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CAMTECH/C/04

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

HANDBOOK
ON
MAINTENANCE OF SWITCH
EXPANSION JOINT
FOR L.W.R./C.W.R.

CAMTECH/C/04

December - 1997
Centre
for
Advanced
Maintenance

Excellence in Maintenance

TECHnology
Maharajpur, GWALIOR - 474 020

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

HANDBOOK
ON
MAINTENANCE OF
SWITCH EXPANSION
JOINT

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

CONTENTS
S.No.

Description

Page

1.

INTRODUCTION

2.

MAINTENANCE OF SEJ.

3.

GAPS AT SEJ.

4.

DAMAGE TO SEJ.

5.

BUCKLING OF TRACK

6.

GAPS OF SEJ FOR VARIOUS


TEMPERATURE AND VARIOUS
TYPE TRACK STRUCTURE.

i.

B.G. 60 Kg PRC sleeper, 1660 nos/km,


r = 13.74 kg/ cm/ rail.

11

ii.

B.G. 60 Kg PRC sleeper, 1540 nos/ km,


12
r = 13.28 kg/cm /rail.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

S.No.

Description

Page

iii.

B.G. 60 Kg ST sleeper, 1540 nos/ km,


r = 12.14kg/ cm/ rail.

13

iv.

B.G. 52 Kg PRC sleeper, 1660 nos/ km,


r = 13.74 kg/ cm/ rail.

14

v.

B.G. 52 Kg PRC sleeper, 1540 nos/ km,


r = 13.28 kg/ cm/ rail.

15

vi.

B.G. 52 Kg ST sleeper, 1540 nos/ km,


r = 12.14 kg/ cm/ rail.

16

vii.

B.G. 52 Kg CST-9 sleeper, 1540 nos/ km,


r = 10.65 kg/ cm/ rail.

17

viii.

B.G. 90 R PRC sleeper, 1540 nos/ km,


r = 13.28 kg/ cm/ rail.

18

ix.

B.G. 90 R ST sleeper, 1540 nos/ km,


r = 12.14 kg/ cm/ rail.

19

x.

B.G. 90 R CST-9 sleeper, 1540 nos/ km,


r = 10.65 kg/ cm/ rail.

20

xi.

M.G. 90 R ST sleeper, 1540 nos/ km,


r = 3.86 kg/ cm/ rail.

21

xii.

M.G. 90 R CST-9 sleeper, 1540 nos/ km,


r = 3.47 kg/ cm/ rail.

22

xiii.

M.G. 90 R ST sleeper, 1540 nos/ km,


r = 3.86 kg/ cm/ rail.

23

xiv.

M.G. 90 R CST-9 sleeper, 1540 nos/ km,


r = 3.47 kg/ cm/ rail.

Handbook on Maintenance of Switch Expansion Joint

24

Dec, 97

CAMTECH/C/04

PREFACE
The track structure on Indian Rlys has now been modernised to
a great extent. The old concept of Rail Joint being a
necessary evil no longer holds true. Rails are now being welded
as long continuous welded rails to provide joint less track with
smooth side.
The officers and supervisors staff of civil engineering
department have since long felt book for maintenance of switch
expansion joints for long welded rails and continuous welded
rails.
Most of the data, sketch and information are available
in some form or other in various books or other printed matter
of various railways. The objective of this handbook is to serve
as a ready reckoner for day to day problems on field with all
standard practices schedules.
A lot of initiative was shown enormous assistance was
received from all technical staff of civil wing.
I shall be grateful to the readers for pointing out errors
if any and invite their valuable suggestions for improving this
handbook in order to enhance its utility.

Gwalior
Date : 10 July,98

R.S.Dubey
Joint Director (Civil)

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

FOREWORD
Indian Railways have a running track of about 81,000 Kms. As
on 31.03.97, 60618 Kms. has been modernised into Welded
Track out of which 31,914 Kms. is with long Continuous
Welded Rails and 28,704 Kms. is with Short Welded Rails.
Due to continuous increase in the amount of LWR and
CWR, the proper maintenance of SEJs has assumed great
importance in the interest of safe and punctual running of
trains.
This handbook has been prepared for the assistance of
field staff by Centre for Advanced Maintenance Technology in
order to consolidate and put together all information related to
maintenance of Switch Expansion Joints. The tables for SEJs
gaps at various temperatures for varying sleeper density and
ballast resistance have been systematically compiled and
produced in the handbook to serve as a useful ready reckoner
for proper maintenance of SEJ.

