines and 52Kg., IRS T-12-96, IRS 52Kg
sidings, all SEJs, glued insulated 72UTS/ 90UTS.
joints, all turnouts and derailing (1st or 2nd quality)
switches on loops and sidings.
Check rails at level crossings and 52Kg., IRS T-12-96, IRS 52Kg
guard rails on bridges and bridge 72UTS/ 90UTS.
approaches (1st or 2nd quality)
Note: Released 52 Kg
rails, if available, can
also be used.
5.1.2 Rail Manufacture
5.1.2.1 Rail sections as mentioned above shall be manufactured in

accordance with the following specifications:
(a) UIC Code 860 - 0

(b) IRS T-12-1996. The stipulations of IRS T-12-1996 shall
supersede the provisions of UIC Code 860-0
5.1.2.2 Rails will be supplied by the Employer only for laying in track in mid
sections and yards for main lines and loops, including for laying in
between turnouts in crossovers ( between heels of crossings), check
rails for Level crossings and guard rails for bridges. In case the
Contractor proposes to use PQRS method for installation of track,
free rails for a maximum length of 2KM only will be issued free of
cost. The contractor shall plan to use these service rails ultimately in
permanent works.
Rails will not be supplied for fabrication of turn outs including lead
rails, SEJs and glued insulated joints. The contractor should obtain
rails of appropriate specifications.
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5.1.2.3 For accountal of rails , recovery for shortages etc., refer to Part II
(Employer‟s Requirements) of Bidding Document.
5.1 TRACK COMPONENTS
5.1.1 Rail Fastening System for Ballasted Track

1) All ballasted plain line track laid on PSC sleepers shall be equipped
with the following fastening components.
a) ERC MKIII clips as per RDSO drawing no.T-3701
b) 6 mm thick grooved rubber sole plate as per RDSO drawing
no.T-3711
c) GFN liners as per RDSO drawing no.T-3706 Alt V/T-3707/3708.
d) Metal liners as per RDSO drawing No-T-3740/T-3741 / T-3742 E
e) Combination Liners as per RDSO drawing No. T-3707, T-3708.
ERC MK III, GFN liner, GR sole plate & SGCI inserts shall be
manufactured in accordance with the relevant technical specification
of Indian Railway mentioned clause 2.1.2 (7)
5.2.2 Standard Fishplates and Fish bolts
Standard fishplates and fish bolts shall be of four bolt type, suitable for
use with UIC60 / 52 Kg rail section, and shall be manufactured in
accordance with the relevant technical specifications of Indian Railways
as mentioned in clause 2.1.2 (7)
5.2.3 Glued Insulated Rail Joints

The Glued Insulated Rail Joints (GIRJ) shall be manufactured in
accordance with the RDSO Drawing no. T - 5843 and relevant Technical
Specifications/manuals of Indian Railways as mentioned in clause 2.1.2
(7) for the Supply of Glued Insulated Rail Joints.
5.2.4 Ballast
The ballast shall be supplied by the Contractor in accordance with the
specifications as laid down by the Indian Railways. Specifications are
given as Annexure A to Section J – Specification to Permanent Way
Works.
5.2.5 PSC SLEEPERS
Reference to the drawing numbers of sleepers to be arranged by the

Contractor is given below for guidance.
All plain track sleepers and sleepers for special locations like SEJs, turn
outs, Level crossings etc., required shall be arranged by the Contractor.
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Specifications RVNL
1) Mono block PSC sleepers shall be used on plain track, ballasted

deck bridges and bridge approaches with the guard rails, level
crossings with check-rails, SEJs, Derailing switches and turnouts as
per the relevant drawings of Indian Railways mentioned below:
 PSC sleeper for plain track (60kg) - RDSO drawing no. T-2496.
 PSC sleeper for bridge with arrangement of guard rails (60 kg
rails) - RDSO drawing no. T-4089 to T-4097
 PSC sleeper for level crossing (60kg/52 Kg rail)- RDSO drawing
no.T-4148/T- 4148 A.
 PSC sleeper for SEJ/ (60kg rails) - RDSO drawing no. T- 4149.
 PSC Sleeper for derailing switch – RDSO drawing No T- 4512
(Layout drawing No: RT-5836)
 PSC sleeper for turnout 1 in 8.5 (60 kg rails) (Lay out drawing No:
RT-4865) - RDSO drawing no. T-4793 to T- 4844 and T-4512. (5
approach sleepers, 8 exit sleepers, 54 turnout sleepers)
 PSC sleeper for turnout 1 in 12 (60kg rail)(Lay out drawing No:

RT-4218) - RDSO drawing no. T- 4512 to T-4594. (5 approach
sleepers, 8 exit sleepers, 83 turnout sleepers)
2) The ERC MKIII fastening system of Indian Railway shall be used for
ballasted track on PSC sleepers. Sleepers shall be stacked/stored
duly separated by hardwood dunnage placed on each rail seat in
such a manner as to avoid damage to the sleeper or its fittings.
3) The Contractor shall ensure his proposed handling and
transportation methods do not cause any damage to the sleepers
and /or its fittings. The damaged sleepers as decided by Engineer
shall be rejected. .
5.2.6 ALUMINO-THERMIC WELDING PORTIONS

The welding portion and equipment required for the alumino-thermic
Rail welding process shall be manufactured and tested in accordance
with relevant Technical Specifications mentioned in Clause 2.1.2 (7).
Approval for the Thermit welding process, Supply of portions, Thermit
welding of Rails, performance and acceptance of welded joints have
been detailed in Technical Specification of Indian Railways mentioned
in Clause 2.1.2. (7).
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Specifications RVNL
5.2.7 SIGNAL AND TRACTION RETURN RAIL BONDS :
At locations shown on the Drawings, and/or specified, signalling and / or
traction return rail bonds are to be attached to the rail through holes,
brazing or any other suitable technique by designated contractors as
approved by Engineer.
6 MATERIAL AND WORKMANSHIP: MANUFACTURED ITEMS
6.1 INTRODUCTION
6.1.1 General
This para details the requirements for manufactured items for the
Works.
6.1.2 Approved Manufacturers
1) The Contractor shall submit to the Engineer for each item or
component to be manufactured, full details of the previous relevant
experience of the proposed manufacturer in the production of that
item, and also his previous experience of manufacturing similar
products for the Railway industry. The major items that require
particular and specific previous manufacturing expertise and
require prior approval of the Employer are as follows :
(a) Switches, Derailing Switches, Switch Expansion Joints and
Glued Insulated joints.
(b) Cast manganese steel crossings;
2) All the track materials shall be procured from RDSO approved

vendors, (included in the part I list of vendors approved by RDSO),
duly inspected by the authorised inspecting agency as specified by
Railway Board or RDSO and shall have prior approval of the
Engineer.
3) All cost and charges for inspection including shall be borne by the
contractor.
6.2 TURNOUTS AND CROSSOVERS.
6.2.1 General
1) The following types of turnouts shall be provided as indicated in the
relevant drawings:
a) 1 in 12
b) 1 in 8.5 or 1 : 8.5 symmetrical split
c) Derailing switches
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Specifications RVNL
2) All turnouts and derailing switches shall be provided on PSC sleepers.
3) The contractor shall adhere to standard layouts of Indian Railways. He
shall supply all fittings, fastenings, fixtures, various blocks, base
plates, check rails, switches, crossing, stretcher bars, etc. complete
based on basic geometry as provided in relevant drawings with
approval of Engineer.
4) The turnouts and derailing switches shall be manufactured as per the
approved layout drawings so that the provisions of base plate fixation,
other fixtures and their positioning are interfaced to ensure full
compatibility.
5) The contractor shall be responsible to make provisions on PSC
sleepers for fixation of point driving machines, double pull
arrangement and any other arrangement required for fixation of S&T
equipments.
6) Turnouts on main lines and other lines shall be suitable to take the
LWR through turnouts, if required.
7) At all turnouts, and derailing switches, on main lines and other lines
rails shall be fixed vertical (i.e. without cant). The transition between
approach tracks laid with 1 in 20 rail slope and the turnout laid with
vertical rails shall be suitably designed and achieved during
installation with prior approval of Engineer. Use of approach and exit
sleepers of RDSO design affords this facility automatically.
8) Machining/manufacturing tolerances of the turnouts, and derailing
switches shall be as shown on relevant drawings.
6.2.2 Turnouts & crossovers.
1) For turnouts, crossovers, and derailing switches, the contractor shall

use the basic geometry and manufacturing details of relevant
drawings of Indian Railways for fan shaped layouts developed by
RDSO for manufacturing & supply of all fittings and fastenings,
fixtures, various blocks, base plates, check rails, switches, crossings,
stretcher bars etc. complete. The modifications in fittings and fixing
arrangements for continuing LWR through the turnouts shall be
designed, specified and got approved from RDSO by the contractor.
2) For ballasted turnouts and derailing switches on main lines and other
lines, rail clips shall be ERC MKIII as for the plain track PSC sleeper.
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Specifications RVNL
6.2.3 Switches
6.2.3.1 General
1) All switches on main lines as well as on loop lines and sidings ,
shall be manufactured from ultrasonically tested 60 / 52 kg. rails to
IRS Specification T 12. The switch rail shall be in one piece with
no joint within the switch rail length.
2) All switches with slide chairs and other components shall confirm
to relevant RDSO drawing and IRS Specification as mentioned in
clause 2.1.2 (7).
3) Switches shall provide adequate flange way clearance between
the stock rail and the switch rail with the switch rail in the open
position at JOH.
6.2.3.2 Manual switches

1) The contractor shall be responsible for detailed design of operating
mechanism for hand operated switches, if any, including its
connections with the switches with prior approval of Engineer.
6.2.4 Crossings
6.2.4.1 General
1) The crossings for use in main lines shall be cast manganese
steel crossing.
2) The cast manganese steel - crossings shall be manufactured
from Austenitic Manganese steel as defined in UIC Code 866
and as per relevant technical specification of Indian Railways
for CMS x‟ings as mentioned in clause 2.1.2 (7) and as per
RDSO Drawings.
3) The wheel load transfer surfaces of all CMS crossings shall be
artificially hardened by explosive hardening to achieve
hardness of about 350 BHN before installation.
4) All crossings shall conform to RDSO Drawings and IRS
Specifications.
6.2.5 Check rails
1) Check rails in all turnouts & diamond crossings shall have facility for
adjustment of check rail clearances up to 10 mm over and above the
initial designed clearance. Each check rail end shall be flared by
machining.
2) Height of check rail above running rail & the lengths and positions of
the check rail shall provide safety and be compatible with the overall
track layout and Schedule of Standard Dimensions (BG) 2004.
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Specifications RVNL
6.3 SWITCH EXPANSION JOINTS.
1) Switch expansion joints shall be manufactured to suit the rail and
supporting structure movements indicated on the Drawings.
2) Switch expansion joints shall be as per relevant approved drawing
of Indian Railway.
3) SEJ on ballasted track shall be laid on PSC sleepers.
4) SEJ shall be supplied with all fittings, fastenings, fixtures, various
blocks, base plates etc. complete as per RDSO Drawing.
5) The fixation of switch expansion joints on PSC sleepers shall be
through base plates.
6) The switch expansion joints shall be manufactured strictly as per
the specified drawings so that the provisions of base plate fixation,
other fixtures and their positioning are interfaced so as to ensure
full compatibility.
6.4 BUFFER STOPS / DEAD ENDS.
Buffer Stops / Dead ends shall comprise of a structure made out of rails
fixed to the running rail by bolts and nuts etc. Rails required for buffer
stops will be issued by the Employer. Buffer beam and two buffer stops
shall be provided at buffer level to counter the impact of rolling stock.
Dead end shall be painted with two coats of black bitumastic paint, buffer
beam painted white and buffer stops painted red.
The design of the dead end shall be submitted by the contractor for
Engineer‟s approval. The contractor shall interface with the Engineer for
the details required for the design of stops.
6.5 Derailing Switches.

1. Derailing switches or trap points with slide chairs and other
components shall confirm to relevant RDSO drawings and IRS
specifications.
2. The switch rail shall be in one piece with no joints within the switch
rail length and shall house well when closed.
7 MATERIAL AND WORKMANSHIP: SURVEY AND SETTING OUT
7.1 The setting out of longitudinal and vertical alignment for track
construction and for laying curves, turnouts etc. shall be the
responsibility of the contractor; the following principles shall be
adopted for setting out and execution.
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Specifications RVNL
7.2 Functional Responsibilities
7.2.1 The planning, organisation and process of surveys for transferring the
alignment for track construction on finished road bed /bridges/stations
shall be the sole responsibility of the Contractor. He shall at all times
maintain common survey interface with others.
7.2.2 Survey and setting out of works shall be carried out by surveyors of
appropriate experience and qualification.
7.2.3 The Engineer may carry out checks to verify the accuracy of the
setting out and Contractor‟s compliance of the completed works with
given alignment and the specifications. Provisions and arrangement
shall be made by the Contractor to facilitate the checks. However, full
responsibility lies with the Contractor for the accuracy of line and level
of the tracks
7.3 Survey Controls in General and setting out
7.31 As a part of the Survey on site and review of the technical
requirements shown in this specification and the Employer‟s drawings
mentioned above, the following work shall be done by the Contractor
at his cost.
7.3.2 The details of alignment, curves, gradients, bridge locations, level

crossing locations, yard locations, bench marks etc., are indicated in
the design drawing sheets showing Plans and „L‟ sections and
conceptual yard plans forming part of the Tender. Approved yard
plans will be supplied to the successful tenderer at the time of start of
work.
7.3.3 The successful tenderer shall take action for verification of the details
of the established bench marks and alignment references,
establishment of working bench marks, working alignment references
etc., and getting them approved by the Engineer before
commencement of work.
7.3.4 The action to be taken by the successful tenderer for verification of

the details of the established bench marks and the alignment
references and establishment of working bench marks, working
alignment references etc., and getting the approved by the Engineer
for commencement of track works have been detailed in the earlier
sections.
7.3.5 Based on these reference markers, the entire work shall be carried
out by the Contractor.
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Specifications RVNL
7.3.6 The contractor should fix reference markers on both the cesses at
intervals of not more than 200 m on straight and 20 m on curves to
indicate the centre line of track. On these reference markers, marks
should also be made to indicate the levels of bottom of the sleeper
and the rail levels. The rail level so fixed should be the inner rail level
in the case of curves.
7.3.7 These reference markers which also indicate the bottom level of the
sleepers and the rail levels should be got checked and approved by
the Engineer.
7.3.8 The track setting marks for the centre of the track shall be shown by
plates or nails fixed to the bridge spans, on the upper surface of the
slab or as approved by the Engineer. The track setting marks for the
vertical setting of the track running surface shall be shown by angle
plates sealed onto the bridge side walls. They shall be referenced
with respect to the theoretical track level as approved by the
Engineer.
7.3.9 The part of the works detailed from Para 7.3.1 to 7.3.7 above should
be done before the start of any work related to installation of track.
7.3.10 It shall be the contractor‟s responsibility to protect and preserve all
the markers mentioned in the above Paras. In the event of any
damage to the alignment markers or to the bench marks, the
contractor shall replace the same and re-establish the points at his
own cost to the satisfaction of the Engineer.
7.4 SURVEY INSTRUMENTS
7.4.1 Survey instruments used and the methodology adopted shall be
appropriate to the intended measurement task and accuracy
specifications. Test measurements and instrument calibration shall be
carried under local field conditions.
7.4.2 It is essential that before starting any initial surveys, and at frequent
intervals all measuring equipment should be tested for their accuracy.
7.4.3 All instruments deployed in the Contract shall be in good condition
and properly calibrated. Calibration certificates and / or statements of
services by local authorised instrument agents of not more than
twelve months shall be the proof that the instruments are in good
service conditions.
7.4.4 Notwithstanding the above, instruments shall again be checked to
ensure good condition before the Contractor proceeds to carry out a
critical survey task. Any error causing superfluous work will have to be
rectified by the contractor at his own cost.
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Specifications RVNL
7.5 CONTROL OF TRACK WORKS
7.5.1 The Contractor shall ensure that critical dimensions laid down for the
project are met. Regular checking should be carried out during the
construction stages to ensure that the specified permissible deviations
are not exceeded.
7.5.2 The Contractor shall ensure that all survey and setting out points shall
be established on Site to required accuracy. He shall also be
responsible for each stage of the setting out work and for verifying
compliance before construction starts.
7.6 INSTALLATION OF PERMANENT SURVEY MONUMENTS
The contractor should propose a suitable survey monument and get it
approved from Engineer.
7.7 QUALITY PLAN
7.7.1 The Contractor shall submit to the Engineer, for acceptance a separate
quality plan related specifically to survey matters. The plan shall
address for following:
 Identification of the Contractor‟s key survey staff and the lines of
communication
 Scope of the surveying section including interface and designated
contractors
 List of proposed surveying equipment & computer hard/software;
 List of surveying procedures;
 List of detailed method statements for all critical surveying
activities;
 Survey test and inspection plan;
 Control of survey data and records;
8 MATERIAL AND WORKMANSHIP : INSTALLATION
8.1.1 INTRODUCTION
8.1.2 General
All installation of track shall generally confirm to Indian Railway

