SOUTHERN RAILWAY

CE’S CIRCULAR NO.01/2011

Sub: Corrosion of rails and welds – preventive measures.

1.0 GENERAL RAIL CORROSION:

Corrosion of rails occur in coastal areas (due to salinity), tunnels and cuttings (due
to dampness), vicinity of industrial areas (due to chemical pollution), sidings (due
to handling of corrosion causing goods), platform lines (due to sweeping of dust
from the platforms). Corrosion reduces the cross section area of the rail primarily at
the bottom flange.

2.0 CORROSION OF THE LINER SEAT:

Corrosion takes place on the inside of track due to outfall from the restrooms of
passenger carrying coaches. Corrosion is aggressive in sections where density of
passenger/express trains is more during the early morning hours particularly at
major stations/junctions where these trains stop and also at the approaches where
trains are slowed down.

2.1 Classification of sections based on corrosion proneness:

The preventive measures required to protect the rails from corrosion shall depend
on the corrosion proneness of each section. The sections on this Railway shall be
classified based on corrosion proneness into 3 groups viz. (i) Very severe corrosion
prone locations; (ii) Severe corrosion prone locations and (iii) Moderate corrosion
prone locations. The periodicity of protective measures shall depend on the severity
of corrosion at various locations in each section:

2.1.1 Very severe corrosion prone locations:

These are the locations where corrosion is very severe viz. (1) locations where
general rail corrosion is high such as coastal areas, tunnels, cuttings, vicinity of
industrial areas, sidings, platform lines, etc. (2) The locations where the liner seat
corrosion is very severe such as approach of important stations where number of
express trains stop and sections where large number of express trains run during the
early morning hours. The sections and locations where the liner seat corrosion
recorded is more than 3mm in 3 years shall be classified under this group. As per
the details available in this office, the following sections shall fall under this group:

a) SPE-MAS Up line
b) MS-TBM-CGL up line
c) CGL-VM Up line (presently single line)
d) MAS-AJJ up fast line
e) MAS-PER Dn fast line
f) Mandapam – Pamban
g) IGU-CBE Dn line
h) Yard lines of stations where large number of express trains stops and approaches -
to be identified by divisions.
i) Platform lines at stations - to be identified by divisions.
Signature Not j) Any other locations/sections to be decided by Sr.DEN/Co based on measurement of
Verified corrosion and to be approved by CTE.
Digitally signed by
MANOHARAN S
Date: 2018.05.28
17:03:01 IST
1
Reason: IREPS-CRIS
Location: New Delhi
 2.1.2 Severe corrosion prone locations:
All sections where liner seat corrosion recorded is between 1mm and 3 mm in 3
years shall be classified under this group. All sections which are not falling under
very severe corrosion prone locations and moderate corrosion prone locations shall
fall under this group. The severe corrosion prone locations in moderate corrosion
prone sections shall be identified periodically and be approved by Sr.DEN/Co of the
divisions.

2.1.3 Moderate corrosion prone locations:

The sections where liner seat corrosion recorded in 3 years is less than 1mm shall
fall under this group. As per the details available in HQ, the following sections
shall be classified under this group:

MAS Division: AJJ-CGL; MAS-AJJ (Slow line-UP&DN); MS-TBM (slow

line Up & Down) MSB-VLCY
SA Division: CBF-MTP; MTP-ONR-UAM; KRR-DG; VRI-SXT;
MGSJ-MTDM
PGT Division: SRR-NIL
TVC Division: NCJ-CAPE; TCR-GUV
MDU Division: TPJ-KKDI-MNM-RMD; MDU-MNM, MNM-VPT; VPT-TSI;
TEN-TSI; TEN-PUU-QLN; TEN-TCN, MEJ-TN
TPJ Division: VRI-CUPJ, TJ-TVR-NCR-VLKN, VM-VLR, VM-PDY

Any other line constructed as new line or under doubling and gauge converted
sections shall also fall initially under this category.