Gwalior
Date : 20th July, 1998

Handbook on Maintenance of Switch Expansion Joint

D. K. Saraf
Director

Dec, 97

CAMTECH/C/04

SWITCH EXPANSION JOINT(SEJ)


1.

INTRODUCTION
Switch expansion Joint is an expansion joint installed at each
end of LWR CWR to permit expansion contraction of the
adjoining breathing lengths due to temperature variations.

2.

3.

MAINTENANCE OF SEJs

Once in a fortnight SEJs shall be checked by PWI.

Packing & Alignment on SEJ shall be corrected


regularly in every fortnight.

Oiling & greasing of stock rails & tongue rail of SEJ


shall be done..

Tightening or fastening shall be done regularly.

Movement of SEJ shall be checked in every fortnight


if found any abnormal behavior action taken for
destressing of LWR.

GAPS AT SEJ
Gaps at SEJ shall be adjusted at the time of laying/
subsequent destressing of LWR/CWR.
Rail section laid
52 kg/60kg
others

Gap to be provided at td
40mm
60mm

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

The gaps at SEJ at various rail temperatures shall not differ


by more than +/- 20mm from the theoretical range
Where fishplated or SWP track is joined on one side of SEJ,
the gap between the reference mark and tongue rail tip/ stock
rail corner on LWR/CWR side shall not differ by more than
+/- 10mm from half the theoretical range.

4.

DAMAGE TO SWITCH EXPANSION JOINT


The damaged/broken SEJ shall be replaced. The new SEJ
shall be adjusted as per para 3. Traffic may be allowed if
necessary at a restricted speed and thereafter restriction
relaxed progressively.
If damaged SEJ is not available for replacement, both the
damaged SEJ and the undamaged SEJ on the opposite rail at
the same location, shall be replaced by a closure rail and
connected to LWR/CWR with special clamps and fish
plates.
The traffic over the clamped joints may be permitted at the
restricted speed. The restriction may be relaxed only after the
new SEJ has been inserted in the correct position and the
clamped joint has been replaced with in-situweld.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

5.

BUCKLING OF TRACK
General
Buckling or a tendency towards buckling may occur, among
others, in the following circumstances :-

Failure to adhere to the temperature ranges specified


for operation on LWR/CWR.

Inadequate resistance to longitudinal, lateral and


vertical movement of track due to deficiencies in
ballast section or/ and inadequate ballast
consolidation.

Use of ineffective fastenings or missing fastening


resulting in loss of creep resistance and torsional
resistance.

Excessive settlement of formation.

Improper functioning of SEJ.

*****

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE


AND TRACK STRUCTURE
1.

Gaps at SEJ depends on following factors :(a)


(b)
(c)
(d)
(e)
(f)

2.

Longitudinal Ballast Resistance of sleepers


Area of rail section
Modulous of Elasticity (E) for rail steel
Coefficient of linear expansion ( a ) for rail steel
Destressing temperature of the section where
gap at SEJ is required
Initial gap at SEJ at destressing temperature

Values of above variable for Indian Conditions are


tabulated below:
Table - I
PARAMETERS FOR STANDARD I.R. RAIL SECTIONS

(/)

Rail Section

Area
(cm2)

E
(Kg/cm2)

60 Kg (UIC)

78.86

2.15 x 106

1.152 x 10-5

52 Kg

66.15

- do -

- do -

90 R

56.95

- do -

- do -

75 R

47.37

- do -

- do -

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

Table - II
LONGITUDINAL BALLAST RESISTENCE (R) FOR
VARIOUS SLEEPERS AND SLEEPER DENSITY.

Type of sleeper

Longitudinal Ballast Resistance in Kg/cm/rail


Broad Gauge

Metre Gauge

1310 sle- 1540 sleepers/km epers/km


PRC
ST
CST-9
Wooden

12.93
11.48
9.92
7.58

13.28
12.14
10.65
7.97

1660 sleepers/km
13.74
12.68
11.04
8.06

1540 sleeper/ km
-3.86
3.47
5.0

Note : The value given are indicative and can vary


as per site conditions.