Permanent Way Manual, Indian Railway Schedule of Dimensions for
Broad Gauge , RDSO Drawings and other IRS Specifications, Codes
and manuals mentioned in clause 2.2.1 (7) except where stated
otherwise
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Specifications RVNL
8.1.2.1 The proposed method statements, installation procedures and
installation plans for the Works shall be submitted for the approval of
the Engineer in accordance with this Chapter. These submissions
shall be summarised and detailed in the Contractor‟s Submission
Schedule (CSS). The documents forming the submissions shall use a
standard format which shall be submitted by the Contractor for the
approval of the Engineer
8.1.2.2 Notwithstanding the nominal track to supporting structure dimensions
indicated on the Drawings, the as constructed dimensions may vary
subject to the allowable tolerances. In addition the supporting
structure may contain ramps, steps, channels, drains, anchor bolts,
manholes, upstands and the like. The methods of construction shall
accommodate these constraints.
8.1.2.3 All temporary/service tracks required for track work on main lines and
yard lines shall be arranged & laid by the contractor with prior
approval of the Engineer. The contractor shall remove these
temporary/service tracks after completing the track work as approved
by Engineer. The rails released from temporary/service track may be
used on yard lines, if the condition of rails is within specified
tolerances and approved by Engineer.
8.2 METHODS OF WORKING
8.2.1 Method statements
8.2.1.1 Method statements detailing the proposed methods of working and
incorporating all temporary works required shall be submitted to
Engineer for his approval. No Permanent Work shall commence until
the Engineer approves the method statements.
8.2.1.2 Method statements for track laying shall, as a minimum ,cover the
following items, where ever applicable:
(a) shipping
(b) handling & transport
(c) stacking
(d) pre-assembly/assembly
(e) delivery
(f) surveying
(g) setting out
(h) assembly
(i) ballasting
(j) track installation
(k) welding
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Specifications RVNL
(l) tamping
(m)lining & levelling
(n) stabilisation
(o) as-constructed records
(p) cleaning
(q) final fastening down
8.2.1.3 Method statements shall, as a minimum, incorporate hold points,
tolerances, finishes required, temporary works, test and inspection
plans, and shall include all the environmental, health, safety and
quality control requirements for each activity.
8.2.1.4 Method statements are also required as a minimum for the following
production or installation activities :
(a) Dismantling of existing track where required and stacking &
handing over of released materials.
(b) Slewing of existing track wherever required
(c) Dismantling of existing turnouts, derailing switches wherever
required and stacking & handing over of released materials.
(d) Dismantling of existing Signalling gear and stacking & handing
over of released materials.
(e) Each track form
(f) Turnouts, crossovers, and derailing switches
(g) Switch expansion Joints
(h) Glued insulated joints
(i) Fish plated insulated joints
(j) Level crossings
(k) Guard rail on bridges
(l) Rail welding
(m)Buffer Stops & dead ends
(n) Surveying
(o) Tests on Completion for the design speed.
8.2.1.5 Method Statements shall be prepared and submitted in a standard
format as described in Clause 8.2.1 with descriptions under the
following minimum headings :
(a) Safety
(b) Environment
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Specifications RVNL
(c) Plant, Equipment & Tools
(d) Construction Method
(e) Protection to existing running tracks , drainage facilities, cast-in
items, etc.
(f) Tolerances & finishes
(g) Hold Points
(h) Test and Inspection Plans
(i) Appendices
(j) Sketches
(k) Proforma / check sheets
(l) False works / Formwork
(m)Temporary Works
(n) Calculations
(o) Reference Drawings
(p) Reference Documents/Clauses
8..2.1.6 Method Statements shall be itemised and have Document/Clause

reference column as the right hand side margin.
8.2.1.7 Each method statement shall be referenced to the relevant clauses of
the documents forming the Contract.
8.2.1.8 Method statements which require the use of any specific/specialised
equipment or Constructional Plant shall clearly specify the equipment
or Constructional Plant and the operator‟s experience required.
8.3 TRACK INSTALLATION
8.3.1 General
8.3.1.1 The track gauge throughout except in sharp curves shall be 1673 mm
measured between gauge faces, 14 mm below rail top surfaces
perpendicular to the centre line of the track
8.3.1.2 In all main line & yard line track, (excluding turnouts, crossovers,
diamond crossings and derailing switches) rails shall be laid with -
1:20 inward rail slope.
8.3.1.3 The Contractor shall take due cognisance of his proposed rail jointing
system and the rail fastening assembly spacing in the selection of the
appropriate length of welded rail panels. Rails shorter than the
minimum length shall only be permitted in the following locations:
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Specifications RVNL
(a) To permit a welded rail joint to be located between two adjacent

fastenings to avoid supported joint.
(b) To permit the inside fish plated rail joint on curves to be radial to the
joint on the outside rail of the curve.
(c) Closure rails between plain track, prefabricated components and
turnouts.
(d) Approved manufactured items.
(e) Closure rails at track terminations.
The minimum closure rail length in plain line shall be 6 metres

except for specific locations and components as noted within this
Specification or as shown on the Drawings or as approved by the
Engineer.
8.3.1.4The contractor shall lay the bridge approach sleepers with appropriate
sleeper of the correct RDSO number and at specified spacings. If this
is not done, the flaring end of the guard rails cannot be fitted with
specified fittings. In such an eventuality , the Contractor should make
his own arrangements for either locating the correct sleepers and
replacing or drilling requisite holes in the laid sleepers and fixing the
specified dowels at his own cost. Nothing extra will be paid for this.
8.3.2 Rail Jointing

8.3.2.1 All rail joints throughout in the main lines including turnouts except at
Glued Insulated Rail Joints, shall be welded, except where fish plated
joints are necessitated.
8.3.2.2 The welding of free rails of standard lengths into short welded rail
panels and long welded / continuously welded rail panels for main
lines and yard shall be by adoption of Flash Butt Welding process.
Alumino Thermic Welding of rail joints shall only be used in
exceptional circumstances, where Flash Butt Welding process cannot
be adopted, that too with prior approval of the Engineer. Temporary
joints between rails shall be by fish plates & clamps without drilling of
holes in rails.
8.3.2.3 All the welded joints for welding less than 13 m rail length shall have
prior approval of the Engineer.
8.3.3 Locations of Welds
The distance between any two consecutive welds should be a
minimum of 6 m; for any deviation to this, specific approval of
Engineer shall be required in each case. .
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Specifications RVNL
8.3.4 Long Welded Rails
Long welded rail panels (LWR) shall generally be a minimum of about
130 m. Shorter panels shall only be permitted when dictated by site
conditions / site constraints and as approved by the Engineer.
8.3.5 Fish-plated Rail Joints
8.3.5.1 Standard and Insulated fish-plated joints wherever required in plain
track shall be square.
8.3.5.2 Standard and insulated fish-plated joints shall be installed centrally
between two adjacent fastenings and shall be manufactured and
installed to permit the use of standard rail fastening assemblies.
8.3.5.3 All fish-plated joints shall be fitted with the nuts on the inside of the
track.
8.3.6 Glued Insulated Rail Joints
8.3.6.1 All glued insulated rail joints shall be shop manufactured using
minimum 6 m long rails. Site fabricated glued insulated joints shall be
provided only with the prior approval of the Engineer,
8.3.6.2 Except in the case of glued insulated joints in the turnout zone, the
positioning of the glued insulated joint with respect to the approach
shall be such as to keep a minimum distance of 6.00 m from an
existing weld in the rail.
8.3.7 Switch Expansion Joints
8.3.7.1 Particular attention shall be given to ensure that rail expansion joints
are assembled and installed in accordance with the Drawings and
correctly located with relation to the type of SEJ and the direction of
traffic.
8.4.7.2 Immediately prior to completion of installation of track of a section, all
sliding surfaces of rail expansion joint shall be cleaned and greased.
8.3.8 Rail Temperature

Rail temperatures shall be measured using appropriate dial type
magnetic rail thermometers placed on the web of the rail on the
shaded side. The minimum number of thermometers required to be
used per rail for measuring average rail temperature of a segment of
track shall have the prior approval of Engineer. Temperature records
shall be kept and made use of appropriately for laying, welding and de-
stressing operations.
8.3.9 Cleaning of Track
The track form structure (including the rail surface) as installed shall be
thoroughly cleaned to an acceptable standard as approved by the
Engineer immediately after installation and as required thereafter to
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Specifications RVNL
maintain the standard until the arrangement of service trials so as to
provide adequate levels of electric insulation & rail surface quality for
correct performance of train control & signalling equipment under
prevailing climate & environmental conditions.
8.3.10 Rail Insulation
The track form as installed shall be thoroughly cleaned immediately
after installation and as required thereafter to maintain the standard
specified in Clause 10.1.7, until the issue of the Certificate of
Completion. This shall be necessary to provide adequate levels of
electrical insulation for the correct performance of the signalling and
traction equipment under the prevailing climatic and environmental
conditions.
8.3.11 Cutting of Rails
8.3.11.1 Rails shall only be cut by using rail cutting machines. The proposed
method and equipment for the cutting of rails shall have the prior
approval of the Engineer. Gas cutting of rails is strictly prohibited.
8.3.11.2 Rails required to be cut shall be cold sawn square and vertical across
the rail. A deviation from square or vertical of more than 0.50 mm,
measured about the rail head, shall not be permitted. All burrs shall be
removed from the rail ends.
8.3.12 Drilling of Rails
8.3.12.1 All fish bolt holes in rails, where ever required shall be drilled by using
proper jigs and drilling machines. The proposed method and
equipment for the drilling and cutting of rails shall have the prior
approval of Engineer.
8.3.12.2 Any holes required for signal and traction bonds shall be formed with
prior approval of the Engineer.
8.3.12.3 All holes in the rails shall be chamfered using chamfering kit &
procedure approved by the Engineer.
8.4 Ballasted track installation
8.4.1 General
8.4.1.1 The components of ballasted track shall be:
(a) Support structure
(b) Drainage
(c) Ballast
(d) Sleepers and fastenings.
(e) Rail and fastenings.
(f) Grooved Rubber Sole Plate
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Specifications RVNL
(g) GFN liner
(h) ERC MKIII
(i) SGCI inserts (cast in PSC sleeper)
8.4.1.1 The completed track shall have the following minimum ballast
cushion under the sleeper or bearer:
(a) Ballast cushion : (Measured from underside of sleeper to the
formation)
- Main lines (under lower rail) As per Para 263
(2) (a) of IRPWM.
- Loop lines and Sidings (under lower rail) 250 mm
(b) Ballast Shoulders profile shall be as shown in relevant drawings

in Indian Railway Permanent Way manual.
8.4.1.2 Sleepers shall be spaced in ballasted track at the following centres:
(a) Main line tracks straight /curve 600 mm
(min.1660 No. per Kilometre)
(b) Loop lines and Sidings . 650 mm.
The above spacing is for the track to be converted to
L.W.R/C.W.R. Wherever single rails or S.W.R has to be laid
sleeper spacing shall be provided as per standards laid down In
Indian Railways Permanent Way Manual and as approved by the
Engineer.
(c) Sleeper centres shall be measured along the track centre line
for straight track and along the high rail in curved track.
8.4.1.3 A “Request for Inspection” (RISC), complete with all necessary
information to allow assessment, shall be submitted to the Engineer
for the following activities and Approval must have been received prior
to commencing any follow-on activity:
(a) Acceptance of supporting structure,
(b) Acceptance of bottom ballast,
(c) Acceptance of the track and turnouts for the movement of
plant, machinery & equipment
(d) Acceptance of the track and turnouts for in situ welding,
(e) Acceptance of track for tamping
(f) Acceptance of track for de-stressing
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Specifications RVNL
8.4.2 Bottom Ballast
8.4.2.1 Bottom ballast shall be laid directly on the prepared support structure
(formation) using methods that avoid road traffic over the support
structure and also avoiding damage to the cable ducts/trenches
already provided for signalling and electrical cables on the sides of
embankment. The formation would have been properly dressed and
well compacted to true profile and levels before running ballast on to
the formation. The bottom ballast shall then be laid in layers of loose
ballast layers of maximum of 100 mm each, each layer being
compacted by a minimum of 4 passes of a smooth vibrating roller,
with a minimum static load of 4 kN per 100 mm of width or similar as
approved by Engineer.
8.4.2.2 The bottom ballast shall be laid to a maximum level of 200-mm (+0, -
20 mm) above the supporting structure. .
8.4.2.3 On completion of the bottom ballast a survey shall be undertaken to
demonstrate the acceptability of the bottom ballast for track laying.
The survey shall include graphical plotting of cross-sections and
computing quantities of ballast.
8.4.2.4 The bottom ballast survey shall be undertaken on a longitudinal grid of
30 metres along the line of the ends of the sleepers and at the
extremities of the specified profile.
8.4.2.5 On completion and acceptance of the bottom ballast for track laying,
no vehicle of any type shall be permitted to run over the bottom
ballast.
8.4.2.6 The use of vehicles on the completed bottom ballast will result in the
rejection of the bottom ballast in that particular length where the
vehicle has been used. In such a length all contaminated ballast
should be removed and replaced with new ballast. Re-grading and
rolling of such line should be done to the satisfaction of the Engineer.
No further track laying operation shall be done until the bottom ballast
has been re-inspected and approved by the Engineer.
8.4.3 Track laying over the ballast