2.1.4 Classification of the sections based on the corrosion proneness as mentioned above
shall be reviewed every year depending on the corrosion recorded. The locations
classified under each group shall be recorded in the section register being
maintained by each SE/P.Way/incharge

2.2. Measurement of liner seat corrosion:

SE/JE P.Way shall record the liner seat corrosion at every 100m and the details
shall be recorded in the following proforma in the register. The corrosion details
recorded by SE/JE p.way shall be test checked atleast 5% by ADEN & DEN in each
block section. 5% test check by DEN should be done at the locations other than 5%
test check done by ADEN.

Date of Engine Line Bet. km Location Rail Lowest Lowest Reduction Action
measure run Up/ Stations secti thickness thickness of in width initiated
ment section Dn Hectometer rail flange at of bottom
No.
on of rail the original flange
& flange at liner seat
UTS the present locations after
liner seat shifting/interch
* anging *
From To Left Right Left Right Left Rig
rail rail rail rail rail ht
rail

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 * The reduction in width of bottom flange need not be considered for measurement
of minimum thickness of rail flange.
Corrosion shall be recorded once in a year in very severe corrosion prone locations
and severe corrosion prone locations and once in 2 years in moderate corrosion
prone locations.

3.0 PREVENTIVE MEASURES TO REDUCE CORROSION OF RAILS

3.1 General
(i) Ensure 100% complete and tight track fastening and earth bonds.
(ii) Ensure rail foot is away from stagnated water and ballast.
(iii)Ensure that drainage condition is good and anti-corrosive treatment is given to all
parts of fastening of rail, prone to corrosion.
(iv) Ensure that corrosion of rail is controlled by various measures such as greasing of
liner seats, sealing of liner seat, painting of rails, shifting of liner seats etc.

3.2 Shifting of corroded liner seats:

By shifting the corroded liner seats from its original location, the locations affected
by liner biting where the rail foot got reduced due to corrosion gets shifted away
from the liner seat and a new location with normal thickness at rail foot comes
under the liner seat and avoid further corrosion of the corroded liner seat.

This is done in two ways.

3.2.1 Longitudinal shifting of the rail:
In longitudinal shifting the corrosion affected portion is shifted between the
sleepers. This shall preferably be done when the rail is relatively new and reduction
at the bottom flange is less than 2 mm. However, where the minimum thickness of
flange anywhere at liner seat is more than 4 mm which is to be certified by ADEN
before taking up the work, longitudinal shifting may be resorted to. When the
minimum thickness is less than 6 mm, but more than 4 mm, the shifting shall be
done duly taking the precaution of ensuring these corroded liner seat locations
within 100 to 200 mm from center of sleepers to avoid these locations falling either
at the location of maximum shear force or at the maximum bending moment
locations.

This shifting of liner seats shall be done by 150 mm systematically along

with destressing once in every 4 years in moderate corrosion prone locations and
once every 3 years in severe corrosion prone locations and once in every 2 years in
very severe corrosion prone locations. Such shifting of liner seat can be done 3
times if systematically done before liner seat corrosion exceeds permissible limits
as above. However, if in view of the special precautions suggested above in case of
minimum thickness between 4 mm and 6 mm, only two such shifting is feasible
duly avoiding the shift to the center of sleepers.

3.2.2 Interchanging of rails:

Interchanging of rails may be done when the rail is relatively old and shifting of
liner seat from all sleepers is not practical i.e. where shifting of liner seat will not
result in all liner seats to be away from the sleepers such as increasing sleeper
density locations and locations where liner seat got shifted non-uniformly during
casual renewal, destressing, TWR etc. Interchanging of rail shall not preferably
be done if minimum thickness of bottom flange is less than 4 mm either at
present liner seat or shifted liner seat locations.. However, interchanging may

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 be done if minimum thickness is between 2 mm and 4 mm to avoid further
corrosion till TRR is done provided the liner seats are not shifted from the
sleepers which can be done only if special care is taken by conducting detailed
survey before doing the work to ensure the same. In curved track while
interchanging rails, the location of liner seating cannot be maintained at any desired
location. Hence, interchanging shall not be resorted to if minimum thickness of
bottom flange is less than 4 mm in curves.