Table - III
INITIAL GAP TO BE PROVIDED AT DESTRESSING
TEMPERATURE (td)

Rail Section

Intial gap at Td (mm)

60 Kg(UIC)/ 52 Kg
Other
EXAMPLE

40 mm
60 mm

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

To find out the gap at SEJ at rail temperature of 58C with


the following data :
i)
ii)
iii)
iv)
v)
vi)

Rail section
Type of sleeper
Sleeper density
Temp. zone
Destressing temp.
Gap at SEJ at td

52 kg/m
PRC
1540 sleeper/ km
IV
td = 48C
40 mm

First of all hysteresis curve of movement of tongue/ stock


rail of SEJ will be drawn at different temperatures.

1. Movement of tongue/ stock rail from the stage of


destressing temperature (point O) to the stage of maximum
temperature (point A) for rising trend of temperature will be
= A E2 t2/ 2R

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 48)2 / 2 x


13.28
= 0.557 cm
= 5.57 cm
Hence coordinate of maximum temperature (point A) will be
(td + 28, + 5.57)

2.

Movement of tongue/ stock rail from stage of maximum


temperature (point A) to stage of minimum temperature
(point B) for decreasing trend of temperature will be
= A E2 t2/ 4R
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28
= 2.052 cm
= 20.50 mm
Hence coordinate of minimum temperature (point B) will be
(td + 28-76, + 5.57 - 20.52)

3.

Movement of tongue/ stock rail from stage of minimum


temperature (point B) to stage of maximum temperature
(point A) for increasing trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28
= 2.052 cm
= 20.52 mm

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

Hence coordinate of maximum temperature (point A) will be


(td -48+76, -14.95 + 20.52) or (td + 28, +5.57)
Temperature at which gap at SEJ is required is 58C i.e.
(td +10) C say point P.
4.

Value of movement of tongue/ stock rail at (td + 10) C


point P for falling trend of temperature will be
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 58)2 / 4 x
13.28
= 0.115 cm
= 1.15 mm
Hence coordinate at point P for falling trend of temperature
will be :
(td + 10, +5.57 - 1.15) or (td + 10, +4.42)

5.

In the same way, value of movement of tongue/ stock at


(td + 10) C point P for rising trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (58)2 / 4 x 13.28
= 1.195 cm
= 11.95 mm

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

ABC-

GAP AT SEJ AT DISTRESSING TEMPERATURE (td)


GAP AT SEJ AT 38 C (td + 10C) FOR FALLING
TREND OF TEMP.
GAP AT SEJ AT 38C (td + 10C) FOR INCREASING
TREND OF TEMP.

Hence coordinate at point P for rising trend of temperature


will be :
( td + 10, -14.95 + 11.95) or ( td + 10, - 3.0)

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

10

The calculations done above indicatesthat at temperature td


+ 10C i.e. at 58C, movement of one side of tongue/ stock
rail for decreasing trend of temperature is + 4.42 and for
increasing trend temperature is -3.0 mm.
Hence taking twice of movement of tongue/ stock rail for
each side of SEJ, minimum gap at SEJ for decreasing trend
of temperature at td + 10 i.e. (58C) will be 40 -2 x 4.42 =
31.16 mm and maximum gap at SEJ for increasing trend of
temperature at td + 10 i.e. (58 C) will bw = 40 + 2 x 3.0 =
46 mm.
Note : * value of 40 mm taken as gap at SEJ at destressing
temperature td . In case gap is set as 60 mm value of 60 mm
is to be taken for calculation .
Hence theoretical range of gap at SEJ at 58C shall be
within (31.16 mm to 46 mm). Taking into consideration
allowance as per para 5.6.1 the gap should be (31.16 - 20 =
11.16 mm to 46 + 20 = 66 mm ).
Similarly values of gaps for various temperatures, track
structures, temperature zones etc. can be calculated.