8.4.3.1 General
The system of track laying over the laid and compacted ballast shall
be as proposed by Contractor and approved by Engineer. The
following stipulations shall also be followed by the Contractor.
 Flash butt welding shall not be undertaken until the track has
sufficient ballast to hold it to alignment both before and after
welding.
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Specifications RVNL
 The track laying system shall be such that no wheeled vehicles
shall travel directly over the bottom ballast during the track laying
operation.
 In case the top surface of the ballast gets disturbed, the same
shall be repaired/re-compacted to prescribed levels, to the
satisfaction of the Engineer.
 The sleepers shall then be laid out on the bottom ballast at the
specified spacings. The sleepers shall be correctly aligned and
squared.
 Alternatively, pre-assembled panels may be laid directly onto the
prepared bottom ballast for installation of track by utilisation of
PQRS or by any other method, which should have prior approval
of the Engineer.
 Sleeper shoulder then shall be adequately ballasted and
compacted to obtain enough lateral resistance of track.
 The rail panels shall then be laid on the sleepers and fastened to
the sleepers.
 After a suitable length of track has been laid, but before any
movement of rail mounted Construction Plant or equipment on that
track, the laid sleepers shall be levelled and tamped by
mechanical means, approved by the Engineer, to ensure the final
lines and levels of the resulting track are within acceptable
tolerances as approved by Engineer. However the contractor shall
be responsible for safety of track after Engineer‟s inspection &
approval and track components damaged due to running of rail
mounted construction plant and equipment or any other reason
shall be replaced by the contractor to the Engineer‟s satisfaction
 Track markers, bonding, etc shall not be installed until the track is
aligned to final line and level, and the final fastening down
operation has been completed.
8.4.3.2 Top ballasting, tamping & lining
(i) Prior to the placing of top ballast the track shall be marked in
preparation for tamping and lining operations with the
following information:
 All horizontal and vertical tangent points
 Transition curve details
 Circular curve details
 Cant details
 Vertical curve details
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Specifications RVNL
 Chainages
(ii) The tamping parameters such as the rate of tamping, number
of passes, number of insertions per sleeper, depth of
insertion, length of tamping and optimum frequency of
vibration for the tamping, squeezing pressure and tamping
cycle shall be submitted for the approval of Engineer.
(iii) Once the top ballast is adequately regulated the track shall be
lifted, levelled and aligned as required, using on-track
tamping / lining machine to be arranged by the Contractor.
The top ballasting, regulating, tamping and lining shall be
repeated in stages of a lift of upto 50 mm at a time, until the
track is at the designed horizontal and vertical alignment
(iv) Generally when the work of lining and tamping of track with
heavy on track tampers is done, the track becomes fit for
different speeds of operations, as mentioned below:
First round of packing .. 50 kmph
Second round of packing .. 75 kmph
Third round of packing .. 100 kmph
Attempt should be made to obtain this standard of track for
different rounds of packing. If such standards are not
achieved, additional rounds of packing at the cost of the
Contractor will become necessary.
(v) It will be preferable to use on-line tampers similar to Plassers
Duomatic 8-Series of machines, which have been specially
built for tamping at constructions sites.
(vi) Concurrent with the tamping and lining, the ballast shoulders
and the sleeper cribs shall be compacted with suitable
equipment as approved by the Engineer.
(vii) The completely tamped track with designed line and levels
and with designed ballast profile having compacted shoulder
and crib ballast shall be distressed after formation of
LWR/CWR.
8.4.4 Drainage
The contractor shall be responsible for installation of track drainage
system and its connection to main drainage system, if any, provided.
Details of the final connection to the main drainage shall be provided
by the Contractor with the prior approval of Engineer.
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Specifications RVNL
8.5 TURNOUTS, CROSSOVERS, DIAMOND CROSSINGS, DERAILING
SWITCHES AND RAIL EXPANSION JOINTS.
8.5.1 General-
 The moveable length of a switch rail shall be securely strapped to
the stock rail during all handling and transportation. In any case,
before installation of switch the prevailing camber due to pre-
curving should be checked. If the switch or stock rail has lost
camber, pre-curving should be redone by cold bending with jim-
crow to the satisfaction of the Engineer.
 Check rails shall be set and checked to the correct clearance by
using the running edge of the crossing as the datum.
 The assembly sequence of turnouts, diamond crossings, derailing
switches and rail expansion joints shall be submitted for
Engineer‟s Approval as part of the overall method statement for
pre-assembly, handling, storage, transportation, unloading and
installation.
 On completion of a turnout, the Contractor shall immediately
scotch the switches with a purpose made hardwood timber scotch
and securely clamp the switches as directed by the Engineer with
an appropriate clamp as approved by the Engineer. The clamp
shall be capable of being padlocked with the switch in the closed
position.
 No on-track Constructional Plant, equipment and machinery shall
be allowed to operate over a turnout until it has been inspected
and approved by the Engineer.
 The contractor at this time shall interface and ensure the designed
switch opening while fixing the first stretcher bar.
 All stretcher bars for switches shall be supplied and installed by
the Contractor and approved by the Engineer.
After thoroughly cleaning a completed turnout, all bolted
components (except Glued Insulated Rail Joints) shall be, cleaned
and an approved lubricant applied to the threads before the nuts are
re-torqued.
8.5.1.1 Pre-assembly of Turnouts, Crossovers, Derailing Switches and
Switch Expansion Joints
 All turnouts, crossovers, derailing switches and switch expansion
joints shall be pre-assembled for the inspection and approval of
the Engineer, prior to installation in the Works.
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Specifications RVNL
 The contractor shall provide all gauges and measuring equipment
and labour necessary to completely check the pre-assembled
turnouts, crossovers and switch expansion joints.
8.5.1.2 Installation
The turnouts, crossovers, derailing switches and switch expansion
joints shall be laid on bottom ballast prepared as described in clause
8.4.2 - Bottom Ballast. They shall be installed in accordance with the
approved method mentioned in the methods statement and
temporarily jointed.
The installation of turnouts on the prepared ballast bed and
further packing and lining of the turnouts should be done by
Mechanical means only. The required machines should be obtained
by the Contractor.
8.6 DESTRESSING OF CWR/ L.W.R

8.6.2.1 The destressing of rails shall not be undertaken until it has been
demonstrated to the Engineer‟s satisfaction that the track has been
completed to the specified standards and specifications and the
method of working for destressing of the relevant track form has been
approved by the Engineer.
8.6.2.2 The final welding of joints within turnouts shall be undertaken as per
sequence approved by Engineer and within the stress free
temperature range.
8.6.2.3 The long welded rails shall be laid on rollers placed on the metal base
plates or sleeper or rail table, with the rollers placed at a maximum
spacing of 6 m. Rollers shall have suitable diameter to avoid contact
between rail and intermediate sleepers.
8.6.2.4 After placing the long welded rail on rollers, it shall be stress relieved
by causing it to vibrate simultaneously over its whole length, either by
use of vibrators distributed along the whole rail length, and in
sufficient number, or by tapping the rail on each side of the head with
wooden mallets as approved by Engineer.
8.6.2.5 The switch expansion joint shall be carefully greased prior to fitting.
Destressing operations of LWR / CWR, should be done, following the
provisions of the latest LWR manual of Indian Railway
8.6.2.6 The rails for continuously welded track shall be destressed in
accordance with temperature conditions as per Indian Railway Manual
for L.W.R.
8.6.2.7 The stress free temperature for destressing of the long welded rail
shall be achieved either naturally or artificially by the use of hydraulic
rail tensors as approved by Engineer.
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Specifications RVNL
8.6.3 Buffer stops and dead Ends.

The installation details for buffers stops and dead ends shall be
submitted by contractor for Engineer‟s approval.
8.6.4 Snag Dead Ends / Sand humps .
 Sand humps shall be provided in conformity to relevant S.C.
Railway plans. Apart from the track structure and track
parameters, brick channels filled with clean sand shall be
provided.
 Sand humps shall be finished complete as per details and
specifications given on the plans.
 Symmetrical split provided for the sand hump up to the back of
crossing shall be treated as a part of the crossover and the portion
beyond back of crossing as the sand hump.
8.7 LEVEL CROSSINGS
8.7.1 Specifications and requirements of level crossings are contained in

Chapter IX of Indian Railways Permanent Way Manual. Provision of
Track on level crossings and other associated works shall be executed
in conforming to the same as applicable.
8.7.2 Track on level crossings shall be laid on PSC sleepers with provision
for check rails as per RDSO drawing no. T-4148 mentioned in clause
5.2.5 complete with check rails, MS brackets, distance blocks, flare of
check rails, all fittings and fixtures complete as shown on the plan.
8.7.3 Joints should be avoided in check rails and on the running rails within
the level crossings and a further 3 meters on either side. In the case of
SWR, the short welded panel may be continued through the level
crossing, avoiding fish plated joint on the level crossings and within 6
meters from the end of level crossing. The level crossing should not
fall within the breathing length of LWR as per the provisions contained
in LWR Manual.
8.7.4 Level crossings beyond the outermost stop signals of the station /
block hut shall be under the control of the Engineering Department of
Railways and shall be termed as Engineering Gates.
At all Gates which are unmanned, the contractor shall provide rail
posts in the new locations. At all manned gates, the contractor shall
shift the lifting barriers / gate leaves complete with associated
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Specifications RVNL
equipment like winches and locking arrangements to the new
locations and re-fix on new foundations.
8.7.5 Minimum width of gates, minimum length of check rails, provision of

wicket gates, arrangements for lights on gates, minimum distance of
gate posts, minimum length and other requirements of level crossings
are contained in Annexure 9/1- Chapter I Railway Permanent Way
Manual, which shall be complied with.
8.7.6 All road signs and level crossing indicators shall be shifted by the
Contractor to appropriate locations as permanent markers as per para
916 of IRPWM.
At every manned level crossing there should be distance indication at

600 meters and 1200 meters on either side to guide the gateman for
placing the detonators in case of obstruction at the level crossing.
Indicator posts should be provided with one dot and 3 dots at these
distances. Arrangements for exhibiting the danger signal at a distance
of 5 meters during emergency should also be made.
8.7.7 Rails and fastenings in contact with the road shall be thoroughly
cleaned with wire brush and a coat of anti corrosive paint applied.
8.7.8 Flange way clearances shall be maintained as per Indian Railway

Schedule of Dimensions for Broad Gauge.
i) Min. clearance of check rails at Level crossings : 51 mm

ii) Max. clearance of check rails at Level crossings: 57 mm
iii) Min. depth of space for wheel flange from Rail level : 38 mm
8.7.9 Flange way clearances, cross level, gauge and alignment should be
checked and corrected as necessary, fittings and fastenings properly
fixed and tightened and the track packed thoroughly before laying the
road surfacing or pavement between the gates.
8.8 Bridges and Bridge approaches
8.8.1 Specifications and requirements of Track on Bridges and Bridge

approaches are contained in Chapter II, Part G of Indian Railways
Permanent Way Manual.
8.8.2 Provision of Guard Rails on Bridges:
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Specifications RVNL
8.8.3 Guard rail should be provided on all girder bridges (including Pre-stressed
concrete girder bridges without deck slab) whether major or minor.
Guard rails should also be provided on all major and important ballasted
deck bridges and also on such other minor bridges where derailment may
cause serious damages.
On all flat top, arch and PRC girder bridges with deck slab, where
guard rails are not provided, the whole width of the bridge between the
parapet walls shall be filled with ballast upto the top of sleeper level.
8.8.4 Sleepers: On Steel girder bridges steel channel sleepers as per RDSO
Drawing No. B-1636 and B-1636/1, and on ballasted deck bridges and
bridge approaches PSC sleepers as per RDSO Drg. No. RDSO/T-4089
to 4097, shall be provided to accommodate the guard rails.
8.8.5 i) The typical arrangement showing important dimensions for fixing

guard rails is shown in the sketch and table below para 275(2) of
IRPWM. The same should be followed.
ii) The guard rails should be splayed; ends of guard rails should be
bent vertically and buried ; and a block of timber fixed at the end.
Fixing of guard rails to the sleepers shall be as shown in RDSO
plans for steel channel sleepers (for steel girder bridges) and PSC
sleepers (for ballasted deck bridges and all bridge approaches).
iii) The top table of the guard rail should not be lower than that of the
running rail by more than 25 mm. In the case of bridges on curves
with super-elevated track, the difference should be measured with
reference to a straight line connecting the running tables of inner
and outer rails.
8.8.6 General
i) Track geometry on the bridge and bridge approaches should be

maintained to the best possible standards.
ii) Rail joints be avoided within three meters of a bridge abutments.
iii) Full section of ballast shall be maintained as per profile given in
IRPWM.
iv) Correct cess level should be ensured.
v) Uniform and correct distance between the running rail and guard
rail should be maintained as per the prescribed dimensions.
vi) Where switch expansion joints are provided on the girder bridge,
free movement of the switch should be ensured.
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Specifications RVNL
vii) On small span girder bridges, where foot paths are not provided,
walkways should be provided in the centre of track over sleepers
to help staff cross the bridge during their inspection.
8.9 RAIL WELDING

8.9.1 General
8.9.1.1 All main line rails shall be welded to form SWR/LWR/CWR. Welding of
rail joints should normally be by the adoption of Flash-butt welding
process. Where Flash Butt Welding cannot be done, the rail joint may
be done by adoption of Alumino Thermic process, as decided by the
Engineer on a case to case basis.
8.9.1.2 The welding process shall be suitable for 60 Kg. rail sections to 880
Grade of IRST-12-96 Specification. Welding process should also be
suitable for 52 kg. section of 710 grade of IRS T 12-96 Specification.
8.9.1.3 The record of Rail joint welds, as executed, shall be submitted at
intervals not exceeding 1 km of welded length. The proforma to be
used for the records of welds shall be submitted by contractor for
Engineer‟s approval. This record shall contain, as a minimum, the
following information:
(a) Weld chainage to the nearest metre,
(b) Weld number,
(c) The rail grade and section,
(d) Date welded,
(e) Welding Company‟s code
(f) Welders code.
(g) Rail temperature at the time of welding,
(h) Weld test record sheet.
(i) USFD test results
(j) Dimensional check results
8.9.1.4 Arrangements shall be made to have test welds and their testing for
proving the flash butt welding technique use and the alumino-thermic
weld process used and also the competence of the welders deployed
for welding work.
8.9.1.5 The welds shall be finished to final profile by controlled grinding as
approved by Engineer. The dimensions and other details of the
finished welds shall be within the specified tolerances. Rail head
profile grinding to produce the finished weld.
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Specifications RVNL
8.9.1.6 All welds shall be indelibly marked with an individual number that
clearly identifies the welder and the weld. This weld number shall be
painted on the rail web. The number, once painted on the rail, shall be
maintained until taking over the works. The weld identification shall
contain a maximum of five characters.
8.9.2 Flash-butt welding
8.9.2.1 General
 The Flash Butt Welding of rail joints shall be undertaken in
accordance with the relevant Indian Railway Manual for Flash Butt
Welding of rail mentioned in Clause 2.1.2 (7) and further
supplemented below.
 Rails with ends which are outside the required end straightness
tolerance shall not be welded; the rail end can be cut to bring it to
within the specified tolerances or the rail shall be removed from
the site. Rail ends that are out of tolerance for straightness after
welding may be straightened by the use of a purpose made rail
end straightener approved by Engineer which does not cause
damage/indentation to the rails, Alternatively the executed weld
may be cut and re-welded.
 The Contractor shall make arrangement for the measurement of
residual stresses on the test welds on both side of rail and weld.
8.9.2.2 Welder qualification
All flash butt welding machine operators shall be trained and
certified either by the manufacturer of the Flash Butt Welding
machine or by an independent Institution(s) approved by the
Engineer.
8.9.2.3. Flash Butt Welding quality control
Depending upon the cause for defective welds, it may become
necessary to test some of the welds from the previous shift
production, treating them as samples, as directed by the Engineer.
The necessary tests, as instructed by the Engineer, shall be at the
contractors expenses. If any of these welds fail in testing, welding
shall immediately stop until the cause is identified and rectified.
After rectification it shall be demonstrated by the Contractor to the
satisfaction of the Engineer that all similarly affected welds have
been removed from the track.
8.9.2.4 Flash Butt welding plant
 The flash butt welding machine shall be of mobile type capable
of welding long strings of rails.
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Specifications RVNL
 The welding clamps of rail shall provide contact area along the
entire web of rail and shall be fitted with spring loaded balls for
optimum alignment of rails ends.
 The welding head shall be equipped with an integrated
shearing device for shearing the excess upset metal of the
weld seam automatically, immediately after welding has been
completed..
 A recorder system shall be provided for the simultaneous
recording of butting pressure, upset, and magnitude of current
and duration of welding.
8.9.3 Alumino-thermic welds
8.9.3.1 General
 An alumino-thermic short pre-heat period welding process,
approved as per Indian Railway practices shall be used for the
welding of rail joints. The process of welding, testing and supply of
portions, qualifying the welder shall be in accordance with the
relevant technical specification T 19 mentioned in clause 2.1.2 (7)
above.
 Where rails of dissimilar rail steel grade are to be welded together
the weld portion to be used shall be that of the higher grade rail.
8.9.3.2 Qualification of welders for alumino-thermic welds
All alumino-thermic welders shall have competency certificate issued
by RDSO/ LKO and approved by the Engineer.
8.10 PERMANENT MARKERS