3.2.3 If the reduction in width of bottom flange at any location of liner seat exceed 7
mm, shifting of liner seats or interchanging of rails shall not be resorted to.

3.3 Destressing of LWR and CWR:

Para 6.4 of Manual of Instructions of long welded rails deals with destressing
during maintenance. Though the periodicity for destressing is not mentioned in the
LWR manual, destressing shall be done as per the following periodicity to avoid
corrosion of rails at the liner seats:
(i) In very severe corrosion prone areas, destressing shall be done once in 2 years;
(ii) In severe corrosion prone areas, destressing shall be done once in 3 years;
(iii) In moderate corrosion prone areas destressing may be done once in 4 years;

Destressing of LWR shall be done by cutting and removing the rails for a length of
150 mm or in multiples of sleeper spacing +150 mm so as to ensure shifting of liner
seat by 150mm uniformly at all locations during the process of destressing.

3.4 Painting of Rails with anti-corrosive bitumen black paint as per IS:9862

3.4.1. Surface preparation:

The surface preparation of rails is one of the most important pre-requisite for the
painting to serve the purpose. Sufficient care should be taken in preparing the
surface and is, therefore, required to be done under proper supervision. The surface
shall be made free from oil, grease and dust. The surface shall be rubbed with wire
brush and sand paper etc. The tools used may be hand or power operated such as
light hammers, scrappers, wire brushes, sand paper, pumice stones etc. Wire
brushing should invariably be done at the end so as to obtain a uniform rubbed
surface. The surface prepared may be checked by visual observation for uniformity
of surface.

3.4.2 Special care should be taken in preparing the surface at the weld collars.
Generally weld collars are considered severe corrosive areas.

3.4.3 Surface preparation/painting shall not be done in the following conditions:

i) When the ambient temperature is below 10º centigrade or above 50º centigrade.
ii) In rainy season.
iii) Extremely windy/misty/dust blowing conditions.
iv) Chemicals should not be used for surface preparation.

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3.4.4 Painting scheme:
i) 1st coat: Anti corrosive bituminous black paint conforming to IS:9862-1981
ii) 2nd coat: Anti corrosive bituminous black paint conforming to IS:9862-1981.

3.4.5 Periodicity of painting during laying and maintenance shall be as follows:

Painting of rails shall invariably be done at the time of initial laying of rails.
Painting of SKV welds over the weld collar and 100 mm on either side shall be
done immediately after welding. Painting of flash butt welds will get automatically
covered along with the painting of rails at the time of initial laying. Painting of rails
during maintenance shall include painting of welds both SKV and FBW as per the
periodicity given below:

i) Painting of both inside and outside of the rails shall be done once in a year in
very severe corrosion prone locations.
ii) Painting of inside of rail in severe corrosion prone locations shall be done once in a
year.
iii) Painting of rails on outside of rail in severe corrosion prone locations and both
inside and outside in moderate corrosion prone locations need not be done.
However painting of welds (both SKV & FBW) shall be done on inside of track
once in a year in moderate corrosion prone locations.

3.5 Greasing:

3.5.1 General

The following precautions to be taken for greasing.

(i) DO not use untested grease. Grease must have oxidation stability and rust
inhibitors.
(ii) Apply recommended cleaning agent and rust inhibitors before anticorrosive
treatment.
(iii)Use preferably mechanized cleaning brush to scrap the rusted surface.
(iv) Greasing shall not be done in rainy condition and hot weather conditions.

