LONG WELDED RAILS

By
G S Yadav, IRSE 1994
PB2, IRICEN
7420041112
gsyadav@iricen.gov.in
PERMITTED LOCATIONS
 PERMITTED LOCATIONS
• Alignment : LWR/CWR shall not be laid on curves sharper than 440 metre
radius both for BG and MG.
• However, in temperature zone-I LWR/CWR may be laid on curves up to
350metre radius (5°curve)on BG with following additional precautions
(ACS-11)
i) Minimum track structure should be 52kg rail on PSC sleeper, m+7 sleeper
density with 300mm clean ballast cushion.
ii) Shoulder ballast for curved track sharper than 440m radius should be
increased to 600mm on out side of curve and upto 100m beyond tangent
point.
iii) Reference marks should be provided at every 50 m interval to record
creep if any.
iv) Each curve of length greater than 250 m should be preferably provided
with SEJ on either side .SEJ should be located in straight track at 100 m
away from tangent point.
 PERMITTED LOCATIONS
• Alignment : Reverse Curve
• LWR/CWR shall not be laid on reverse curves sharper than
875 m meters radius both for BG and MG.
 PERMITTED LOCATIONS

• The steepest Gradient permitted shall be 1 in 100.

• Vertical curve shall be provided at the junction of the grade when algebraic
difference between the grades is equal to or more than 4mm per metre or 0.4
percent (as per Para 419 of IRPWM)
• FORMATION – to be stable
• Ballast: 250mm clean cushion at the time of installation
• In case speed in excess of 130KMPH for BG / 100 KMPH for MG is to be
introduced – 300mm clean cushion or 200mm ballast cushion over 150mm
sub-ballast
• Standard ballast profile shall be ensured for upto 3 rails beyond the SEJ (on
SWR / Fish-plated track)
• Special provisions for continuation of LWRs on Bridges
LWR ON BRIDGES
 LWR ON BRIDGES ( Without Bearings)

• Bridges with ballasted deck (WITHOUT BEARING):

• LWR/CWR can be continued over bridges without bearings
like slabs, box culverts and arches with no restrictions.
 LWR ON BRIDGES ( With Bearings)
Following stipulations should be met while continuing LWR on
BRIDGES WITH BEARINGS:

a) Rail-free fastenings shall be provided throughout the length of the bridge

between abutments. In case bridges are provided with creep resistant fastenings,
proper Rail Structure Interaction (RSI) Analysis has to be done.

b) The approach track upto 50 m on both sides shall be well anchored by providing
any one of the following:-
i) ST sleepers with elastic fastenings
ii) PRC sleepers with elastic rail clips with fair ‘T’ or similar type creep
anchors.

c) The ballast section of approach track upto 50 metre shall be heaped upto the foot
of the rail on the shoulders and kept in well compacted and consolidated
condition during the months of extreme summer and winter.
 LWR ON BRIDGES
Bridges WITH/WITHOUT ballasted deck (with bearing):
For MG – Not more than 20 M
For BG as under – CASE 1
TEMP. RAIL SECTION RAIL FREE FASTENING ON BRIDGE SINGLE SPAN NOT EXEEDING
ZONE USED 30.5M IN METRE AND SLIDING BEARINGS ON BOTH ENDS
60KG 30
I
52KG/90R 45
60KG 11
II
52KG/90R 27
60KG 11
III
52KG/90R 27
60KG 11
IV
52KG/90R 27
 LWR ON BRIDGES - Case - 2
TEM
RAIL RAIL FREE FASTENING ON BRIDGE &PARTLY BOX
P.
SECTION ANCHORED, SINGLE SPAN NOT EXEEDING 30.5 M AND
ZON
USED SLIDING BEARINGS ON BOTH ENDS
E
60KG 77
I
52KG/90R 90
60KG 42
II
52KG/90R 58
60KG 23
III
52KG/90R 43
60KG 23
IV
52KG/90R 43
 LWR ON BRIDGES - Case - 2

• On each span, 4 central sleepers shall be box-anchored with fair ‘V’ or

similar type creep anchors and the remaining sleepers shall be provided
with rail-free fastenings.
• The bridge timbers laid on girders shall not be provided with through notch
but shall be notched to accommodate individual rivet heads.
• The track structure in the approaches shall be laid and maintained to the
standards as discussed earlier.
• The girders shall be centralized with reference to the location strips on the
bearing, before laying LWR/CWR
• The sliding bearings shall be inspected during the months of March and
October each year and cleared of all foreign materials. Lubrication of the
bearings shall be done once in two years.
 LWR ON BRIDGES - Case - 3
Welded rails may be provided from pier to pier with RAIL-FREE
FASTENINGS and with SEJ on each pier.
The rail shall be box-anchored on four sleepers at the fixed end of the
girder if the girder is supported on rollers on one side and rockers on
other side.
In case of girder supported on sliding bearings on both sides, the central
portion of the welded rails over each span shall be box-anchored on four
sleepers
 LWR ON BRIDGES - Case - 4
LWR/CWR may also be continued over a bridge with the provision of SEJ at the far end
approach of the bridge using RAIL-FREE FASTENINGS over the girder bridge
WITH SEJ ON FAR END
TEMP.
ZONE APPROACH WITH ST/PRC 190MM SEJ (120MM) APPROACH WITH CST-9 190MM SEJ (120MM)

IV 55 45
III 70 70
II 110 / (20) 100 / (15)
I 160 / (50) 150 / (50)

CS No 18 of 11-03-2019 - (i) SEJ is to be installed 10 metre away from the abutments.

(ii) lmproved SEJ with 2 gaps of 65mm (max.] each (Drawing no. RDSO/T-6922 and RDSO/T-
6930) may also be used for laying at far end approach of bridges in lieu of IRS design SEJ with
120 mm max. gap.
 LWR ON BRIDGES - Case – 5 (ACS 9)
Welded rails may be provided over a SINGLE SPAN BRIDGE with RAIL
FREE FASTENINGS and SEJs at 30m away from both abutments. The rail
shall be box anchored at fixed end if rocker and roller bearings are
provided. It shall be box anchored at the centre if provided with sliding
bearing on both sides.
On both sides of approaches, full creep anchored fastenings shall be
used. The length of single span bridge with 190mm SEJ (td=tm)
Temp Zone Max Length of single span girder bridge

I 146 m

II 110 m

III 87 m

IV 75 m