PRESENTATION ON

BALLAS1 LLSS 1RACK

(BL1) SYS1LM
by
RAJLSH AGARWAL
General Manager(Projects)/KRCL
BALLAS1LD 1RACK DLILC1
Irregular Settlement
Defects at special track Positions P&C, joints,
SEJ, LCs
Damage of Ballast at places with irregularities
eg. Rail defects, welded joints, insulating rail
joints, bridge approaches.
Track maintenance after 30-60 million tonnes /
after track has settled about 20 mm
Deep screening after 10 years
Complete ballast renewal after 30 years.
PRIME REASONS
High frequency vibrations
Uneven settlements
FIG. 1
DISPERSION OF CONTACT
STRESSES
1.2 10100 Ballast-Formation
5 2380 Sleeper-Ballast
25 510 Bearing Plate-sleeper
62 200 Rail-Bearing Plate
4200 3 Rail- Wheel
(25 t -axle load)
Pressure
(kg/cm2)
Area (cm2) Location
TRACK MODULUS FOR DIFFERENT
TYPES OF SOIL
150-200 250-300 Concrete bottom /stone/rock
100-150 150-200 Very good gravel/rock
80-100 100 Good course sand/gravel
50 50 Poor soft to rigid
20 20 Very Poor fine grained
Moorum Ballast
Track Modulus N/cm3 Soil Type
DESIRABLE CHARACTERISTICS
Rail settlement > 1.2 mm
Track Modulus 0.1 N/mm
2
Rail foot tension 60 N/mm
2
FUTURE SCENARIO
Quarrying may be banned
Long lead cost implications
Restrictions on maintenance time
Technological development and research in
Railway track construction has lead to
introduction of BLT usually referred as slab
track. This system was first introduced in
Japan in late 60s.
BALLAST LESS TRACK
(BLT)
A VIEW OF BLT ON ELEVATED
TRACK
FIG. - 4
ADVANTAGES
Reduced maintenance cost
Reduced traffic blocks
Low structure height
Dust free
Road rescue vehicles can ply over BLT in
tunnels
ADVANTAGES &
DISADVANTAGES
DISADVANTAGES
Requires high precision laying by automated
machines
Expert supervision
High cost of construction- about 1.5 to 2 times
over the conventional Ballasted track.
Derailments can cause costly damage
Repair work is more complicated
Increase in noise level
ADVANTAGES &
DISADVANTAGES
Firm formation (Normally used in tunnels)
Investigate upto 6m depth, every 50m
Upto 2.5m below, in normal case and upto 4m
in clay soils- earthwork of designed Qlty
Take care in deep cuttings
Compaction of Highest quality
Formation profile +/- 2mm
Hydraulically Bonded layer-300mm
On formation additional cost 2 to 2.5 times
ESSENTIALS FOR BLT SYSTEM
Efficient drainage in tunnels
Design for Piezometric head
Transitions to be designed
Advance planning for signaling and track
circuiting.
ESSENTIALS FOR BLT SYSTEM
IMPORTANT ISSUES
Expected life 50-60 years
Not preferred in Earth quake areas
Alteration in geometry not possible
Fixed cant values
Fixed curvature and transitions
DEFECTS DUE TO WATER
INGRESS
DAMAGE TO POLYSULPHIDE
WATER OOZING FROM BOTTOM
TYPES OF SLAB TRACK
Rheda- ----continous sleeper trough
Rheda-Berlintwin block with
untensioned reinforcement
Rheda-2000Modified twin block
sleeper with braced girder reinforcement
Heitkamp Design- concrete trough gravel
filling
Zublin Design- 10 sleepers inserted into
unset concrete
TYPES OF SLAB TRACK
Laid-on design- slab track on asphalt
SATO design
FFYS design
ATD design-
BTD design
GETRAC design
Lawn slab Track- two beams, central
grass
TYPES OF SLAB TRACK
FFC design-Concrete sleeper of length
Bogl design
OBB-Porr design
Plate track in Japan (Shinkansen)
INFUNDO design- Rail sealed in synthetic
material
SFF design longitudinal sleeper
SAARGUMMI design
BLT SYSTEMS IN USE AROUND
THE WORLD
BLT SYSTEMS
Support @ discrete points
Embeded Rail Structure
Netherland
BLT SYSTEMS
Support @ discrete points
Twin Block (bi-block system) Monoblock System
Cast in- situ
Prestressed monoblock sleepers
into pretensioned slab
BLT SYSTEMS
Cast- in- situ
Stedef
France
Sonneville
France
Shinkansen
Japan
Edilon block
Netherland
Swisswalo
Rheda
Germany
Zubin
Germany
Prefabricated
Germany
BLT SYSTEMS
Rheda
Germany
Rheda 2000 Rheda Berlin
Rheda
Rathenow
ATD GETRACA 1
BLT SYSTEMS
Prestressed
monoblock
sleepers
embeded
in to
pretensioned slab
OBB-Porr
Austria
Porr
Austria
Zublin
Germany
BLT SYSTEMS
Embeded Rail
Structure
Low Noise SA 42
BB
Embeded
Rail
ERIA (Embeded
Rail in
Asphalt
FIG.- 3
FEATURES OF SHINKANSEN SLAB
TRACK (JAPAN)
Size of Slab: 4.93X2.34X0.19/ 0.16
Cylindrical Stopper: To restrict longitudinal
and lateral movement
Sleeper blocks kept in position with rubber pad
below and side and grouted to concrete bed.
