I thank Mr. ManasKumar Behura, and Mr Jasimuddin Ahmed Site Engineer Systra, whose presentation and support helped me to develop this presentation on Ballastless and Ballasted Track for Mumbai Metro Line-4. This presentation gives a basic idea on how ballastless track and Ballasted Track works are executed showing the picture of Riyadh Metro Track Works as example. I tried to contact Mr ManasKumar Behura , but unable to get his contact. Thanks and Rgds Vijay Raj. P Sr Engineer Track Mumbai Metro Line-4

1. Mumbai Metro Line 4&
4A& 4A
Presentation on Track Work

2. Riyadh Metro – Slab Track

3. Mumbai Metro Line 4 & 4A Track Structure.
a) Ballastless Track:
 Track elements comprising of running rails, rail-fastening,
embedded in concrete at-grade slab, a concrete viaduct deck,
or a concrete underground invert.
 Track slab will be Cast in situ/ plinth, The track slab shall be
designed as plinth beam or slab type ballastless track with
derailment gaurds.
Track Structure

4. MumbMumbai Metro – Plinth Track
-Plinth Track
Ballast-less Track
Components:
• Rail (Hardened Rail UIC
60E1)
• Track fastening system
• Track Plinth

5. Sl. No. CRITERIA DIMENSION
1 Gauge 1435 mm Standard Gauge,
2 Max.train speed a) Maximum
(Design)
b) Maximum (Operating)
90 Kmph (in straight) and 80 kmph (in curves upto Radius
300m)
80 Kmph (To be confirmed by Employer at later stage)
3 Max. axle load, loaded condition 17 tonnes Standard Gauge,
4 Max. desirable gradient running track
Absolute max. gradient running track
3%
4%
5 Minimum vertical curve radius
Minimum horizontal curve radius
1500 m
120 m
6 Electric power 25KV AC overhead traction
7 Inclination of Rail 1 in 20
8 Wheel profile IRS type to be interfaced with Rolling Stock Supplier.
9 Rail profile UIC 60E1
10 Design Rail Temperature 8 Deg C to 54 Deg C
Technical Criteria and Operation Standards

6. a) Rail Section:
b. Fastening:
Having record of minimum three years in service in regular revenue
for a length of at least 5km with speed potential of 80 kmph & design
axle load 16T.
Track Components – Plinth TrackComponents:

7. c) Concrete:
 The concrete shall be of minimum M45 grade as per the
Indian Standard IS-456 – 2000
d) Steel Reinforcement:
 Reinforcement & shear connector shall be IS 1786 in
accordance with relevant IS codes.
PlinthTrack Components – Plinth Trackmponents:

8. Trac Alignment – Specificationponents
tructure ParameterDescription Standard Gauge Corridor
Rail type main line UIC 60E1, IRS-T-12-2009 with all correction
slips, 1080 grade head hardened (HH)
Tentative Base Plate Spacing (Shall be
reviewed by Contractor as per detailed
design, following approval from Engineer
for varying curvature)
650 mm ( Main line (on elevated viaducts
and stations in straight) and curves with
radius >300M
600 mm in case of curves with radius ≤ 300
M
Standard Rail Length Main line 18m
Maximum cant permissible 110mm
Maximum cant deficiency Permissible 85 mm
Maximum cant gradient Permissible
Maximum cant gradient Desirable
1 in 440
1 in 720
Rate of change of cant/cant deficiency
Standard Gauge maximum Permissible
Standard Gauge maximum Desirable
40mm/sec
25mm/sec
Type of turnouts – Standard Gauge 1 in 9 :300m radius
Type of Scissor Crossover 1 in 9: 300 m radius Diamond Crossing

9. Track Gauge

11. Picture: Taking over of Finished over Grade / Vaiduct Section
Track Installation

12. Track Installation
Fig : Total Station Survey Capturing of Finished Levels

13. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Flash Butt Welding of Rail

14. Track Installation
(4) Step 4 – Rail Drop into position – Track Site
Fig: Unloading of Rails over Deck slab

15. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Marking of alignment center

16. Fig : Lifting and Rails with GSF Supports over the alignment center
Track Installation

17. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Fixing of Dummy Plates with Vossloh Fastenings

18. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Vossloh Fastenings FE 336 used in Riyadh Metro