8.10.1 General
1) As the track is completed permanent markers shall be provided
and installed which shall include but not limited to the followings:
(a) Kilometre posts / markers,
(b) Change of gradient posts / markers,
(c) Curve Reference markers,
(d) LWR/CWR reference markers,
(e) Expansion joint markers including its reference markers,
(f) Fouling point markers,
(g) Turnout markers,
(h) Level Crossing markers,
(i) Creep posts,
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Specifications RVNL
(j) Whistle Boards,
(k) Warning Boards,
(l) Jurisdiction Boards etc.
(m) Permanent restricted speed indication and its termination
board.
8.10.2 All permanent marker plates/boards including colour scheme and
fixation arrangement shall be as per practice of Indian Railways and
shall have prior approval of Engineer.
8.10.3 All information to be marked on the markers shall be submitted by the
contractor for Engineer‟s approval.
8.10.4 All markers required to be painted on rail for curves, turnouts and
SEJs etc. shall be paint marked by the contractor, the scheme for
which shall be submitted by the contractor for Engineer‟s approval.
8.11 Addition and alteration to running lines.
8.11.1 Any addition or alteration whether temporary or permanent to any

running line shall be carried out only after obtaining approval from the
Railways or after obtaining sanction from the C.R.S, if required. The
contractor shall advise the Engineer of his intention to carry out any
such works sufficiently in advance to enable the Engineer to obtain
such approval/sanction. The Engineer shall advise the contractor of
such approvals/sanctions obtained, after which only such works can be
undertaken. The contractor while carrying out such works shall ensure
compliance to the railway rules/conditions of such approval or
sanctions and any directions of the Railway/Employer/Engineer in this
regard.
8.12 Working under Running-Traffic
8.12.1 The scope of work includes dismantling/ slewing of existing track at

places to suit the new layout as per approved drawings. The scope
also requires working under running traffic and traffic blocks either
during non interlocked working or otherwise as required.
8.12.2 Traffic Blocks and speed restrictions;
The contractor should assess the duration of traffic/ power blocks

and any other facility required by him and advise the Engineer well in
advance who shall arrange the same in consultation with the
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Specifications RVNL
Railways and advise the contractor. The contractor should
nevertheless, arrange to plan and ensure completion of his
operations of work well within the allotted time as per agreed
schedule and to the satisfaction of the Engineer.
In all such cases the contractor shall be required to ensure and

provide all precautionary and protection measures as per railway
rules & procedures .He shall provide trained flagmen and protect the
track by providing banner flags, hand signals, detonators etc.
Similarly whenever and wherever a need to impose a speed
restriction on existing track arises, the contractor shall advise the
Engineer of the requirements who will arrange for Railway‟s
permission for the same, if in the opinion of the Engineer, such speed
restriction is essential for safe execution of the work and safety of the
traffic and it is not possible to do the work without it. The contractor
shall provide necessary indicator boards, signals and trained flagmen
as per railway rules and procedures.
During non-interlocked working for final phase/ commissioning of

works, the contractor shall interface with railway authorities and shall
provide temporary goomties with furniture for A.S.M,s etc and provide
adequate and efficient staff round the clock as per agreed schedule
till the work is completed, tested and commissioned to the
8.13 Dismantling
8.13.1 Scope:
a) The scope of work includes dismantling part of track in yards or in

between stations, turnouts in station yards etc., in the case of
Doubling and New Lines and Dismantling of existing MG Track in
the case of Gauge Conversions.
b) Dismantling of existing level crossing, road surface including check

rails for the portion required for installing new B.G. Track is also
included in the scope.
8.13.2 The contractor shall advise the Engineer of his intention to

dismantle any portion of the track which is required to complete
the work. The Engineer shall consult the Railway authorities and
prepare an agreed schedule jointly with the contractor for taking
the inventory of existing materials and to ensure the interruption /
inconvenience to the Railway, if any, is kept to bare minimum.
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Specifications RVNL
8.13.3 a) A foot by foot inspection of the proposed portion to be dismantled
shall be carried out jointly by the representatives of the contractor,
Railway and Engineer and a record of inventory of existing
materials should be made .
b) The released sleepers, rail pieces , small fittings such as fish

plates, fish bolts & nuts, cotters, loose jaws, dog spikes, screw/rail
spikes, tie bars, elastic fastenings switches and crossings with
components have to be accounted for and handed over to the
authorised Railway Representative through the Engineer except
for the materials permitted to be re-used.
c) The contractor shall hand over these released materials after

dismantling as per the inventory taken during joint inspection. In
the event of shortfall of released materials, the contractor shall be
liable to pay for the shortfalls as under :
 Rails and rail pieces @ Rs22,000/- per MT

 Other steel materials @ Rs.20,000/- per MT
 Wooden sleepers @Rs.400/- per sleepers
8.13.4 a) The released rail panels (if any) shall be cut into lengths of 11m to
13m by using gas cut/flame. The rails shall be cut in plumb
without any structural damage. The length of each rail shall be
measured and written at the end of rail in white paint.
b) All the rails released on dismantling shall be transported and

stacked at nominated places/station yards.The handling,
transportation and stacking shall be in accordance with provisions
of paragraph 254 and 255 of IRPWM and as per instruction of
Engineer.
c) However, if 52 kg released rails are permitted to be used for re-

laying in loops and sidings of station yards, these shall be marked
and stacked separately in accordance with paragraph 321 of
IRPWM as per instructions of the Engineer.
d) Each rail end should be marked with the length in metres to two
decimal places, in white on black painted back ground on the web.
e) For each lot of stacked rails, there shall be a board of steel plate of
20 cm x 20 cm with welded angle of 50 x 5 mm and height of 90
cm above ground level and encased in concrete foundation. This
display board shall indicate lot no., type of rail, total number of rails
and total length.
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Specifications RVNL
8.13.2 Disposal of released materials
All released materials shall be handed over at nominated places

within the section to the concerned authorized Railways
Representative through the Engineer. These shall be handed over
as under:
a) Sleepers, fish plates and bearing plates in numbers

b) Rail pieces in Running metres
c) Other small fittings by weight or by any measure agreed
upon during joint inspection.
8.14 Track Tolerances

8.14.1 General
 The track parameters of completed track work, shall be measured
by the Contractor in the presence of Engineer and the
measurement recorded shall be in a format approved by the
Engineer and submitted both in hard and electronic copy.
 The variations in horizontal alignment, vertical alignment versines,
cross level/cant, twist and gauge shall not exhibit cyclic patterns.
 All the track parameter measurements shall be taken in the
unloaded condition of the track.
 For no individual component / manufactured item / assembly
tolerances shall be allowed to exceed the specified completed
track tolerances limit.
8.14.2 Dimensional tolerances
Track tolerances shall comply with the limits as laid down in para 2.3.2
and as below:-
Tolerances
Curves Twist on transition portion of 0.5 mm / m
curve(over designed value)
Turn- Stock rail joint (longitudinal location) + 15 mm
outs
Nose to Nose of crossing in + 10 mm

crossovers
Flange-way clearance at the of the + 5mm/ -0 mm

switch planning
Switch toe opening + 1mm / -0 mm
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Specifications RVNL
Switch toe squareness 5 mm

Deviation of measured versine over + 1mm
its designed value for switches, lead
track and curved crossing (measured
on 6 meter half overlapping chord)
Switch (i) Gauge + 1mm
Expansi
on Joint
(ii) Gap at opening + 2mm
(iii) Out of squareness of switch rails + 2mm
Packing Sleepers should not be loose (when Max. 10 %

of checked by a canne-a-boule) Sleepers
sleepers
8.14.3 Methods of measuring and recording

8.14.3.1 The completed track geometry shall be measured for the following track
parameters as a minimum.
(a) Gauge
(b) Horizontal Alignment (Versine) of minimum one rail
(c) Cross Level/Cant
(d) Twist
(e) Vertical unevenness (Right hand rail)
(f) Vertical unevenness (Left hand rail)
8.14.3.2 The proforma for the measurement of track parameter submitted by
contractor for Engineer‟s approval shall consist of the following as a
minimum:
a) A common base point for recording of location
b) cross level/cant
c) gauge
d) horizontal alignment (versine)
e) vertical unevenness both for right & left rail.
The proforma shall show the design figure, actual figure and the
difference between design and actual and shall allow columns for
marking of twist.
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Specifications RVNL
8.14.3.3 The versine shall be measured at the centre of a 20m chord on
moving forward at 10 m intervals. The versines shall be measured on
the inside running edge of the outside rail in curves, and either rail in
straight tracks, at a level of 14mm below top of rails. Where a
recording changes its measuring rail there shall be a minimum overlap
of readings for 60 meters.
8.14.3.4 The as-built recordings of rail level and horizontal alignment along
longitudinal direction with respect to the designed level and alignment
shall be obtained by the use of appropriate electronic survey
instruments as directed by the Engineer. Horizontal location readings
shall be presented as co-ordinates. Deviation from designed co-
ordinates shall also be shown.
8.14.3.5 The vertical and horizontal rail location readings shall be taken at
coincidental kilometrages.
The recordings of rail level and horizontal location shall be taken at
the intervals as proposed by the Contractor and Approved by the
Engineer.
8.14.3.6 Longitudinal locations shall additionally include, but not be limited to,
switch and crossings locations.
8.15 TRACK LAYING REGISTER
8.15.1 It shall be ensured that all track laying confirms to the prescribed
standards.
8.15.2 A track laying register shall be maintained at site by the contractor. In
this register he shall arrange concurrent recording of relevant data
including the approved longitudinal section, programme of work,
requirement and availability of materials, position and performance of
tools, equipment, track machines, daily labour position and output,
position and the condition of the finished track both structural as well
as geometrical.
8.15.3 After the completion of the track laying, sleeper by sleeper inspection
shall be done by the contractor who will record in the track laying
register the followings;
(a) All structural differences with respect to the prescribed standards.
b) Track geometry achieved as compared to the standards
recommended for track laying. The deficiencies should be made
up and the final condition again recorded in the register.
8.16 FINAL CONDITION OF TRACK
8.16.1 Throughout construction generally and immediately after installation of
the track, the rails, rail fastenings, the track base, including ducts, cross
track drains and any exposed support structure shall be made clean.
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Specifications RVNL
This cleaning may also include the use of air/water pressure jetting and
vacuum cleaners as necessary.
8.16.2 All necessary precautions shall be taken by the Contractor to avoid

washing/flushing any contaminants or deleterious material down the
drain.
9 MATERIAL AND WORKMANSHIP: TESTING AND INSPECTION
9.1 GENERAL
9.1.1 Laboratory testing
All materials, components and assemblies shall, unless otherwise noted,
be tested by an approved certified independent testing facility as
approved by Engineer on case to case basis to demonstrate that they
satisfy the Employer‟s requirements, when tested in accordance with the
specified procedures. Where no procedure is specified, the Contractor
shall propose suitable standard or procedures for adoption for Engineer's
Approval. All costs in this respect shall be borne by the contractor.
9.1.2 Quality assurance

1. All materials, components or assemblies shall be tested and inspected
at the frequency stated within the Specification. All costs and charges
for testing and inspection whether in India or outside India shall be
borne by the contractor.
2. A comprehensive schedule of all material inspection/tests at the
required/specified frequency of testing shall be submitted by the
Contractor for Engineer's approval.
3. A sample proforma, with typical examples, for adoption for recording
the material inspections/test results shall be submitted by the
Contractor for Engineer‟s approval. After approval all inspection / test
results should be recorded in such an approved proforma only.
4. On receiving approval of the material inspection/test schedule, the
Contractor shall follow the schedule to prepare the required individual
test and inspection plans and submit for Engineer‟s approval.
Such of those tests and inspections, for which Engineer has opined to
witness, shall be carried out only in the presence of Engineer. For
other tests & inspections, test/inspection results and certification
thereof shall be submitted as directed by Engineer for his approval.
However, Engineer may at his discretion conduct test checks which
will be directed to be done by the Contractor for validation of
test/inspection results. The expense of all such tests shall be borne by
the Contractor.
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Specifications RVNL
5. Confirmation of date of a test or inspection shall be presented on an
Approved Proforma, not less than 21 Days prior to the date for test /
inspection.
6. No material, component or assembly shall be shipped until the
clearance for this has been obtained from the Engineer.
7. Should the items to be tested or inspected fail to meet the
requirements of this Specification, necessitating additional visits to the
laboratories or works for retesting or inspection the costs of these
additional visits shall be at the expense of the Contractor.
8. Periodically, during the progress of work the Engineer may conduct
inspections of manufacturing activities at the premises of the
Contractor and those of his suppliers and subcontractors. Such
inspections shall include quality procedure checks, witness
inspections, both routine and prototype, and shall also be for the
purpose of monitoring progress. During each inspection suitably
qualified staff shall be provided by the Contractor.
9.2 Acceptance tests

9.2.1 The tests and inspections have been divided into categories as
defined in the following clauses. The tests listed below are not
comprehensive and shall be revised to include all identified
Specification tests by the Contractor.
9.2.2 Category 1: Works Tests :
(a) All material/component manufacturing tests as detailed in the
material inspection/test schedule prepared by the Contractor.
(b) The assembly verification tests.
(c) The tests and inspections of the switch, crossing, derailing
switches and switch expansion joint assemblies.
(d) The concrete sleeper & turnout tests for plain track and turnout.
(e) Buffer stops tests. .
(f) Insulated rail joint tests.
(g) Welding materials.
(h) Weld/welder proving tests.
9.2.3 Category 2: Site Tests :

(a) Insulated rail joint tests.
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Specifications RVNL
(b) Main line and loop line turnouts, crossovers, derailing switches
and switch expansion joints.
(c) Rail insulation tests.
(d) Holding down assembly tests
(e) Site weld quality tests.
9.2.4. Test on Completion
(a) All the tests and inspections specified
9.2.5. The site tests and commissioning tests may be duplicated / repeated
by the Contractor as necessary to ensure the commissioning is
completed to the satisfaction of the Engineer.
10 MATERIAL TESTS
1. In addition to the requirements of the present Specification, all
materials shall be tested in accordance with all specifically listed
Codes and Standards and any Code, Standard or procedure
submitted by the Contractor and Approved by Engineer.
2. The Contractor shall submit the test and inspection proforma for
approval of the Engineer for any test or inspection.
10.1 MATERIALS AND COMPONENTS
10.1.1 Rail
All rails shall be tested/inspected in accordance with/IRS-T-12-96. All
the rails shall be ultrasonically tested for any flaws. Defective rails, if
any shall be rejected and removed.
10.1.2 ERC MK III, GFN Liner, SGCI insert and Grooved Rubber sole
plate
ERC MK III, GFN Liner and grooved rubber sole plate rail pad for
ballasted track on PSC sleeper shall be inspected and tested in
accordance with the relevant technical specification of Indian
Railways as mentioned in clause 2.1.2 (7)
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Specifications RVNL
10.1.3 Standard fishplates and fish-bolts
Standard fishplates and fish-bolts for UIC 60 kg and IRS 52 kg rail
section shall be tested and inspected in accordance with relevant
technical specification of Indian Railway mentioned in clause 2.1.2(7).
10.1.4 Glued insulated rail joints

