TRACK MAP DFCC L&T

A Sojitz - Larsen & Toubro Consortium

Ludhiana

Dadri GMR
L&T-SOJITZ Rewari (46KM)
(CTP 1 &2) Khurja
TATA-ALDESA
626 KM
(343 KM)
Ajmer Kanpur
GMR
(393KM) Tendering
Mughalsarai “PPP”
EMP4 L&T-SOJITZ (538KM)
C&C and Somnagar
Iqbalgarh (914KM) BSCPL
L&T-SOJITZ Ahmedabad (118KM)
(289KM) CTP3R (289km) Dankuni
Makarpura
(Vadodara)
TATA-IRCON Sachin
CTP12&13 (422km)
(289KM)
Vaitarna
JNPT STP17 (422km)

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FEATURES OF DFCC L&T
A Sojitz - Larsen & Toubro Consortium

Operating Features
 Train Headway - 10 minutes : interval of time between two trains
 End of Train Telemetry System (EOTT) - Trains to run without Guard
 Facility for long-haul operation
Advanced Technology & Innovation
 Unidirectional automatic signalling with 2 km inter-signal distance
 Stations with Electronic Inter-locking system with LED light Multi-aspect color light signals
 Mobile Radio Train Communication System (GSM-R)
 2x25 KV, 50 Hz AT traction feeding system
 Usage of 60 kg curved thick web switches
 Distance between two TSS 60-80 km
 Use of Canted Turnouts

Indian Railway Turnouts

- Sleepers without slope
- Speed on turnout - IR limited to 15-20kmph
DFCC Turnouts
- Canted Turnouts –1:20 slope is provided to Rail
- Higher speed limit compared to IR IR Turnouts DFCC Turnouts
FEATURES OF DFCC L&T
A Sojitz - Larsen & Toubro Consortium

UNIQUE FEATURES
 25 meter 1080 Head Hardened Rails Imported from Japan
 Fully mechanized Track Laying by NTC
 Fully equipped Depots with Machineries for quality control & maintenance.
 Continuous Welded rails throughout project
 ERC Clipping machine used for the first time in Indian Railways
 De-stressing with Superpuller
 Interface with Public Works Department, Indian Railways, National Highway Authority of India, Water
Resources Department, Electricity Boards, Bharat Sanchar Nigam Limited etc in this Mega-Project.

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WDFC PROJECT DETAILS L&T
A Sojitz - Larsen & Toubro Consortium

SN Item Description Quantity

1 Project Civil, Building, & Track Works for 626 km Double Railway line from Rewari – Iqbalgarh Section.

Dedicated Freight Corridor Corporation of India Limited (DFCCIL)

2 Client
SPV set up under the administrative control of Ministry of Railways (MoR)
3 Contractor Sojitz- L&T Consortium
4 Job Value Rs. 6699.50 Crores
6 Bid Currency Indian Rupee, Japanese Yen and 2 free trading currencies (Euro & USD)
7 PMC Consultant (NKOC Rites) Nippon Oriental Consultants Rites
8 Project Duration 208 weeks
9 LOA issue Date 7th June’13
10 Commencement date 2nd Sept’13
11 Defect Liability period 104 weeks from the date of issue of Taking-Over Certificate by the Engineer
12 Specialized Agencies Design – L&T Ramboll. Track work- Harsco Rail USA
13 STEP Component HH Rails (Japan)

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WDFC MAJOR SCOPE L&T
A Sojitz - Larsen & Toubro Consortium

Canted
Yards SN Item Description Unit QTY
Turnout
20 Nos 1 Route length KM 626
530 Nos. 2 Length of Track Parallel to IR TKM 594 (95%)
3 Detour length TKM 32 (5%)
4 Total Track length (Main Line) TKM 1252
5 Sidings (8 No’s) TKM 34
Rails Level
6 Total Track length (Loop Line & Sidings) TKM 148
173000 Crossing
7 Total Track Length TKM 1388
MT 2 Nos.
8 T/O’s (1:12 & 1:8.5) No’s 530
9 No of Crossing station No’s 15
10 No of Junction station No’s 5
Ballast Sleeper
11 Level Crossing No’s 2
23.3 Lac
38 Lac Cum 12 Head Hardened Rails MT 1,53,800
Nos
13 Normal Standard Rails MT 20,125
14 Points & Crossings Set 553