*******

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

11

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC


SLEEPER, 1660 Nos/Km, VALUE OF r (BALLAST RESISTANCE) ASSUMED
= 13.74 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg. rails and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

--

28

td + 25

--

--

30

28 to 31

td + 20

--

34

30 to 35

28 to 31

td + 15

36

34 to 38

31 to 40

29 to 42

td + 10

37 to 40

34 to 42

32 to 45

30 to 47

td + 05

37 to 44

35 to 46

33 to 49

32 to 51

td

38 to 47

37 to 50

35 to 53

34 to 55

td - 05

40 to 49

39 to 53

37 to 56

36 to 59

td - 10

41 to 51

41 to 55

40 to 59

39 to 62

td - 15

44 to 53

43 to 57

43 to 62

42 to 65

td - 20

46 to 55

46 to 59

46 to 64

46 to 67

td - 25

49 to 56

50 to 61

50 to 66

50 to 69

td - 30

53 to 56

54 to 62

54 to 67

54 to 71

td - 35

56

58 to 62

59 to 68

59 to 71

td - 40

--

62

64 to 69

64 to 73

td - 45

--

--

69

70 to 74

td - 48

--

--

--

74

Note :

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

12

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.28 kg/cm/rail AND td = tm + 5 C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

--

27

td + 25

--

--

30

27 to 28

td + 20

--

33

30 to 35

27 to 31

td + 15

36

34 to 38

31 to 40

28 to 37

td + 10

36 to 40

34 to 43

32 to 45

30 to 42

td + 05

37 to 44

35 to 46

33 to 50

32 to 52

td

38 to 47

37 to 50

35 to 53

34 to 56

td - 05

40 to 50

39 to 53

37 to 57

36 to 60

td - 10

41 to 52

41 to 56

40 to 60

39 to 63

td - 15

44 to 54

44 to 58

43 to 63

42 to 66

td - 20

46 to 55

47 to 60

46 to 65

46 to 67

td - 25

50 to 56

50 to 61

50 to 67

50 to 70

td - 30

53 to 57

54 to 62

55 to 68

55 to 72

59 to 69

60 to 73

td - 35

57

56 to 63

td - 40

--

63

65 to 70

65 to 74

td - 45

--

--

70

72 to 75

td - 48

--

--

--

75

Note :

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

13

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg ST


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 12.14 kg/cm/rail AND td = tm + 5C to tm + 10C kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

--

26

td + 25

--

--

29

26 to 30

td + 20

--

33

29 to 35

26 to 36

td + 15

36

33 to 38

30 to 40

27 to 42

td + 10

36 to 40

34 to 43

31 to 46

29 to 48

td + 05

37 to 44

35 to 47

32 to 50

31 to 53

td

38 to 47

36 to 51

34 to 55

33 to 57

td - 05

40 to 50

38 to 54

37 to 59

36 to 61

td - 10

41 to 53

41 to 57

42 to 62

39 to 65

td - 15

44 to 55

44 to 60

43 to 65

43 to 68

td - 20

47 to 56

47 to 62

46 to 67

47 to 71

td - 25

50 to 58

51 to 63

51 to 69

51 to 73

td - 30

54 to 58

55 to 64

56 to 71

56 to 75

td - 35

58

61 to 72

72 to 77

td - 40

--

65

67 to 73

68 to 77

td - 45

--

--

73

74 to 78

td - 48

--

--

--

78

Note :

60 to 65

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

14

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg PRC


SLEEPER, 1660 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.74 kg/cm/rail AND td = tm + 5C to tm + 10 C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

--

29

td + 25

--

--

31

29 to 32

td + 20

--

35

32 to 36

30 to 37

td + 15

37

35 to 39

32 to 40

30 to 42

td + 10

37 to 40

35 to 42

33 to 44

32 to 46

td + 05

38 to 43

36 to 45

34 to 48

33 to 50

td

39 to 46

37 to 48

36 to 51

35 to 53

td - 05

40 to 48

39 to 51

38 to 54

37 to 56

td - 10

41 to 50

41 to 53

40 to 57

39 to 59

td - 15

43 to 51

43 to 55

42 to 59

42 to 61

td - 20

45 to 53

46 to 57

45 to 61

45 to 64

td - 25

48 to 53

48 to 58

49 to 62

49 to 65

td - 30

51 to 54

52 to 59

52 to 64

52 to 67

55 to 59

56 to 64

57 to 68

td - 35

54

td - 40

--

59

60 to 65

61 to 69

td - 45

--

--

65

66 to 69

td - 48

--

--

--

69

Note :