19. Fig : Reinforcement of Track Slab
Track Installation

20. Fig : From Work for Track Slab including Derailment Guard
Track Installation

21. Fig : Third Rail Dowel Provision Works
Track Installation

22. Fig : Final Inspection Works
Track Inspection
Inspection of vertical & horizontal
alignment with Track Master
Inspection of vertical alignment

23. Fig : Adjustment of Errors
Track Inspection
Ignment

24. Track Installation
Dimensional Tolerances Ballastless Track
Gauge maximum variation +/- 2 mm
Mean Gauge per 200 m -1 mm
Max difference of any point in relation to the designed
layout ( Vertical )
-4 mm/+4 mm
Max difference of any point in relation to the designed
layout ( horizontal)
-4 mm/+4 mm
On curve, deviation of measured versine 20 m chord:
(half overlapping)
+/- 2 mm
Maximum deviation of measured versine (vertical) over
its designed value on a 10 m chord (half overlapping)
+/- 2 mm
Baseplate to base plate (ballastless) Variation of cant/x-
level
 1 mm
Twist: (over & above designed value) straight and circular
portion of curve
On transition portion of curve
1 mm/m
0.5 mm/m

25. Fig : Track Slab Concrete
Track Installation

26. Fig : Surface finishing Track Slab Concrete
Track Installation

27. Fig : Rear Works of Finished Track Slab
Track Installation

28. Fig : Fixing of Fastenings
Track Installation

29. Fig : Destressing Works at Temp 37°C to 43°C
Track Installation
N

30. Fig : Final Track installation and Recording Data
Track Installation

31. a) Track Structure in Depot :
 Ballasted Track for Main Lines.
 Pedestal Track for inspection lines.
 Embedded track inside the Workshop.
 Plinth type for Washing Plant line.
Depot Track Works

32. Track elements running rails, rail-fastening rail pads,, concrete
sleeper blocks, stone ballast installed upon a well compacted
subgrade.
Ballasted Track In Depots

33. Ballasted Track Standard
Description Standard Gauge Corridor
Rail type UIC 60E1, IRS-T-12-2009 with all
correction slips, 880 grade and 1080
grade head hardened (HH)
Tentative Base Plate Spacing (Shall be
reviewed by Contractor as per detailed
design, following approval from
Engineer for varying curvature)
700 mm +/- 25 mm
600 mm +/- 25 mm (curve radius ≤ 300
m)
Standard Rail Length 18 m
Minimum ballast cushion depth 200 mm
Formation cross fall 1 in 20
Type of turnouts – Standard Gauge 1 in 7 :190m radius
Type of Scissor Crossover 1 in 7: 190 m radius
Diamond Crossing (to be adequately
designed by Contractor)

34. b. Components of Ballasted track :
 Rails: UIC 60E1, IRS-T-12-2009 with all correction slips, 880
grade and 1080 grade head hardened (HH)
 Sleepers :The PSC sleepers shall be used in accordance with
RDSO drawing no.T-2496 and specification IRS-T-39 (revised
from time to time)
 Fastenings : compatible fastening system with minimum toe
load of 1045kg and approved by Indian Railway shall be
used.
Ballasted Track Structure

35. c. Rail Fixtures of Ballasted track :
 The various types of rail fixtures and fastenings commonly
used in a permanent way are the following:
1. Fish plates 8. Check rails
2. Bolts 9. M.C.I. Insert
3. Spikes 10. Rubber pads
4. Chairs
5. Keys, cotters and tie bars
6. Bearing plates
7. Guard rails
Ballasted Track Structure

36. d. Pictures of Rail fixtures in Ballasted track :
Dog Spike Chairs with Tie plates
Ballasted Track Structure

37. e. Specificaitons:
 Basic Quality:
Ballast should be hard durable and as far as possible
angular edges/corners, free, organic Impurities
and inorganic residues.
 Shape:
Ballast should be cubical in shape as far as possible.
Track ballast

38. f. Physical Properties of Ballast:
 Ballast sample should satisfy the following physical properties
in accordance with IS: 2386 Pt. IV-1963 when tested as per
RDSO detailed specifications.
 Aggregate Abrasion Value: 30% Max.
 Aggregate Impact Value: 20% Max.
 The “Water Absorption” tested as per IS2386 Pt.-III 1963
following the procedure given in in RDSO detailed
specifications should not be more than 1%.
Specification of Track ballast