Glued Insulated Rail Joints shall be tested in accordance with the
relevant Technical specification of Indian Railways mentioned in
clause 2.1.2 (7).
10.1.5 Welding
10.1.5.1 General
1) All Welds done by adoption of Flash Butt or Alumino Thermic
process shall be tested ultrasonically as per relevant Manual for
Ultrasonic testing of rails and welds as mentioned in clause
2.1.2 (7).
2) All the defective welds whether identified as a result of USFD
testing or otherwise shall be removed from the track and re-
welded by the contractor. The cost of re-welding of the defective
/ rejected welds and that of associated rail length including
cutting of rails, adjustments and all related works shall be borne
by the contractor.
10.1.5.2 Welding materials
Welding materials for adoption of Alumino-Thermic welding shall

be tested in accordance with the relevant technical specification
for approval the process, portion supply for thermit welding of rails
of Indian Railways as mentioned in clause 2.1.2 (7).
10.1.5.3 Test on Alumino-thermic weld

Tests for Alumino-thermic Welding shall be carried out in
accordance with the Indian Railways Manual for Alumino-thermic
Welding of Rails as mentioned in clause 2.1.2 (7).
10.1.5.4 Tests on Flash Butt Welds :

Tests on Flash Butt Welds shall be carried out in accordance with
the Indian Railways Manual for Flash Butt Welding of Rails
mentioned in Clause 2.1.2 (7).
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Specifications RVNL
10.1.7 Electrical insulation test
Short pieces of clean rail shall be fitted to an assembly using the
complete rail fastening system as specified by the Engineer. The
complete assembly shall then be immersed in distilled water for
minimum of 6 hours. Within 1 hour of removal from the water a DC
10-volt potential shall be applied across the two rails for a period of
15 minutes. If the rails become rusty or contain mill scale, the
contact points shall be cleaned .The current flow in amperes shall
be read using a DC ammeter and the resistance determined by
dividing the voltage (10 v) by the current flow in amperes. The
requirement of the test shall have been met only when a
resistance in excess of 20,000 ohms is recorded.
10.1.8 SWITCHES, CROSSINGS AND SWITCH EXPANSION JOINTS
Switch inspection & crossing inspection

1. Switches with fixed heel blocks shall be checked as full sets.
Running edge offsets and gauge shall be checked at
coincidental locations, on both the main and turnout track.
Switches shall be checked unrestrained.
2. Running edge offsets shall be taken at maximum 1000 mm
intervals and there shall be no variation between consecutive
offsets greater than 1mm. Running edge offsets shall be within
+2mm/-1mm of their design value.
3. Checks may be exercised for camber obtained on pre-curving
of stock and switch rails. If camber has been lost in handling
and transit, the stock/switch rails should be bent cold using jim
crow to obtain cambers specified in the design drawings.
4. The inspection of switches and derailing switches shall include,
but not be limited to, the following:
(a) The switch rail evenly butts with the stock rail throughout
the length of the switch planing with the switch lying
naturally.
(b) The underside of the switches and stock rails bear evenly
on all slide base plates.
(c) The switch rail is in contact with all the switch blocks.
(d) All dimensional checks of opening of switch, gauge,
alignment, cross level offset, lead, check and wing rail
clearances, clearance of nose flange-ways are within
tolerance.
(e) The moving parts i.e. switches can be moved by a force
within that specified.
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Specifications RVNL
(f) The switch rails over their free length are not twisted / bent.
5. The switch toes shall not be out of square beyond specified
tolerances.
6. Crossings shall bear evenly on all base plates.
7. Approved templates shall be used to check the nose profile.
10.1.9 Switch expansion joints inspection

1. Switch expansion joints shall be laid out in pairs. All faces in
contact shall be checked.
2. The Switch expansion joints shall bear evenly on all base
plates.
3. The gauge through each switch expansion joint shall be
checked.
4. The machining of the switch and stock rails of switch expansion
joint shall be checked.
5. The running edge alignment through the machined section
shall be checked on both sides of the rail head.
10.1.10 BUFFER STOPS/ DEAD ENDS/ SAND HUMPS

The buffer stops Dead ends and sand humps shall be inspected
for their completeness as per approved drawings.
10.2 TESTS ON COMPLETION

10.2.1 General.
(a) As soon as the work in one or more block sections is
completed and inspected as aforesaid, the same shall be
connected to the existing system at one or both ends as a
siding with prior sanction of the C.R.S either through a
connection to be retained permanently or a temporary
connection as a phase to be removed subsequently. On the
specific requirement of the Contractor, the Engineer shall
arrange to obtain approvals to the proposed plan and sanction
of the C.R.S through the Railways. The Contractor on receipt of
the advice of receipt sanctions should arrange to provide the
connection as per approved plan to the satisfaction of the
Engineer observing the railway rules in this regard. The
completed track as aforesaid shall then be rolled, repacked and
tested by several passes of a D.M.T/ Goods train with a
locomotive to be arranged by the Engineer. Any defects
noticed during or after such trial runs, shall be immediately
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Specifications RVNL
attended and rectified by the contractor to the entire
(b) For commissioning of the line ( as a whole or in phases).,C.R.S
sanction shall be obtained by the Engineer / Employer /
Railway under rules for opening of the Railways for public
carriage of passengers. The Engineer will co-ordinate with the
Railways and finalise the day –to-day programme and arrange
for inspection by the C.R.S. After the C.R.S has inspected and
granted sanction and permitted the final alterations to be done
,the Engineer shall advise the contractor and finalise a joint
programme in consultation with the contractor and the Railways
for carrying out the alterations and commissioning the work to
traffic. The contractor shall arrange to carry out the work as per
approved plan to the entire satisfaction of the Engineer within
the agreed schedule under sanctioned traffic blocks.
(c) On commissioning of the line, the Engineer may arrange to
carryout recording of track parameters by running Track
Recording Car (TRRC). The recording should show the track
to be within the following limits of track geometry.
Parameters Standard Deviation

(mm)
Unevenness (3.6 m chord) 1.20
Unevenness (9.6 m chord) 2.50
Twist (3.6 m base) 1.75
Alignment (7.2 m chord) 1.50
In cases where TRC recording is not possible, recording shall be
done using a portable accelerometer and at no location should the
vertical and lateral acceleration values exceed 0.20 g. In case the
accelerations exceed this limit, track at such locations should be
attended and then retested.
10.2.2 Submissions
Before any Section of the Works is accepted as complete the
following information shall have been submitted for the approval of
the Engineer:
(a) Records and certification for all the completion tests and
inspections identified in Clause 10 .3.1 to 10.3.3.
(b) As-built records/Drawings of the following :
 Vertical Alignment
 Horizontal alignment
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Specifications RVNL
Recording unit traces of versine, gauge, twist,
cant/cross level and rail top longitudinal profiles
Junctions including location, gauge, cross level, level,
alignment, clearances, dimensions and operation of
movable parts.
 Weld record plan
 All weld test results.
 De-stressing records
 Electrical insulation tests
 Distance in kilometres, co-ordinates, offsets of all
permanent track markers
 Rail Inclination records
 Clip toe loads records
(c) The results and reports of all tests and materials, assemblies
and items /components.
(d) The results of all Tests on Completion shall be submitted in
hard copy and electronic format in accordance with Clause
2.1.2 (7)
10.3.1 Insulation test of sleepers-
All Monobock PSC sleepers in the track circuited lengths shall be
tested for individual sleepers impedence, which shall be not less than
500 ohms.
10.3.2 Ballast resistance test
1. A ballast resistance test shall be undertaken on all track circuited
lengths over 50 metres as a check on the leakage of current
through the track base and rail fastening system from one rail to
the other.
2. The ballasted track base resistance test shall be undertaken after
the track has been completed and cleaned but before it is finally
formed into a continuous length and all the bonds are attached.
3. The testing procedure and the minimum resistance shall comply
with the requirements proposed by interfacing with designated
E&M and as approved by Engineer.
4. Generally the minimum ballast resistance in the station yard shall
be 2 ohms/ Km and in the block section it shall be not less than 4
ohms /Km.
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Specifications RVNL
10.3.3 Switch operation
The switches shall be thrown in both directions a minimum of ten times
and the peak force required to throw the switches recorded. The peak
force recorded for each direction shall not exceed the maximum specified
peak force .
Should the force required exceed the maximum permitted, the causes
shall be investigated and all necessary modifications/repairs undertaken
as approved by the Engineer, before repeating the test.
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Specifications RVNL
ANNEXURE – ‘A’ TO SPECIFIC ATION FOR PERMANENT WAY WORKS
SPECIFICATION FOR TRACK BALLAST

1. SCOPE
These specifications will be applicable for stone ballast to be used for all
types of sleepers on normal track, turnouts, tunnels and deck slabs etc.
on all routes.
2. DETAILED SPECIFICATIONS
2.1 GENERAL
2.1.1 Basic Quality: Ballast should be hard durable and as far as possible
angular along edges/corners, free from weathered portions of parent
rock, organic impurities and inorganic residues.
2.1.2 Particle Shape: Ballast should be cubical in shape as far as possible.

Individual pieces should not be flaky and should have generally flat faces
with not more than two rounded/sub-rounded faces.
2.1.3 Mode of Manufacture: To ensure uniformity of supply, machine crushed

ballast should be preferred for broad gauge and metre gauge routes,
procurement of hand broken ballast shall be resorted to only with the
prior personal approval of the Engineer.
2.2 PHYSICAL PROPERTIES

2.2.1 Ballast sample should satisfy the following physical properties in
accordance with IS: 2386 Pt IV-1963 when tested as per the procedure
given in Annexure 1 & 2.
- Aggregate Abrasion Value: 30% Max.

- Aggregate Impact Value: 20% Max.
2.2.2 The “Water Absorption” tested as per IS2386 Pt-III 1963 following the
procedure given in Annexure 3 should not be more than 1%.
2.3 SIZE AND GRADATION

2.3.1 Ballast should satisfy the following size and gradation:
a) Retained on 65 mm sq. Mesh sieve 5% Maximum.
b) Retained on 40 mm sq.mesh sieve 40% -60%
for machine crushed ballast.
c) Retained on 20 mm sq.mesh sieve Not less than 98% for

machine crushed.
Not less than 95% for
hand broken
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Specifications RVNL
2.3.2 Oversize Ballast
i) Retention on 65 mm square mesh sieve.
A maximum of 5% ballast retained on 65 mm sieve shall be

allowed and no deduction in payment shall be made for this.
In the case of hand broken ballast, only in isolated stacks, upto

10% ballast retained on 65 mm sieve may be permitted but the
average of various samples taken at the time of any measurement
shall be within 5%. In case, average exceeds 5% all the stacks
shall be rejected and a lumpsum penalty of Rs.5,000/- be levied on
contractor and contractor shall be advised to restack the ballast
after screening.
d) In case ballast retained on 40 mm square mesh sieve exceeds

60% limit prescribed in 2.31 (b) above, payment at the following
reduced rates shall be made for the full stack.
- 95% of payable rates if retention on 40 mm sq.mesh sieve is

between 60% (excluding) and 65% (including).
- 90% of payable rates if retention on 40 mm sq.mesh sieve is

between 65% (excluding) and 70% (including).
di) In case retention on 40 mm square mesh sieve exceeds 70% the

stack shall be rejected.
dii) In case of hand broken ballast supply 40 mm sieve analysis may

not be carried out. The contractor may however ensure that the
ballast is well graded between 65 mm and 20 mm size.
2.3.3 Under Size Ballast
The Ballast shall be treated as undersize and shall be rejected if:-
i) Retention on 40 mm Sq.Mesh sieve is less than 40%.
ii) Retention on 20 mm square mesh sieve is less than 98% ( for

machine crushed) or 95% (for hand broken).
2.3.4 Method of Seive Analysis
i) The Screen for sieving the ballast shall be of square mesh and
shall not be less than 100 cm in length 70 cm in breadth and 10
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Specifications RVNL
cm in height on sides. The following tolerances in the size of holes
for 65 mm and 20 mm sieve shall be permitted.
65 mm Square Mesh Sieve Plus Minus 1.5 mm
the Squareness of the individual hole in the sieves viz. 65 mm, 40

mm and 20 mm should be ensured. The sieves to be used for the
ballast measurement shall be obtained from approved suppliers of
the Railway.
ii) While carrying out sieve analysis, the screen shall not be kept
inclined, but held horizontally and shaken vigorously. The pieces
of ballast retained on the screen can be turned with hand to see if
they pass through but should not be pushed through the sieve.
iii) The percentage passing through or retained on the sieve shall be

determined by weight (volume by water displacement method).
3. CONDITIONS FOR SUBMISSION OF TENDER
3.1 Each tenderer at the time of tendering shall submit the test report of
Impact Value, Abrasion Value, Water Absorption Value from approved
laboratories.
3.2 The tenderer shall also furnish an undertaking as incorporated in the

tender document that the ballast supply at all times will conform to
Specifications for Track Ballast.
4. METHOD OF MEASUREMENT
4.1 STACK MEASUREMENT
Stacking shall be done on a neat, plain and firm ground with good
drainage. The height of stack shall not be less than 1 m except in hilly
areas where it may be 0.5m. Top width of stack shall not be less than 1.0
m. Top of stack shall be kept parallel to the ground plane. The side
slopes of stack should not be flatter than 1.5:1 (Horizontal:Vertical).
Cubical content of each stack shall normally be not less than 30 cum in
plain areas and 15 cum in hilly areas.
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Specifications RVNL
4.2 WAGON MEASUREMENT
4.2.1 In case of ballast supply taken by direct loading into wagons, a

continuous white line should be painted inside the wagon to indicate the
level to which ballast should be loaded. The cubical content in cubic
meter corresponding to white line should also be painted on both sides
outside the wagon.
4.2.2 In addition to painted line, mentioned in para 4.2.1, short pieces of flats
(cut pieces of tie bars or other wise) shall be welded at the centre of all
the four sides as permanent reference.
4.3 SHRINKAGE ALLOWANCE
Payment shall be made for the gross measurement either in stacks or in

wagons without any deduction for shrinkage/voids. However, when
ballast supply is made in wagons, shrinkage upto 8% shall be permitted
while verifying the quantities at destination.
5. SAMPLING AND TESTING
5.1 A minimum of 3 samples of ballast for sieve analysis shall be taken for
measurement done on any particular date even if the numbers of stacks
to be measured are less than three.
5.2 The tests viz., determination of Abrasion Value, Impact Value and Water
Absorption should be got done through approved laboratories or
contractor‟s own laboratory in the presence of the Engineer.
5.3 In order to ensure supply of uniform quality of ballast, the following norms
shall be followed in respect of sampling, testing and acceptance.
5.3.1 On supply of the first 100 cum, the tests for size, gradation, Abrasion
value, Impact value and water absorption (if prescribed) shall be carried
out by the Contractror in the presence of the Engineer. Further supply
shall be accepted only after this ballast satisfies the specifications for
these tests.
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Specifications RVNL
5.3.2 Subsequent tests shall be carried out as follows:
Supply in stacks Supply in wagons