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparison of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

15

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg PRC


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.28 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

-- 29

td + 25

--

--

31

29 to 32

td + 20

--

34

31 to 36

29 to 37

td + 15

37

34 to 38

32 to 40

30 to 42

td + 10

37 to 40

35 to 42

33 to 44

31 to 46

td + 05

38 to 43

36 to 46

34 to 48

33 to 50

td

39 to 46

37 to 49

36 to 52

34 to 54

td - 05

40 to 48

39 to 51

38 to 55

37 to 57

td - 10

41 to 50

41 to 54

40 to 57

39 to 60

td - 15

43 to 52

43 to 55

42 to 60

42 to 62

td - 20

46 to 53

46 to 57

46 to 62

45 to 64

td - 25

48 to 54

49 to 58

50 to 63

49 to 66

td - 30

51 to 54

52 to 59

53 to 64

53 to 68

56 to 60

57 to 65

57 to 69

td - 35

55

td - 40

--

60

61 to 66

td - 45

--

--

66

td - 48

--

--

--

Note :

62 to 69
67 to 70
70

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparison of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

16

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg ST


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 12.14 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV
28

td + 28

--

--

--

td + 25

--

--

30

td + 20

--

34

30 to 36

28 to 37

td + 15

37

34 to 38

31 to 40

29 to 42

28 to 31

td + 10

37 to 40

35 to 42

32 to 45

30 to 47

td + 05

37 to 44

36 to 46

33 to 49

32 to 51

td

38 to 46

37 to 49

35 to 53

34 to 55

td - 05

40 to 49

39 to 52

37 to 56

36 to 58

td - 10

41 to 51

41 to 55

40 to 59

39 to 62

td - 15

44 to 53

43 to 57

43 to 61

40 to 64

td - 20

46 to 54

46 to 59

46 to 64

46 to 67

td - 25

49 to 55

50 to 60

50 to 65

52 to 69

td - 30

52 to 56

53 to 61

54 to 67

54 to 70

td - 35

56

58 to 68

59 to 71

td - 40

--

62

63 to 68

64 to 72

td - 45

--

--

68

69 to 73

td - 48

--

--

--

73

Note :

57 to 62

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparison of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

17

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg CST-9


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 10.65 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 28

--

--

--

26

td + 25

--

--

29

26 to 30

td + 20

--

33

29 to 35

27 to 36

td + 15

36

33 to 38

30 to 40

28 to 42

td + 10

36 to 40

34 to 43

31 to 46

td + 05

37 to 44

35 to 47

32 to 50

30 to 52

td

38 to 47

36 to 51

34 to 54

33 to 57

td - 05

40 to 50

38 to 54

37 to 58

36 to 61

td - 10

42 to 53

41 to 57

42 to 61

39 to 65

td - 15

44 to 55

44 to 59

43 to 64

43 to 68

td - 20

47 to 56

47 to 61

47 to 67

47 to 70

td - 25

50 to 57

51 to 63

51 to 69

51 to 73

td - 30

54 to 58

55 to 64

56 to 70

56 to 74

td - 35

58

61 to 71

61 to 76

td - 40

--

65

66 to 72

td - 45

--

--

72

73 to 77

td - 48

--

--

--

77

Note :

62 to 65

29 to 48

67 to 77

The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparison of gaps at site.

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

18

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R PRC


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.28 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

47

td + 30

--

--

49 47 to 49

td + 25

--

52

td + 20

55

49 to 53

53 to 56

50 to 57

47 to 54
48 to 58

td + 15

55 to 58

53 to 59

50 to 60

49 to 61

td + 10

56 to 60

54 to 62

51 to 64

50 to 65

td + 05

57 to 63

55 to 65

53 to 67

51 to 68

td

58 to 65

56 to 67

54 to 69

53 to 71

td - 05

59 to 67

58 to 69

56 to 71

56 to 73

td - 10

61 to 68

60 to 71

59 to 73

58 to 75

td - 15

63 to 69

62 to 72

61 to 75

61 to 77

td - 20

65 to 70

65 to 73

64 to 77

64 to 79

td - 25

67 to 70

67 to 74

67 to 78

67 to 80

td - 30

70

71 to 74

71 to 78

71 to 81

td - 35

--

74

75 to 79

75 to 82

td - 40

--

62

79

79 to 82

td - 43

--

--

--

82

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

19

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R ST


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 12.14 kg/cm/rail AND td = tm + 5 C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