Blocks are fixed over deck slab having required
cantt.
FEATURES OF GERMAN SLAB
TRACK
15 cm reinforced bed.
20 cm light concrete
14 cm, M35 concrete
Concrete sleeper embedded grouted
10mm rod passes through 3 cm dia. hole
horizontally.
A VIEW OF BLT
LT UNDER CONSTRUCTlON
LT WlTH MASS SPRlNC SYSTEM
FEATURES OF BLT ON KONKAN
RAILWAY
Total length 22 km on Roha-Mangalore Section.
Existing PSC sleeper are embedded into the
concrete bed.
Rubber pad below sleeper.
Polyethylene Foam used around the sleeper.
FASTENINGS OF SLAB TRACK
Insulation & resilience GRP under rail seat
Microcellular pad below bearing plates
Steel clips/ Liners with insulation coating
Anchor bolts
Hole in slab for fixing inserts with epoxy
2 stages of resilience.
Resilient pad below sleeper block
CAM under Concrete slabs (Japan)
GENERAL METHOD OF
CONSTRUCTION
Sleeper cast into concrete slab
In embedded sleeper - cast into slab, rubber
boots provided for elasticity
Special slip form paver lay concrete slab
following which sleeper fitted with pads
position and cast in suite
OBB-Porr, monoblock sleeper enclosed in
rubber are cast in prefabricated slab.
In top-down system place rails & lock first in
position and casting using corkelast to provide
elasticity
BLT SYSTEMS IN USE IN
DIFFERENT COUNTRY
Germany,
Netherlan
d, Tyavan,
Spain,
Bretain,
DMRC,SR
1993-
2006
160-350 270++ Rheda Family 2
1964
Year of
Laying
Tokyo,
S.Koria &
Rome
350 km 1010
(D/L)
Shinkansen
(Japan)
1
Country Speed
Potential
KM Name of
System
Sr.N
o
DEVELOPMENT IN INDIA
Introduction of BLT in India started decades
back, first by Calcutta Metro followed by
Konkan Railway, Chennai Metro and Delhi
Metro.
The scope for development of the system is
very large due to future development planned
for Mumbai Metro, Bangalore Metro and
introduction of high speed Routes.
Technological innovation is therefore a must to
accomplish the task of above mentioned Metro
Systems.
FIG - 2
FIXED DIMENSION
A
A
A
SHEAR CONNECTOR
INVERT LINING
KERB CONCRETE
C.L. OF TUNNEL & TRACK
FINISHED LINE
OVERT LINING
MINIMUM EXCAVATION LINE
DRAIN
RAIL TOP
STEEL RIBS ISHB 150 X 150 @ 34.6 KG /M
100 MM TH. SHOTCRETE WITH WIREMESH
FUTURE DEVELOPMENT
Modified form of KRCL earlier design/development.
Based on indigenous fittings
Embedded systems/
Slab system
Top down construction
FASTENINGS
BEARING PLATE AND ANCHOR BOLTS
ELATOMERIC PADS
ELASTIC FITTINGS
INSULATIONS
SHEAR CONNECTOR
WORK IN PROGRESS-MTP
PERFORATED PLATE
FIG.- 5
BALLASTLESS TRACK
RAIL TOP
DRAIN
STEEL RI BS I SHB 150 X 150 @ 34.6 KG /M
100 MM TH. SHOTCRETE WI TH WI RE MESH
OVERT LINI NG
C. L. OF TUNNEL
MI NIMUM EXCAVATIONLINE
FI NISHED LINE
300mm THI CK LINI NG
STEEL RI BS I SHB 150 X 150 @ 34. 6 KG /M
LEVEL LING COURSE 1: 3:6
NEED FOR MAINTENANCE
MANUAL
Check of wear on fastenings.
Level and gauge
Rail defects
Concrete slab defects
CONCLUSION
An effort should be made in the right earnest to
develop future BLT for mass utilization for the
construction in Indian Railways with high
precision accuracy by automated machines
which infact can save lot of Foreign Exchange
revenues.
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