39. g. Size and Gradation of Ballast:
 Ballast should satisfy the following size and gradation:
 Retained on 65 mm sq. Mesh sieve 5% Maximum.
 Retained on 40 mm sq. Mesh sieve 40% -60% for machine
crushed ballast.
 Retained on 20 mm sq. Mesh sieve not less than 98% for
machine crushed. Not less than 95% for hand broken.
Specification of Track ballast

40. Gradation of Ballast
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Ballast Sieve Analysis

41. Earth Works of Ballasted Track
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Earth Works of Ballasted Track

42. a. Blanket layers :
This layer is placed between the prepared subgrade and ballast
layers and may consist of one or several layers:,
It has the following functions:
 improving the bearing capacity by a better distribution of
transmitted loads,
 protecting against erosion and frost,
 acting as a filter between subgrade and ballast,
 shedding surface water.
Earth Works of Ballasted Track

43. b. Formation/Subgrade :
 Prepared subgrade (also named as “Form layer”): this layer
must have bearing capacity to support the ballast and
blanket layers and to avoid water infiltration in the
embankment.
c. Embankment or Cutting:
 If the design level of the rails is above the current surface
ground, it will be necessary to build an embankment; in the
opposite case, a cutting of the natural ground will have to be
performed.
Earth Works of Ballasted Track

44. For efficient execution of track work the following tools and
machinery are proposed to be deployed. This list is not
exhaustive and is subject to change as per site requirement.
 Mobile Flash butt Welding machine
 New Track layer self propelled with sleeper Gantry Crane
 Tractor/Dozer / Loader for pulling Rail Panel
 Clip applicator mounter on Track
 Sleeper Loading Gantry Crane
 Fixed rail Gantry Crane 21 X 2T
 Rail Profile Grinder
Plant and Equipment

45.  Flat Wagons for Rail & Sleeper transport
 Hopper Wagons for Ballast training out
 Wheel Loader
 Grader
 Vibratory Roller 8T
 Hydra Crane
 Mobile Crane 25 Tonne Capacity
 Loco / UTV
 Unimat Tamping machine for plain track and turnout
 Dumoatic Tamping Machine for plain track
 DGS 62 N dynamic Track Stabilizer.
Plant and Equipment

46.  Abrasive Rail Saw
 Rail drilling Machine
 Rail head Grinding machine
 Rail Web Grinding Machine
 Rail tensor
 Motor Trolley,
 Motorized dip lorries
 Push trolley
 Welding Tool: Gas cutter, Single Phase Welding M/C,
Industrial Tool Kit set. Rail Gripper and allied tools etc
Plant and Equipment

47. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Sub Grade Soil Cutting and Filling

48. Track Installation
(5) Step 5 – Welding Pulling of Rail Panels
Fig : Compaction of Subgrade and Blanket Materials not
exceeding 250 mm to 103% relative compaction

49. Track Installation
Fig : Survey Capturing of Finished Levels and Marking of Track
Centers

50. Track Installation
Fig : Laying of Ballast over the Formation

51. Track Installation
Fig : Compaction of Ballast

52. Track Installation
Fig : Rail Panels Pulled Over Ballast

53. Track Installation
Fig : Laying of Sleeper With Track Construction Machine

54. Track Installation
Fig : Laying of Sleepers and Laying of Rails Over the Sleeper by
New Track Construction Machine

55. Track Installation
Fig : Track Laid with New Track Construction Machine

56. Track Installation
Fig : Track Ready for Ballast Works

57. Track Installation
Fig : Completed Ballasted Track

58. DRAFT
Overview

59. Depot Tracks
Fig : Pedestal Tack
• The Pedestal Track structure consists of a
support base and a reinforced concrete
slab in where the steel pillars are fixed.
• Used in workshop building.

60. Depot Tracks
Fig : Embedded Block System (EBS)
• Used to reduce
dynamic loads and
vibrations.
• Used also to reduce
ground-borne noises
and provide electrical
insulation especially
around the depot
areas.

61. Depot Tracks
Fig : Turn Table
• Device for turning
maintenance
trains so that they
can be moved in
different
directions within
the depot
maintenance
facilities.

62. Query