45

td + 30

--

--

48

45 to 48

td + 25

--

52

48 to 52

46 to 53

td + 20

55

52 to 55

49 to 57

47 to 58

td + 15

55 to 58

52 to 59

49 to 61

48 to 62

td + 10

55 to 61

53 to 62

51 to 64

49 to 65

td + 05

56 to 63

54 to 65

52 to 67

51 to 69

td

57 to 65

56 to 68

54 to 70

53 to 72

td - 05

59 to 67

58 to 70

56 to 73

55 to 74

td - 10

61 to 69

60 to 72

59 to 75

58 to 77

td - 15

63 to 70

62 to 73

62 to 77

61 to 79

td - 20

65 to 71

65 to 74

65 to 78

64 to 81

td - 25

68 to 71

68 to 75

68 to 79

68 to 82

td - 30

71

72 to 80

72 to 83

td - 35

--

76

76 to 81

76 to 84

td - 40

--

--

81

81 to 84

td - 43

--

--

--

84

72 to 76

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

20

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R CST - 9


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 10.65 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

43

td + 30

--

--

46

43 to 47

td + 25

--

50

46 to 51

44 to 52

td + 20

54

51 to 55

47 to 56

45 to 57

td + 15

54 to 58

51 to 59

48 to 61

46 to 62

td + 10

55 to 61

52 to 62

49 to 65

47 to 66

td + 05

56 to 64

54 to 66

51 to 68

49 to 70

td

57 to 66

55 to 69

53 to 71

52 to 73

td - 05

59 to 68

56 to 74

54 to 76

td - 10

61 to 70

61 to 73

58 to 77

57 to 79

td - 15

63 to 71

63 to 75

62 to 79

61 to 81

td - 20

66 to 72

66 to 76

65 to 81

65 to 83

td - 25

69 to 73

69 to 77

69 to 82

69 to 85

td - 30

73

73 to 83

73 to 86

td - 35

--

78

79 to 83

79 to 87

td - 40

--

--

84

84 to 87

td - 43

--

--

--

87

57 to 71

73 to 78

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

21

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 3.86 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

14

td + 30

--

--

22

14 to 24

td + 25

--

34

23 to 36

16 to 38

td + 20

43

34 to 46

24 to 49

18 to 52

td + 15

44 to 53

36 to 57

27 to 62

21 to 65

td + 10

45 to 62

38 to 67

31 to 73

25 to 77

td + 05

48 to 70

42 to 76

35 to 83

31 to 87

td

52 to 77

47 to 84

41 to 92

37 to 97

td - 05

56 to 83

53 to 91

48 to 99

45 to 105

td - 10

62 to 87

59 to 96

56 to 106

53 to 113

td - 15

69 to 91

67 to 101

65 to 112

63 to 119

td - 20

77 to 94

76 to 105

75 to 117

73 to 125

td - 25

86 to 95

86 to 107

86 to 121

85 to 129

td - 30

96

97 to 109

98 to 123

98 to 132

td - 35

--

109

111 to 125

111 to 134

td - 40
td - 43

--

--

125

127 to 136

--

--

--

136

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

22

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 3.47 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

td + 30

--

--

18

9 to 24

td + 25

--

31

18 to 34

11 to 36

td + 20

41

31 to 44

20 to 48

13 to 51

td + 15

42 to 52

33 to 56

23 to 62

17 to 65

td + 10

44 to 62

36 to 68

27 to 74

21 to 78

td + 05

47 to 71

40 to 78

32 to 85

27 to 90

td

51 to 79

45 to 86

39 to 95

35 to 101

td - 05

56 to 85

52 to 94

47 to 104

43 to 110

td - 10

62 to 90

59 to 100

55 to 112

52 to 119

td - 15

70 to 95

68 to 106

65 to 118

63 to 126

td - 20

79 to 97

78 to 110

76 to 123

75 to 132

td - 25

89 to 99

89 to 113

89 to 127

88 to 137

102 to 114

102 to 130

102 to 140

td - 30

100

td - 35

--

115

117 to 132

117 to 143

td - 40

--

--

133

134 to 144

td - 43

--

--

Handbook on Maintenance of Switch Expansion Joint

--

144
Dec, 97

CAMTECH/C/04

23

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 3.86 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