For stack of For stack of
volume volume more
less than than 100 cum
100 cum
a) Size and Gradation
Tests.
- No. of Tests One for One for each One for each
each stack stack. wagon
- Size of one sample * 0.027 cum 0.027 cum for

every 100 cum 0.027 cum
or part thereof
b) Abrasion Value
Impact Value and
Water Absorption test
@ Testing Frequency One test every 2000 cum
* This sample should be collected using a wooden box of internal

dimensions 0.3m x 0.3m x 0.3m from different parts of the stack/wagon.
@ These tests shall be done for the purpose of monitoring quality during
supply. In case of the test results not being as per the prescribed
specifications at any stage, further supplies shall be suspended till suitable
corrective action is taken and supplies ensured as per specifications.
The above tests may be carried out more frequently if warranted at the
discretion of the Engineer.
5.5.3 All tests for Abrasion value, Impact value and water absorption shall be
done at the cost of the contractor.
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Specifications RVNL
ANNEXURE – I TO SPECIFIC ATION FOR TRACK BALLAST.
AGGREGATE ABRASION VALUE

(Based on IS 2386 Part IV 1963)
1. Apparatus
1.1 The abrasion test for track ballast shall be carried out using Los-Angeles
machine
1.2 The abrasive charge shall consist of 12 nos. cast iron or steel spheres
approx 48 mm dia and each weighing between 390 and 445 ensuring
total weight of charge as 5,000  25 gm.
1.3 IS sieves of sizes 50 mm, 40mm, 25 mm and 1.70 mm.
1.4 Drying Oven
2. Test Sample
2.1 The test sample of 10,000 gm shall consist of clean ballast conforming to
the following grading.
Passsing 50 mm and retained on
40 mm square mesh sieve 5,000 gm@
Passing 40 mm and retained on
25 mm square mesh sieve 5,000 gm@
@ tolerance of  2% permitted.
2.2 The sample shall be dried in oven at 100-1100C to a constant weight and
weighted (Weight „A‟).
3. Test Procedure
The test sample and the abrasive charge shall be placed in the Los-
Angeles abrasion testing machine and the machine rotated at a speed of
20–33 revolutions/minute for 1000 revolutions. At the completion of test
the material shall be discharged and sieved through 1.70 mm IS sieve.
4. Analysis and reporting of the Result

4.1 The material coarser than 1.70 mm IS sieve shall be washed, dried in
oven at 105 to 110 0C to a constant weight and weighed ( weight B).
4.2 The proportion of loss between Weight „A” and Weight „B” of the test
sample shall be expressed as a percentage of the original weight of the
test sample. This value shall be reported as
Aggregate Abrasion Value = A-B

------ x 100
A
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Specifications RVNL
ANNEXURE – II TO SPECIFIC ATION FOR TRACK BALLAST.
AGGREGATE IMPACT VALUE

(Based on IS 2386 Part IV 1963)
1. Apparatus
The apparatus shall consist of the following.
a) Impact testing machine conforming to IS; 2386 Part IV- 1963 .

b) IS Sieves of sizes 12.5 mm, 10 mm and 2.36 mm.
c) A cylindrical metal measure of 75 mm dia & 50 mm depth.
d) A tamping rod 10 mm circular cross section and 230 mm length,
rounded at one end.
e) Drying oven
2. Test Sample
2.1 The test sample shall be prepared out of track ballast so as to conform to
following grading.
- Passing 12.5 mm IS sieve 100%
- Retention 10 mm IS: 100%
2.2 The sample shall be oven dried for 4 Hours at a temperature of 100-
1100C and cooled.
2.3 The measure shall be filled about one-third full with the prepared
aggregate and tamped with 25 strokes of the tamping rod. A further
similar quantity of aggregate shall be added and a further tamping of 25
strokes given. The measure shall finally be filled to overflowing, tamped
25 times and the surplus aggregate struck off, using a tamping rod as a
straight edge. The net weight of the aggregate in the measure shall be
determined to the nearest gm. (weight „A‟).
3. Test Procedure
3.1 The cup of impact testing machine shall be fixed firmly in the position on
the base of the machine and the whole of the test sample placed in it and
compacted by 25 strokes of the tamping rod.
3.2 The hammer shall be raised 380 mm above the upper surface of the
aggregate in the cup and allowed to fall freely on to the aggregate. The
test sample shall be subjected to a total of 15 such blows each being
delivered at an interval of not less than one second.
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Specifications RVNL
4. Analysis and Reporting of the result
4.1 The sample shall be removed and sieved through 2.36 mm IS sieve. The
fraction passing through shall be weighed (Weight “B”). The fraction
retained on the sieve shall also be weighed (Weight „ C ‟) and if the total
weight ( B + C ) is less than the initial weight ( weight “A” ) by more than
one gm, the result shall be discarded and a fresh test made.
4.2 The ratio of the weight of the fines formed to the total sample weight shall
be expressed as a percentage.
Aggregate Impact value - B/A x 100
4.2 Two such tests shall be carried out and the mean of the results shall be
reported to the nearest whole number as the Aggregate Impact Value of
the tested material.
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Specifications RVNL
ANNEXURE – III TO SPECIFIC ATION FOR TRACK BALLAST.
WATER ABSORPTION
(Based on IS 2386 Part III –1963)
1. Apparatus
The apparatus shall consist of the following
a) Wire Basket – Perforated electroplated or plastic coated, with wire

hangers for suspending it from the balance.
b) Water tight container for suspending the basket
c) Dry soft Absorbent cloth 75 x 45 cm size 2 Nos.
d) Shallow Tray of minimum 650 square cm area.
e) Air tight container of capacity similar to basket.
f) Drying Oven.
2. Test Sample
A sample of not less than 2000 gm shall be used.
3. Test procedure
3.1 The sample shall be thoroughly washed to remove finer particle and dust,
drained and then placed in the wire basket and immersed in distilled
water at a temperature between 22-320C.
3.2 After immersion the entrapped air shall be removed by lifting the basket
and allowing it to drop 25 times in 25 seconds. The basket and sample
shall remain immersed for a period of 24 ½ hours afterwards.
3.3 The basket and aggregate shall then be removed from the water, allowed
to drain for few minutes, after which the aggregate shall be gently
emptied from the basket on to one of dry clothes and gently surface dried
with the cloth transferring it to second dry cloth when the first will remove
no further moisture. The stone aggregate shall be spread on the second
cloth and exposed to atmosphere (away from direct sunlight) until it
appears to be completely surface dry. The aggregate then shall be
weighed (weight „A”).
3.4 The aggregate shall then be placed in an oven at a temperature of 100 –

1100C for 24 hours. It shall then be removed from oven, cooled and
weighed (weight “B”).
4. Analysis and Reporting of the Result

Water Absorption (A-B)/B x 100
Two such tests shall be made and individual and mean results shall be reported.
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Specifications RVNL
ANNEXURE ‘B’ TO SPECIFIC ATION FOR PERMANENT WAY WORKS
INDIAN RAILWAYS STANDARD SPECIFICATION FOR FUSION

WELDING OF RAILS BY ALUMINO – THERMIC PROCESS.
Serial No. IRS T 19 – 1994.

FOREWORD :
This specification is issued under the fixed serial No. T-19. This was originally
adopted in 1961 and was revised in 1965 and 1984. This third revision is
necessitated to include current technological improvements in the process. In
this revised specification, test requirements of 90 UTS, 110 UTS and Head
Hardened rails have been incorporated, acceptable percentage of porosity,
tapping time and transverse breaking load requirements have been revised.
1. INTRODUCTION :
1.1 The soundness of the welds produced by alumino-thermic process

depends on the quality of ( a ) alumino-thermic mixture hereinafter
referred to as the „ MIXTURE “ and ( b ) the technical control exercised
during the preparation for and the execution of the welding by this
process.
1.2 The quantity of the „ MIXTURE „ required for welding one rail joint shall
be called a „ portion „
1.3 A batch shall consist of a number of „ portions „ manufactured from

similarly and simultaneously treated raw materials.
1.4 „ Portions „ manufactured by agencies approved by RDSO and accepted

by nominated inspecting authority shall only be used.
1.5 Except for welds executed for laboratory evaluation and acceptance test,
all welds shall be executed under the supervision of personal possessing
valid competency certificate From RDSO or from Termit Portion Plant,
Northern Railway, Lucknow.
1.6 No change in weld design, range of weld metal chemistry, and

acceptance tests and the methods of welding shall be made without the
content of the approving authority. Approving Authority shall mean
Director General, Research, Designs & Standards Organization (
Ministry of Railways ), Manak Nagar, Lucknow – 226011 or his
representative.
1.7 The numerical values may be rounded off as per I S : 2
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Specifications RVNL
2. SCOPE :
2.1 This specification is for A. T. Welding of rails of IRS Specification T-12

and UIC Specification 860-0, Alloy Steel Rails, viz., Chrome
Manganese and Chrome-Vanadiun and Head Hardened rails.
2.2 This Indian Railway Standard covers :-
a) Technical requirements for thermit portions and welded joints

including various acceptance tests.
b) Procedure for approval of Alumino-thermic “ portion manufacturers
“.
c) Procedure for approval of A. T. Welding Supervisors, Welders and
contracting firms.
d) Acceptance tests for in-situ and cess Alumino-Termic joints.
2.3. Reference Documents : This standard refers to the following Indian

Standards of the Bureau of Indian Standards. These should be available
at the manufacturers works for reference.
i) IS : 2 : Rules for rounding off numerical values.
ii) IS : 187 : Cotton long cloth.
iii) IS : 9738 : Polyethylene bags for general

purposes.
iv) IS : 2500 ( Pt. I ) : Sampling inspection tables Part I

inspection by attributes
and by count of defects.
v) IS 1500 : Method for Brinell hardness test for

metallic materials.
PART A – Technical requirements for Termit Portions.
3. SUPPLY OF THE “ PORTIONS “ :
3.1 The „ portion shall be submitted for acceptance batch wise. A batch shall
consist of 300 portions or part thereof manufactured from similarly and
simultaneously treated raw materials. Batch numbering shall be given
year wise in a six digit code, whose first two digits will indicate two digits
of the year of manufacture and the balance 4 digits, the serial number of
the batch. The batch number at the beginning of each year shall
therefore, commence from 0001.
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Specifications RVNL
3.2 Every portion shall be packed in a moisture proof bag of polythene to IS :
9738, “ Indian Standard Specification for Polyethylene bags for general
purposes “ Grade HM HDPE of 150 micron thickness which should be
sealed so as to make it air tight. The Polyethylene bag should then be
packed in a heavy duty bag made of New cloth to IS: 187.The open end
of the cloth bag shall be stitched and sealed in such a manner that there
is no access to the „ portion „ without damaging the bag or breaking its
seal.
3.3 Following particulars shall be indicated on two similar labels – One

placed inside the Polyethylene bag containing the portion and the other
outside with the seal on the bag.
i) Batch No.
ii) Portion No.
iii) Date of manufacture
iv) The section and grade of rail to be welded.
v) Welding Technique.
vi) Insignia of the firm.
The insignia of the firm and rail type should be printed on the exterior of
the cloth bag as per the under mentioned, colour scheme :
S. No. Rail Type Colour.
1. 72 UTS Red
2. 90 UTS Green
3. 110 UTS Black

( Chrome Manganese
& Chrome – Vanadiun )
4. 110 UTS Head Yellow

Hardened.
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Specifications RVNL
INDIAN RAILWAY STANDARD SPECIFICATION FOR FUSION
( Serial No. IRS T 19 – 1994 )
ADDENDUM & CORRIGENDUM SLIP No. 3 OF AUGUST 2001.
Para 4.2.2 is reworded as under :
Para 4.2.2 Hardness test –
Brinell hardness test shall be carried out at the welded zone, heat affected
zones and parent metal of the rails in accordance with IS:1500, “ Method for
Brinell Hardness test for steel “. The test shall be done on the top surface of the
head of the test weld with a ball of 10 mm dia and a test load of 3000 kg
maintained for 10 secs.
The average hardness values of different rail chemistry is given in Table 1 A for
reference.
Table – 1 A
Type of rail 72 UTS rail 90 UTS rail UIC Cr-Min or Head

Cr-V alloy Hardened
steel rail
Average 229 265 311 341

Hardness
(BHN)
The average hardness number ( of two readings ) determined for the weld metal
( WM ) heat affected zone ( HAZ ) and parent metal ( PM ) at location shown as
„W‟ „H‟ & „P‟ respectively in fig. 1 shall be as per table – 1B given below.
Note :
i) For 25 mm gap SKV welding & for any preheating device used ( Air-
petrol / Compressed Air Petrol / Oxy – LPG )
X = 40 mm
Y = 100 mm
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Specifications RVNL
ii) For 50 mm gap combination joint welding & for any preheating device
used.
X = 60 mm
Y = 120 mm
iii) For 75 mm wide gap welding & for any preheating device used.
X = 80 mm
Y = 150 mm
Table 1 B
Sr.No. Rail Section / Chemistry Hardness BHN

Weld Metal ( Heat affected zone (
W) H)
1 72 UTS rail of all sections with 229 + 20 ± 20 of actual

normal & wide gap -0 parent metal
hardness ( location
„P‟ )
2 90 UTS rail of all sections with 229 + 20 “

normal & wide gap. -0
3 52 kg ( 90 UTS ) Vs 90 R ( 72 265 + 20 “
UTS ) combination joint with -0
50 mm gap.
4 60 kg ( UTS ) Vs 52 kg ( 90 265 + 20 “
UTS ) combination joints with -0
50 mm gap.
5 60 Kg H.H. rail 321 ( min ) Not less than [
actual parent metal
hardness (
Location „P‟ ) – 100
]
6 UIC Cr-Mn or Cr-V alloy steel 311+ 20 ± 20 of actual

rail -0 parent metal
hardness ( location
„P‟ )
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Specifications RVNL
----------------------------------------------------------------------------------------------------------
Type of rail 72 UTS rail 90 UTS rail UIC Cr-Mn or Cr-V alloy Head
Steel rail Hardened Rail
---------------------------------------------------------------------------------------------------------
Average
Hardness 230 265 310 365
( BHN )
----------------------------------------------------------------------------------------------------------
4.2.3. Transverse breaking load test
4.2.3.1 The test weld shall be supported on cylindrical or semi-cylindrical

supports having a distance of one meter between them from center to
center. The weld shall be at the centre of the span and loaded in such a
manner that the foot of the rail is in tension. The diameter of mandrel and
the supports shall be between 30 to 50 mm. The load shall be gradually
increased ( rate of loading shall not exceed 2.5 t/sec. ) till
rupture occurs.
The test weld shall withstand a minimum load and show corresponding
minimum deflection as stipulated in Table – 2 for different sections and
types of rails.
-------------------------------------------------------------------------------------------------
Rail type Rail Section Min. transverse Min. deflection
breaking load in mm at the center .
In tonnes centre at the load
In col.3
1 2 3 4
-------------------------------------------------------------------------------------------------
75 UTS to
IRS T-12 60 R 50 15
- do – 75 R 60 15
- do – 90 R 70 15
- do – 52 Kg 85 18
- do 60 Kg 95 18
90 UTS to IRS 75 R 65 15
T-12/ UIC 860-0 90 R 85 15
Or equivalent 52 Kg 90 15
Alloy Steel 60 Kg 115 15
(Cr-Mn or 52 Kg 95 10
Cr-V type 120 UTS 60 Kg 115 10
Head Hardened rails.60 Kg 115 15
-------------------------------------------------------------------------------------------------
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Specifications RVNL