Elastic Metal 15 Ballast Cum (Lac) 38.60

Rail Clip Liners 16 Main Line Sleepers Nos.(Lac) 23.30
99.68 Lacs 99.68 Lacs 17 Elastic Rail Clips Nos.(Lac) 99.68
Nos Nos.
18 Liners Nos.(Lac) 99.68

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MAJOR STRUCTURE SCOPE L&T
A Sojitz - Larsen & Toubro Consortium

Scope Scope
Type
Nos. Concrete Qty. (Cum)
Major bridges 98 2,80,353
Important Bridges 11 1,04,164
Viaduct 1 39,279
Minor Bridges 797 1,83,131
RUB 306 2,59,962
RFO 5 17,910
ROB 6 66,812
FOB 53 15,845
Pedestrian Subway 61 38,302
Total 1338 10,05,758
MAJOR RAILWAY PROCUREMENT L&T
A Sojitz - Larsen & Toubro Consortium

Sl Machine Manufacture Avlb. Description Machine Photos

 1.5 to 2 TKM/Day.

 550-600 Sleepers per hour

 Self-Propelled machine: 400 HP Cummins Engine lays

HARSCO sleepers and rails in fully automatically.
1 NTC 1
RAIL,USA
 Length-61m, consisting of Truss Beam Conveyor System,
Reception Wagons and Transition Wagons.

 The machine is backed up with Material Wagons mounted

with wagon structure for carrying rails and sleepers

 Fast Tamping M/c – 2 Nos. – (MK-VI)

 Slow Tamping M/c – 1 No. – (STM XLC)

 Harsco Rail’s Jupiter II Control System.

Tamping HARSCO  This system provides synchronized control through arm

2 3
Machine RAIL,USA panel keypads, joysticks and a computer system.

 Lifting of track and tamping of ballast with an output of

250 to 300 m/hour for every lift and insertion.

 STM XLC is capable of 50-80 m/hour output for tamping.

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MAJOR RAILWAY PROCUREMENT L&T
A Sojitz - Larsen & Toubro Consortium

Sl Machine Manufacture Avlb. Description Machine

 42 Nos. BLC wagons supplies 250 m rail panels and PSC Sleepers
to NTC Machine.
Hindustan
3 BLC Wagons Engineering 45  One set of BLC wagon (21 Nos.) 12 rail panels and 2490 Nos.
Kolkata Sleepers (Eqvl. 1.5 TKM).

 Wagon superstructure, for smooth pulling/movement of rails.

 Output=0.5 km/hr and 4 km/day in track stabilization.

Dynamic Track HARSCO  Squeezing pressure: Horizontal Force of 50T and 50Hz & 22T at 33
4 1
Stabilizer RAIL,USA Hz
 Harsco Rail’s Jupiter II Control System.

 BRM machine adjust the ballast profile i.e. desired slope, height,
Ballast width as per requirement.
Progress Rail,
5 Regulating 2
USA
Machine  This machine gives output=0.5 km/hr brooming and
ploughing.

 36 Nos. of Ballast Hoppers, top ballasting (40%).

Hindustan
6 Hoppers Engineering 36  Each Hopper can carry 35cum (52MT) of ballast, so one set of
Kolkata Hoppers (18Nos) can supply 630Cum (945MT) of Ballast which is
equivalent to 200-300m of track.

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MAJOR RAILWAY PROCUREMENT L&T
A Sojitz - Larsen & Toubro Consortium

Sl Machine Manufacture Avlb. Description Machine Photos

 2 Nos. 1400 HP locomotives are taken from RITES Ltd (Wet

Leasing).
7 Locomotives RITES, India 2
 These locomotives are used for movement of NTC material rake
and ballast wagons

 This high precision welding technique to provide a joint of

equivalent strength of rail.
Flash Butt Holland LP,
8 2
Welding Machine USA  As we are using head hardened rails, air quenching technic is
used for head hardening of welded portion of rail in welding
plant.