22

td + 30

--

--

28

22 to 30

td + 25

--

38

29 to 40

23 to 42

td + 20

46

39 to 48

30 to 51

25 to 54

td + 15

46 to 54

40 to 57

23 to 61

28 to 64

td + 10

48 to 62

42 to 66

35 to 71

31 to 74

td + 05

50 to 68

45 to 73

39 to 79

37 to 83

td

53 to 74

49 to 80

44 to 86

41 to 91

td - 05

57 to 79

54 to 85

50 to 93

47 to 98

td - 10

62 to 83

60 to 90

57 to 99

54 to 104

td - 15

67 to 86

66 to 94

64 to 103

62 to 109

td - 20

74 to 88

74 to 97

72 to 107

71 to 114

td - 25

81 to 99

82 to 99

81 to 110

84 to 117

td - 30

90

92 to 113

91 to 120

td - 35

--

101

102 to 114

103 to 122

td - 40

--

--

125

115 to 123

td - 43

--

--

--

123

91 to 101

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

24

GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9


SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 3.47 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure

Zone I

Zone II

Zone III

Zone IV

td + 33

--

--

--

18

td + 30

--

--

25

18 to 26

td + 25

--

36

25 to 38

19 to 40

td + 20

44

36 to 47

27 to 50

21 to 53

td + 15

45 to 54

38 to 57

29 to 61

24 to 65

td + 10

46 to 62

40 to 66

33 to 72

28 to 75

td + 05

49 to 69

43 to 75

37 to 81

33 to 85

td

52 to 76

48 to 82

42 to 89

39 to 94

td - 05

57 to 81

53 to 88

49 to 97

46 to 102

td - 10

62 to 85

60 to 94

56 to 103

54 to 109

td - 15

68 to 89

67 to 98

64 to 108

62 to 115

td - 20

76 to 91

75 to 101

74 to 113

72 to 120

td - 25

84 to 93

84 to 104

84 to 116

83 to 124

td - 30

93

95 to 118

95 to 127

td - 35

--

106

107 to 120

108 to 129

td - 40

--

--

120

121 to 130

td - 43

--

--

--

130

95 to 105

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

**

25

Movement of rail shall be positive in the direction of


traffic on double lines and in the direction of heavier
traffic on single lines which shall be specified.
(a) and (b) will almost always be positive.
Left and right rails on single lines are determined,
looking in the direction of increasing kilometrage.
The reference line for each SEJ shall be marked by two
rail pieces in such away that it is central with respect to
the tip of the tongue and the edge of the foot of stock
rail where planning ends (a+b) at the time of
destressing done immediately after laying of LWR/
CWR. The following line should not be shifted at any
subsequent destressing.
The reference marks at the centre of LWR/ CWR shall
consist of (a) saw marks on the rail pieces fixed as
reference pillars on the cess and (b) paint marks on the
non-gauge side of the rail heads of the LWR/ CWR
rails. Additional reference pillars may erected to
observe the behaviou of movement of LWR/ CWR.
***

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

26

NOTES

Handbook on Maintenance of Switch Expansion Joint

Dec, 97

CAMTECH/C/04

27

OUR OBJECTIVE

To upgrade Maintenance
Technologies and Methodologies
and achieve improvement in
productivity and performance
of all Railway assets and manpower
which inter-alia would cover
Reliability, Availability,
and Utilisation.

If you have any suggestion & any specific comments,


please write to us :
Contact person

Jt. Director (Civil)

Postal
Address

:
:

Centre for Advanced


Maintenance Technology,
Maharajpur, Gwalior (M.P.)
Pin code 474 020

Phone
Fax

:
:

(0751) - 470869, 470803


(0751) - 470841

Handbook on Maintenance of Switch Expansion Joint

Dec, 97