ADDENDUM & CORRIGENDUM SLIP No. 4 OF OCTOBER 2001.
1. Table 2 of para 4.2.3.1.may be read as under :

Table 2
S. No. Rail Type Rail Section Min Min deflection

transverse in mm at the
breaking load center at the
in tones load in col.4
1 2 3 4 5
A 75 UTS to IRS T- 60 R 50 15
12 for normal gap 75 R 60 15
welding & wide gap 90 R 70 15
( 75 mm ) welding. 52 Kg 85 18
60 Kg 95 18
65 15
B 90 UTS to IRS T – 75 R 85 15
12/UIC 860-0 or 90 R 90 15
equivalent for 52 Kg 115 15
normal & wide gap 60 Kg 15
( 75 mm ) welding.
Alloy steel Cr-Mn
C or Cr-V type 110 52 Kg 95 10
UTS for normal 60 Kg 115 10
gap welding.
*52Kg ( 90 UTS 70 15
D Combination joint /90R ( 72 UTS )
( 50 mm gap) 60 Kg ( 90
UTS)/52 kg ( 90 90 15
UTS )
Head Hardened
E Rails to IRS T 12 60 Kg 115 12
for normal gap
welding.
* 90 UTS portion should be used in 52/90 R combination joints.
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Specifications RVNL
4.2.3.2. If the fracture does not occur through weld, a slice shall be cut
transversely at the weld and etched in boiling 1:1 Hydrochloric acid
for about 20 minutes to determine casting defects, if any.
4.2.3.3. The fractured surface of the weld, or in case where macro-etching

is done on transverse section through the joint, shall not show
defects such as blow holes, porosity and inclusions etc.
exceeding total permissible area of defects shown in Table – 3.
However, the size of any individual defect shall not exceed 20 m
diameter. The defects should not be interconnected and none of
these shall extend up to the outer surface of the weld. There shall
not show the presence of accretions or mirror like structure and
shall be crystalline in appearance.
TABLE - 3
Area of permissible defects.
----------------------------------------------------------------------------------------------------------
Rail Section Permissible total area of defect ( mm2 )
-------------------------------------------------------------------------------------------------
60 R 19.0
75 R 23.7
90 R 28.5
52 Kg. 33.0
60 Kg. 38.4
----------------------------------------------------------------------------------------------------------
4.3 Re tests :
4.3.1. It the results of any of the tests referred to in clause 4.1 and 4.2 are found
to be unsatisfactory, the batch will stand rejected. However, retests can
be carried out at the manufacturer‟s request.. These retests shall be
carried out as per para 4.1 and 4.2 on twice the original sample size.
4.3.2 If the results of all the retest samples are satisfactory, the batch
represented by the sample portions shall be accepted. If any sample fails
to meet the requirement of any of the tests, the batch shall be rejected.
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Specifications RVNL
5. REPROCESSING :
In the event of a batch failing to comply with the requirement or clause 4,

the manufacturer may resubmit the batch after necessary reprocessing
ONCE only. The reprocessed portion shall be tested as per Clause 4
above.
6. ACCEPTANCE :
6.1. Acceptance shall be done batch wise. Every individual batch that
satisfies the conditions prescribed in this specification shall be accepted.
Each bag containing the portion shall be sealed by the manufacturers
and the container shall be suitably stamped / sealed by the Inspecting
Officer. The stamp / seal shall be such that it shall not be possible to
open the container without breaking stamp / seal.
6.2. The manufacturer shall dispatch the accepted portions to the consignee
preferably within 60 days from the date of acceptance.
7. DISPOSAL OF REJECTED PORTIONS :
In case the batch rails to meet the requirements of clause 4, it shall be

rejected. The rejected portions shall be separately stored and a proper
accountal shall be kept. The disposal of these rejected portions shall be
advised to the inspecting agency:
8. TESTING FACILITIES :
The manufacturer shall, at his own expenses, supply all labour, materials,
consumables, rail pieces and appliances for testing both for initial tests
and retests as may be carried out in presence of the Inspecting Officer, in
his own premises or at any other acceptable place in accordance with
this specification.
9. INSPECTION OF PREMISES AND RECORDS :
The purchaser or the Inspecting Officer shall have free access to the
premises of the manufacturer at all reasonable times. They shall be at
liberty to inspect all the records and the manufacture of „ portions „ at any
stage.
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Specifications RVNL
10. PART ‘ B ‘ APPROVAL OF “ PORTION MANUFACTURERS “
The approval of “ Portion Manufacturer “ shall be given separately for

each section and metallurgy of rail and for each technique of weld.
11. For the purpose of approval, the following definitions shall apply :
11.1 “ Portion Manufacturer “ shall mean the organization manufacturing the “

portion “.In addition, the “ Portion Manufacturer “ may execute A.T.
Welding of rail joints by his technique.
11.2 “ Approving Authority “ shall be Director General, Research, Designs &

Standards Organization, Ministry of Railways, Manak Nagar, Lucknow
220011 or his representative.
12. PROCEDURE FOR APPROVAL OF “ “ PORTION MANUFACTURER

“.
12.1 The application for approval shall be submitted by the “ Portion

Manufacturer “ to the Approving Authority, indicating the rail for which
portion is being offered and the welding technique.
13. FATIGUE TEST:
13.1 Fatigue testing of thermit welding technique shall be arranged by the

manufacturer at his own expense. Following principle shall be followed :
i) For 90 UTS metallurgy – Anyone section out of 52 Kg / 60 Kg (

when both the sections have been developed the lighter section
should be selected for fatigue testing ).
ii) for 72 UTS metallurgy – Anyone section out of 90 R / 52 Kg ( when

both the section have been developed the lighter section should
be selected for fatigue testing.
iii) Development of any other A. T. welding technology such as, wider

gap, gas heating, Chrome Manganese / Head Hardened rails shall
also be got separately fatigue tested before standardization.
However, one section for one technique shall be required to be
fatigue tested.
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Specifications RVNL
13.2 The weld samples shall be tested in a recognized laboratory / test center
for which prior approval of RDSO shall be necessary.
13.3 Following scheme shall be followed for fatigue testing of thermit welded
rail joints :
i) Three weld samples shall be made in presence of RDSO

representatives.
ii) The weld sample shall be made with one meter long new rail
pieces to have an overall length of 2.0 m. The rail and joint shall
be ultrasonically tested.
iii) Testing shall : done for stress ranges of tensile 20 kg/mm2 to c

stressive 4 kg/mm2 ( These are the stresses on the bottom
surface of rail foot ). The test frequency shall be any one
frequency between 8.33 Hz to 12 Hz.
iv) A joint shall be deemed to have passed if it with stands a minimum

of 2 million cycles.
v) The technique shall be deemed to have cleared fatigue test if all

the three samples pass the above test.
13.4 Retest :
Incase of failure of not more than one joint in the above test, retest can
be carried out at the request of the portion manufacturer. For the
purpose of retest, three more weld samples shall be made in presence of
RDSO representative and subjected to the above test.
The technique shall be deemed to have passed the fatigue test, if all the
three retest samples pass the test.
14. FIELD TRIALS :
14.1 Subject to the results of the tests in clause 12 and 13 being satisfactory,
service trials for a period of one year or till passage of 10 GMT traffic
over the joint, whichever is earlier, shall be undertaken on 50 to 100 trial
joints welded using the above batch of portion. For the purpose of field
trials, an order shall be placed by the nominated zonal Railway on the
manufacturer for supply of portions as well as welding of trial joints. The
trial joints shall be distinctly marked by painting letter “T” on the web of
the rail beyond 300 mm from the joints. During execution of trial welding
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Specifications RVNL
at site spoilt joints, if any, shall be cut and rewelded by the contractor at
his own expense.
14.2 All the trial joints shall be ultrasonically tested soon after welding as per
procedure at Annexure – 1 Up to a maximum of 5% defective welds,
shall be cut and rewelded by the manufacturer at his own expenses. If
more than 5% joints are found defective, the trial shall be discontinued
considering the technique to be unsatisfactory. All the defective joints
shall be removed from track by the manufacturer at his own expense.
14.3 Failure of more than 2% joints during service trial will render the
technique unacceptable.
15. The approving authority shall have free access to the premises of the
portion manufacturer at all reasonable times. The Portions Manufacturer
shall furnish all the technical data to the approving authority as and when
called for.
16. PART - C PROCEDURE FOR APPROVAL OF A.T. WELDING

SUPERVISORS AND WELDERS.
16.1 For the purpose of approval, the following definitions shall apply :
“ Welding Supervisor “ shall mean an individual engaged with portion

manufacturer with adequate knowledge and competence for supervising
and executing Alumino Thermic welding of rail joints.
“ Welder “ shall mean an individual with adequate skill and competence

for executing Alumino Thermic welding of rail joints at site.
The approval of welding supervisors / welders for execution of Alumino –

thermic welds at site shall be given separately for the following categories
of welding techniques :
a) Welding of 72 UTS and 90 UTS rails with standard gap.
a) Wide gap welding.
b) Welding of 110 UTS and Head Hardened rails.
16.2. Competency certificates for welding supervisors and welders of the zonal
railways shall be issued by the Thermit portion Plant of Northern Railway
at Lucknow, Competency Certificates for welding supervisors and
welders of firms shall be issued by D.G. ( M & C ) R.D.S.O, Lucknow.
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Specifications RVNL
16.3. Test weld joints will be made using any rail section at the discretion of
the approving authority. Welding supervisors / welders found competent
shall be deemed to be fit for A. T. welding of all rail sections for the
particular category as per clause 16.1. For execution of test weld joints,
the welding supervisors / welder desires of obtaining approval shall have
to utilize his own welding team, rails, implements and „ portions „
procured from approved manufacturers.
16.4. The firm shall pay, in advance, charge for certification of supervisors /
welders as per the rates decided by RDSO for this purpose. Payment
should be made through demand draft drawn in favour of Director (
Finance ), RDSO, Manak Nagar, Lucknow 226011..
16.5. Six test welds shall be made by the welding supervisors / welders and his
team for the particular category of welding technique ( as per Clause
16.1 ) for which approval is sought. Following tests shall be carried out at
the sponsoring firm‟s works premises or at RDSO, LUCKNOW.
a) Ultrasonic testing as per procedure mentioned at Annexure – 1.

Failure of more than one test weld will disqualify the welding
supervisor / welder.
b) The ultrasonically sound joints will be subjected to following tests :
i) Brinell hardness test on all the test welds as per clause

4.2.2
ii) Transverse load and deflection tests on any three test

welds as per clause 4.2.3
iii) Magnetic crack detection and macro examination of

remaining three test welds longitudinally sectioned across
the weld as per clause12.5.1. (ii) (d ).
iv) Joint geometry as per clause 13.1.
16.6 If the test results are satisfactory, a provisional competency certificate,

valid for two years, shall be issued to the welding supervisor / welder on
behalf of the sponsoring firm. The provisionally approved welding
supervisor / welder‟s competency shall be re-assessed by RDSO / TPP,
Lucknow after two years for issue of competency certificate valid for five
years.
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Specifications RVNL
16.6.1 For the purpose of reassessment, the welding supervisor / welder shall
submit, to the approving authority, the following details duly
countersigned by the concerned Assistant Engineer of zonal Railway.
(a) A record of joints welded / supervised by him.
b) No. of joints failed in service.
16.6.2 Based on the above details and personal interview, the approving
authority will issue competency certificate. Fresh competency certificate
will have to be issued whenever there is a change in the process of
welding or when a person who has been earlier trained and issued with a
final competency certificate has not been executing welding for a period
of more than 2 years or the work done by him has been rated as
unsatisfactory.
16.6.3.Renewal of competency certificate will be made based on performance

on actual testing.
16.6.3 A 10 character “ Identification Code Number “ shall be used for

numbering of competency certificates and identification of supervisors
and welders. The first three characters shall be alphabets which would
indicate the agency ( Railway or Firm ) to which the supervisor or welder
belongs, the nest digit ( S or W ) would denote a supervisors or welder,
the next three numbers would be as noted to the particular person (
Specific person number ), next to number shall denote the Year of issue
of the competency certificate and the last alphabet ( P or F ) shall
indicate whether it is “ Provisional “ or “ Final : competency certificate.
For example, NR)S00190F would indicate a welding supervisor of
Northern Railway with specific person number 1, the Final competency
certificate having been issued in the year 1990. The specific person
number will be continuous for a zonal Railway / Firm. The organization
issuing competency certificate shall ensure that there is no duplication of
the “ Identification Code Number”. An annual list of valid competency
certificate will be circulated by the agency issuing the competency
certificates to the Zonal Railways. Zonal Railways should constantly up
date and maintain the list of supervisors and welders along with their
identification code.
17. PART – 2 ACCEPTANCE TEST OF JOINTS WELDED AT SITE.
EXECUTION OF WELDS AT SITE
17.1 Alumino-thermic welding of rails shall be executed at site only under the
direct supervision of welding supervisor and by welder, both having valid
competency certificate issued by RDSO / TPP, Luck now (see Part„ C „)
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Specifications RVNL
17.2 All Alumino-thermic welding work shall be executed with the use of weld
Trimmer and Profile Grinder. Additionally, rail tensors shall be used
wherever work is done on welded rails.
Note : In case of welding of old rails dispensations for not using

weld trimmers and profile grinder shall be obtained from Chief
Engineer.
18. ACCEPTANCE TESTS :
18.1 Joint geometry.
All the finished welded joints shall be checked and ensure that the joint
geometry is within the following tolerances:-
i) Vertical + 1.0 mm ( Measured at the end of misalignment )
- 0.0 mm ( 1 m straight edge )

( Fig. 18.1 ( a )
Note : Dispensation for joint geometry, in case of old rails may be

permitted by
Chief Engineer.
The details of geometry of each joint shall be jointly signed by the firms
and railway‟s representative and kept as a record. Any joint found not
conforming to the above stipulations shall be cut and rewelded, free of
cost, by the firm.
18.2 Ultrasonic testing :
All the joints shall be ultrasonically tested by the Railways as per the
procedure given at Annexure –1.
This testing shall be completed as early as possible after welding but

before the welding team leaves the welding site. All the joints which are
found to be defective shall be cut and rewelded by the firm using their
portion, equipments, labour and consumables.
Where one bad joint is required to be replaced by the new joints, the
entire cost of both the joints shall be borne by the firm such rewelded
joints shall also be tested ultrasonically and if found defective, shall again
be cut and rewelded free of cost.
18.3 Sample test joint
One out of very 100 joints welded per batch shall be selected at random
by the purchaser or by the inspecting officer within one month of welding
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Specifications RVNL
and subjected to hardness and transverse test as per clause 4.2 and the
joint shall comply with the provisions laid down therein.
18.3.1 In the event of the failure of sample test joint in any of the requirements of
this specification, the Railway will be at liberty to suspend further welding.
However, two more ramdomnly selected joints from the same lot of 100
joints shall be subjected to retests as per clause 4.2. Both the joints
should clear all the tests. IF the report is also not satisfactory, further
welding of joints shall be suspended until the firm has examined the
welding technique and satisfies the requirements of Clause 4 by welding
one test joint. The clearance for recommend of welding shall be given by
RDSO.
19. GUARANTEE
19.1 Rail joints welded by a firm shall be guaranteed against failure for a
period of two years from the date of welding the joints in track or from the
date such welded joints made in cess are inserted in the track. Any such
welded joint within fails within the guarantee period shall be rewelded free
of cost by firm as per stipulations of clause 18.2
19.2 In case of failure of sample test joints ( refer Clause 18.3 ), the period of
guarantee for 100 joints represented by the sample joint shall be
extended for a further period of one year. In case of failure of joints or
joints exhibiting signs of failure by cracking within extended period of
guarantee. All joints shall be welded free of cost by the supplier as per
stipulations of Clause 18.2.
19.3 The welded joints with the extended period of guarantee shall be marked
„X‟ with yellow paint on the outer side of the web of the rail near the joint
in addition to the markings prescribed in Clause 20. Such marked joints
shall be kept under careful observation by the purchaser.
20. MARKING :
Each joint shall have a distinctive mark indicating month, year, welder‟s
code and weld number on the web of the rail in the vicinity of the welded
joint in the following manner :
** ** *** *** ***
Month Last two digits Agency Specific person Weld

of year Number No.
This should be done by punching on an Aluminimum strip which should
be fixed to the web of the rail with suitable epoxy adhesive at
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Specifications RVNL
approximately 300 mm from the joint. The agency and Specific person
number ( for welder ) shall be as per clause.
20.1 The welded joints shall be serially numbered in a Kilometer. Repair welds
/ additional welds done at a later date may be given continuing weld
number in that Kilometer. For example, the last thermit weld number in a
particular kilometer was 88 and subsequently a thermit weld has been
executed, it shall be numbered 85 irrespective of its location in that
Kilometer.
21. WITHDRAWL OF APPROVAL OF PORTION MANUFACTURER /