Utility Track Phooltas,  These utility track vehicles are used for movement of materials,
9 2
Vehicle - UTV India equipments, loading, unloading and other miscellaneous works.

 The AMBERG-GRP1000 with Leica Total Station capable of

collecting track parameters and providing inputs to Tamping
Slab
Amberg, machine.
10 Track Adjustment 1
Switzerland
& Control System
 Tamping machine calculates the difference in design track
parameters and actual track parameters.

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CURRENT PROCUREMENT L&T
A Sojitz - Larsen & Toubro Consortium
Propos
Sl Machine Manufacture Description Machine Photos
ed

 ERC Clipping/De-clipping at site

FCS Rail (Italy)  Total Scope of ERC Clipping in 99 Lacs
ERC Clipping & 1 Avlb.  Clipping/Declipping 4 times due to Tamping & Destressing
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Machine Geismar 1 Prop. Operations
(France)  Planned to procure another machine from Geismar (France)
 1ST TIME IN INDIA

 Self Propelled NTC Machine operating on assembly line principle

PLASSER & consisting sleeper conveying unit, 1 flat wagon for powering unit
12 NTC MACHINE 1
THEURER  Output : 1.5 to 2 Kms per day

 Insertion & Lift: 700 for >40mm lift for Double insertion
 Working/Travel speed: 80Kmph on self propelled 100 km/h on
PLASSER &
13 DUOMATIC 1 Haul
THEURER
 Levelling System: 3-point via steel cables
 Lining System: 3-point/4 point via steel cables

 This high precision welding technic to provide a joint of

equivalent strength of rail.2. One weld in 130 secs.
 As we are using head hardened rails, air quenching technique is
FLASH BUTT used for head hardening of welded portion of rail in welding
14 WELDING CUM HOLLAND LP 1 plant.
DESTRESSING  Super Puller- 160MT Pulling force to pull 1KM welded rail panel at
field (wt-60MT) during the destressing activity.
 Super Puller- 15 inch stroke length

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MAJOR SET-UPS ESTABLISHED L&T
A Sojitz - Larsen & Toubro Consortium

PSC SLEEPER PLANT

 Long Line Method of Sleeper Production
 400 sleeper moulds per line, total 5 Lines
 Daily Production Capacity – 2000 Nos.
 Total scope: 23lacs sleepers

Stages
1) Greasing, Inserts Placing, HT Strands Stressing
2) Concreting – M60 Grade Concrete 3) Steam Curing– 11.5 Hours

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MAJOR SET-UPS ESTABLISHED L&T
A Sojitz - Larsen & Toubro Consortium

PSC SLEEPER PLANT

4) Water Curing– 14 Days 5) Sleeper Loading
3) Strand Cut & De-moulding

6) Turnout Sleeper & Bridge Sleepers 7) Sleeper Stacking

Dowels placing and checking

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MAJOR SET-UPS ESTABLISHED L&T
A Sojitz - Larsen & Toubro Consortium

WELDING PLANT
1) Rail end grinding at feeding table

2) Rail Welding by FBW welder

3) Roller Conveyor for Rail Conveyance

4) USFD & Transv. Load Testing

5) Rail panel stacking

5
1 2

4
- 120-130 secs. for one weld
- Per shift welding output– 50 welds (with
grinding & marking)
- Testing arrangement at construction site
in Unique arrangement in INDIAN
RAILWAY 3
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TRACK LAYING SEQUENCE L&T
A Sojitz - Larsen & Toubro Consortium

Stage 1- Ballast Bed Preparation

Stage 2- Centre line marking & Material Wagon

Stage 3- NTC Track Laying Stage 4- ERC Clipping Stage 5- Field Flash Butt Welding
TRACK LAYING SEQUENCE L&T
A Sojitz - Larsen & Toubro Consortium

Stage 6- Top Ballast by Hoppers Stage 7- Ballast Profiling

Stage 8- Track Co-ordinates & Fast Tamping

Stage 9- Dynamic Track Stabilizer --- 4 Round Fast Tamping --- Final Ballast Profiling