WELDING SUPERVISOR / WELDER FROM APPROVED LIST.
The approving authority can delete the name of any portion Manufacturer /
Welding Supervisor / Welder from the approved list based on complaints
regarding the performance.
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Specifications RVNL
ADDENDUM & CORRIGENDUM SLIP No. 5 OF FEBRUARY 2002.
1. Para - 4.
Para 4 is reworded as follows :
“ 4. ACCEPTANCE TESTS :
Two portions shall be randomly selected per batch and weight of each
portion shall be verified with the approved weight and recorded by the
Inspector.
The following tests shall be conducted for assessing the quality of

portions as selected above :
a) Reaction test.
b) Checking of weld metal dimensions of test weld with approved

weld metal dimensions of that particular welding technique.
c) Ultrasonic test on test weld.
d) Mechanical and Metallurgical tests on test weld.
One portion shall be utilized for conducting reaction test as per clause 4.1
and other portion shall be used for execution of test weld. The test weld
shall be subjected to ultrasonic test as per Annexure – 1 and checked for
weld metal dimensions with the approved weld metal dimensions of that
particular welding technique and if found satisfactory the test joint shall
be subjected to Mechanical and Metallurgical tests as per clause 4.2”.
II. Para 18.
Existing Paras 18.1, 18.2 and 18.3 shall be renumbered as Paras

18.2, 18.3 and 18.4 respectively and a new para 18.1 as given
below shall be inserted in place of existing
para 18.1
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Specifications RVNL
“ 18.1 Visual examination : All the welded joints shall be

cleaned and examined carefully to detect any visible defect like
cracks, blow holes, shrinkage, mismatch, surface finish ( Smooth
surface finish required ) etc. Any joints which shows visible defect
shall be declared defective.
The bottom of the joint shall be checked by feeling with fingers as

well as inspected with the help of a mirror for presence of „ fins ‟ at
the parting line of the mould. If fin is observed in any joint, the joint
shall be declared defective “.
III. Para 20.
Para 20 is reworded as followed.
“ 20. MARKING. :
Each joint shall have a distinctive mark indicating month, year of welding,
agency, welder‟s code and weld number on web of the rail in the vicinity
of the welded joints in the following manner.
XX XX XXX XXX XXX
Month Last two digits of year Agency Specific person

number Weld No.
Details of marking should be painted at approximately 300 mm from the

joint on web of the rail with white paint on black background. The agency
and specific person number ( for welder ) shall be as per clause 16.6.4.
The welded joints shall be serially numbered in a kilometer .
Repair welds / additional welds done at a later date may be given
continuing weld number in that kilometer. For example, the last thermit
weld number in a particular kilometer was 88 and subsequently a thermit
weld has been executed, it shall be numbered 89, irrespective of its
location in that kilometer. In addition to this, firm‟s initial ( two letter code
) and year of manufacture ( last two digits of the year ) shall also be
embossed on the mould to appear on web collar. “
_________________________________________________________________________________
Specifications RVNL
IV. Para 5.1 of Annexure – I of the manual shall be reworded as
under :
“ Till such time more exhaustive studies are carried out for strengthening
the initial testing of AT welds, any flaw signal obtained by normal probe
in the head of 40% height or more shall be treated as defective AT
welded joint. Any flaw signal of 10% height or more obtained from the
normal probe either from web or the foot location shall also be a cause of
rejection of the AT weld. “
The bags containing portion shall be packed in a sturdy wooden / Heavy

duty corrugated card board approved by RDSO / metallic container with
the portion bags shall weight more than 60 Kg. Any bag of „ portion „
found damaged at the time of delivery shall NOT be accepted.
4. ACCEPTANCE TESTS :
The following tests shall be conducted for assessing the quality of

portions :
c) Reaction test.
d) Mechanical and Metallurgical tests on tests welds.
For this purpose, one portion shall be randomly selected per batch for
tests as per Clause 4.1 and 4.2. The weight of each portion shall be
recorded by the Inspector.
4.1 Reaction test.
4.1.1. Reaction test shall be carried out on one of the selected portions.
4.1.2 During the course of the Alumino – thermic reaction, observations is

regard to the characteristics of the reaction, i.e. whether it is quiet, normal
or boiling shall be made. Reaction which is boiling, shall be rejected.
The reaction and tapping shall be within 20 ± 3 seconds. The Alumino -
thermic steel shall be poured in standard mould so as to obtain a bar
having diameter between 25 and 35 mm.
4.1.3 A transverse section shall be cut from the middle third portion of the bar
of Alumino-thermic steel obtained from reaction test as laid down in
Clause 4.1.2. Aluminium content of the steel shall be determined
spectrosopically at two points located at the mid-radius of the cross
_________________________________________________________________________________
Specifications RVNL
section. The Aluminium content at both the points shall be between
0.15% to 0.65%.
4.2. Mechanical and Metallurgical tests on test welds.
4.2.1 Two new rail pieces of same section` and grade, each approximately 750
mm long, shall be used to make test weld joint. The welded joint
shall be made as per the technique offered by the manufacturer. The rail
table and sides of rail head shall be finished to the geometrical tolerance
specified in Clause 18.1.
4.2.2 Hardness Test :
Brinell hardness test shall be carried out at the welded zone, heat
affected zones and parent metal of the rails in accordance with IS: 1500,
“ Method for Brinell Hardness test for steel “. The test shall be done on
the top surface of the head of the test weld with a ball of 10 mm dia and a
test load of 3000 kg maintained for 10 secs. The average hardness
number ( of two readings ) determined for the weld metal at locations
shown as „ A „ in Fig. 1 shall be within +20_ 0 HB of the hardness values
of rail as shown in table – 1. The average hardness number ( of two
readings ) on each heat affected zone at locations shown as „ B “ and „ C
„ in Fig. 1 shall be within ( - ) 20 HB for locations B and ( + ) 20 HB for
locations C of the actual hardness of the parent rail.
_________________________________________________________________________________
Specifications RVNL
PROCEDURE FOR ULTRASONIC TESTING OF ALUMINO

THERMIT RAIL JOINTS
1. Scope
This procedure covers the requirement of ultrasonic testing of alumino

thermit ( AT ) welded rail joints immediately after execution of the weld.
2. General conditions of test.
2.1 Surface preparation.
After execution of the AT weld, the welded zone shall be dressed properly
to facilitate placement of probes and to avoid incidence of spurious
signals on the CRT. The head surface shall be dressed to obtain
reasonably flat and smooth surface. The flange of the web up to a
distance of 200 mm on either side of the weld collar shall be thoroughly
cleaned with a wire brush to ensure freedom from dust, dirt, surface
unevenner etc.
2.2 Couplant
Water / oil be used as couplant.
2.3 Sensitivity.
The equipment sensitivity shall be set for normal 70 and 80 probes in
accordance with the procedure laid down in para 4. The sensitivity so
adjusted shall be considered as normal gain sensitivity and shall be
utilized during ATW testing. The sensitivity level not be altered during the
course of testing.
3. Apparatus required.
3.1 Equipment
Any RDSO approved model of rail tester shall be considered suitable for
testing of AT welded rail joints.
_________________________________________________________________________________
Specifications RVNL
3.2 Probes
During ultrasonic examination of AT welded joints, the following probes

shall be utilized.
a) Normal ( 0 ) , 4 MHz
b) 70 , 2 MHz
c) 80 , 1.25 MHz
3.3 Cable
One co-axial of suitable length for connecting 80 probe to flaw detector
shall be used. The length should not exceed more than 5 m.
4. Sensitivity setting procedure :
4.1 Calibration.
The equipment should be set for a depth range of 260 mm by

manipulating the depth control knob suitably. Each division, therefore,
shall correspond to 25 mm.
4.2 Test Rail
The sensitivity of the ultrasonic equipment shall be set with the help of a
standard AT welded rail piece of 1.5 m length having a simulated flaw at
standard locations as shown in fig. 1.
4.3 Alignment of probes.
The alignment of normal and 70 probes fitted with the trolley may be
checked by placing the rail on the test rail using water / soil as a couplant
and ensuring that the probes travel along the axis of the rail.
4.4 Sensitivity setting for 70 probes.
4.4.1. Place the trolley on the test rails shown in Fig. 1 keep the switches of all
the probes in off positions and turn the potentiometer knobs of all the
probes to 50% of their highest working range.
4.4.2 Switch on only 70 forward probe move the equipment towards the
drilled holes in the rail head. When the probe is just in the reflecting
range, a pulse corresponding to the hole shall appear on the screen
which during onward traveling shall show higher amplitude. The pulse
shall appear moving from right to left. The equipment should be
_________________________________________________________________________________
Specifications RVNL
progressively moved forward till maximum height of the pulse is obtained.
At this location the height of the pulse shall be adjusted to 60% of full
screen height by suitably manipulation of the gain knob.
4.4.3 The forward probe shall be switched off and the 70% backward probe,
shall now be switched on. In this case a flaw signal shall appear moving
from left to right. The signal height in this position shall also be adjusted
to 60% of full screen height. This can be accomplished through suitable
manipulation of relevant potentiometer.
4.4.4 The sensitivity setting for the normal probe has to be done while keeping
all other probes in off position. Switch on only the normal probe and
bring it above 3 mm dia hole of the test rail. Manipulate the
potentiometer control knob to obtain echo height of 60% of full screen
height at 1.0 division horizontal scale.
4.4.5 80 probe shall be connected to the socket available in the ultrasonic
equipment. The selectors which may be set to single crystal mode.
Move the probe towards the 3 mm dia hole drilled in the AT weld and
manipulate knobs to obtain a 60% full screen height on the CRT.
5. Criteria for defect classification.
5.1 Any flaw signal obtained by normal probe of 40% height or more shall be
more treated as a defective AT welded joint. Any flaw signal obtained
from the normal probe either from the web or the foot location shall also
be a cause for rejection of the AT weld.
5.2 In the case of lack of fusion, inclusion, blow holes etc. in the rail head,
moving signal shall be obtained while testing the 70 probe. The position
of one set of the signal and its corresponding range on the horizontal
screen as well as their maximum amplitude shall be recorded.
A welded joint showing the moving signal of 40% or more of the full
screen height shall be considered as a defective welded joint.
5.3 80 probe shall be place4d on the flange at a suitable distance ( 1mm
approx. ) corresponding to position „ L „ in Fig. 2 such that ultrasonic
waves are directed towards the weld. The probe shall thereafter be
moved slowly in a zigzag pattern towards the weld. A welded joint
showing a flaw echo of 40% vertical height or more with the stipulated
gain setting shall be treated as a defective welded joint. Similar testing
shall be carried out from „ C „ region as shown in Fig. 2. In these cases
also the criteria for rejection shall remain the same.
_________________________________________________________________________________
Specifications RVNL
6. The defective joints based on the criteria mentioned at clause –5 shall not
be allowed to remain in service and cropped, re-welded and tested again.
This execution shall be done by the contractor free of cost. The re-
welded joints shall be scanned ultrasonically again with the same set of
acceptance criteria to ensure freedom from any harmful defects.
_________________________________________________________________________________

04 - Part A - Track

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Specifications RVNL

4 – SPECIFICATIONS FOR PERMANENT WAY WORKS

Laying and Linking of new track between the Stations mentioned

1.1.4 Nature of works:

The Permanent Way works to be executed can broadly be grouped as

(c) Supply of 1 in 12 & 1 in 8 ½ Turnouts with CMS crossings

(e) All transportation, handling, stacking materials, watching,

(f) Assembling and laying of new track, turnouts, switch

(g) Dismantling / Replacing existing turnouts where necessary

(h) Insertion of new turnouts on main line and running lines

(i) Slewing and lifting / lowering of track as required with /

(j) Packing of PSC sleepers including lifting and lining of track,

(k) Welding of rail joints by Flash Butt/ SKV process for

(l) De-stressing of LWRs/CWRs, gap adjustments for SWRs

(m) Fabrication of check rails for Level Crossings, shifting of

(n) Installation of P.Way components for all level crossings

(o) Installation of P.Way components for shifting of level

(p) Laying of guard rails on bridges including at bridge

(q) Erection of all type of Boards / Indicators

(2) The finished earth work in formation either in bank or cutting

2.1.2 Standard Specifications - Codes

1. International Union of Railways Standard Codes (UIC)

UIC Code 864 – 2 Technical Specifications for Supply of Steel

6. International Electrotechnical Commission (IEC)

IRS T-10 Switches, crossings and SEJs

IRS T–19 Fusion welding of rails by Alumino-thermic

IRS T–28 High Tensile steel fish bolts and nuts.

IRS T–29 CMS crossings.

IRS T–44 GFN – 66 liners

Indian Railways Engineering Code.

2.3.1 All connected works of supply, installation, testing and commissioning of

(B) Loop Lines and sidings.

11 Maximum cant gradient Generally 1 in 720 or flatter.

(e) Cross Level

(g) Longitudinal Level :

2.4.1 Commissioning of this line requires close coordination among various JV

3. INSTALLATION AND CONSTRUCTION SCHEDULE

3.1.1 General Requirements:

1. The Contractor shall comply with all Enactments in executing the

In addition to the above, the Contractor should also maintain a

3.1.3 Construction and Installation Plan:

3.1.4 Temporary Works:

3.2 PROGRAMME REQUIREMENTS

3.3 SITE FACILITIES FOR THE ENGINEER

4 MATERIAL AND WORKMANSHIP: GENERAL

4.2 ABBREVIATIONS, STANDARDS, TESTING AND INSPECTIONS,

4.2.2 TESTING AND INSPECTION

4.2.2.1All materials and components proposed to be supplied by the Contractor

4.3 PACKAGING, SHIPPING AND STORAGE

i) All materials, components or assemblies shall be packed and

5.1.2 Rail Manufacture

5.1.2.1 Rail sections as mentioned above shall be manufactured in

(a) UIC Code 860 - 0

5.1 TRACK COMPONENTS

5.1.1 Rail Fastening System for Ballasted Track

5.2.3 Glued Insulated Rail Joints

Reference to the drawing numbers of sleepers to be arranged by the

1) Mono block PSC sleepers shall be used on plain track, ballasted

 PSC sleeper for turnout 1 in 12 (60kg rail)(Lay out drawing No:

5.2.6 ALUMINO-THERMIC WELDING PORTIONS

6 MATERIAL AND WORKMANSHIP: MANUFACTURED ITEMS

2) All the track materials shall be procured from RDSO approved

6.2.2 Turnouts & crossovers.