3.5.2 Greasing of ERCs, inserts, liner seats including sealing of liners:

Greasing of ERCs, inserts, liner seats including sealing of liners shall be done at the
time of initial laying and along with through fitting renewal and/or destressing and
during maintenance as per the periodicity given in Para 3.5.2

Graphited grease grade ‘O’ to IS 408 shall be applied on under side of liners as also
the corresponding area of the rail foot in addition to the central leg of elastic rail
clips. To avoid ingress of toilet droppings as well as moisture to the surface of liner
and the rail foot, grease shall also be applied along with the boundary of liner so as
to seal the liner boundary.

3.5.3 Periodicity of greasing during maintenance shall be as follows:

In very severe corrosion prone locations – greasing (both inside and outside) shall
be done once in 6 months.

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 In severe corrosion prone locations – greasing shall be done once in a year only on
inside of track. Since the corrosion due to toilet droppings is almost ‘nil’ on outside
of track, greasing on outside of track may be done only along with destressing, TFR
etc.

In moderate corrosion prone locations, greasing of inside of track may be done once
in 2 years and greasing of outside of track need be done along with destressing
and/or TFR.

3.5.4 Greasing of plate screws at points & xings and at guard rails of bridges shall be done
at the time of initial laying and also during maintenance once every six months, one
year and 2 year in very severe, severe and moderate corrosion prone locations
respectively.

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4.0 Schedule of preventive measures to reduce corrosion of rails is summarised
and given below:

Measures Very severe Severe Moderate

(Corrosion more (Corrosion between (Corrosion less
than 3 mm in 3 1 and 3 mm in 3 than 1 mm in 3
years) years) years)

Classification criteria

Measurement of liner Once in a year. Once in a year. Once in 2 years.

seat corrosion

Destressing & Once in 2 years. Once in 3 years. Once in 4 years.

longitudinal shifting
of liner seats*

Painting of rails Once in a year Once in a year Painting of welds

both inside & inside only. (SKV & FBW) on
outside. inside once in a
year

Greasing of ERCs, Once in 6 months Once in a year Once in 2 years

inserts, liner seats both inside & inside only. inside only.
including sealing of outside.
liners Once in 3 years on Once in 4 years
outside along with on outside along
destressing . with destressing.

Greasing of plate Once in 6 months Once in a year Once in 2 years

screws at points and
crossings and at
guard rails of bridges

* Shifting of liner seat from the insert location shall not be done if the minimum
thickness of flange anywhere at liner seat is less than 4mm.

5. The requirement of grease grade ‘O’ to IS 408 and anti corrosive bituminous black
paint to IS 9862-1981 shall be estimated by each division and the estimated annual
requirement (EAR) shall be advised to COS though the concerned divisional stores depot
for procurement and supply.

(Dani Thomas)
Chief Track Engineer.

No.W.506/14/Circular Dated: 10.01.2011.

Copy to: CPDE CGE CE/TP CE/WORKS CE/WS

CAO/CN/MS Secy. to PCE
Sr.DENs/MAS SA PGT TVC TPJ & MDU SRCETC/TBM
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 nùÎIhÉ ®äú±É´Éä/Southern Railway

|ÉvÉÉxÉEòɪÉÉDZɪÉ/Headquarters Office,
ºÉÆEò®ú¨É ¶ÉÉJÉÉ/Works Branch,
{ÉÉEäò ]õÉ=xÉ/Park Town,
SÉäxxÉè-3/ Chennai 600 003.

ʨÉÊºÉ±É ºÉÆJªÉÉ / W.506/14/Corrosion ÊnùxÉÉÆEò:/Dt . 06.04.2011

Sr.DEN/ Co.Ord/ MAS, SA, PGT, TVC, TPJ & MDU.

×¾ÖÂÖµÖ /Sub :Correction Slip No.1 to CE Circular No.01/2011.

****
CE Circular No.01/2011 was issued vide letter No.W.506/14/Circular dt.10.01.2011.
Following is the correction slip no.1 to the above circular.

Para No. As available in the circular To be read as

3.4.5 (ii) Painting of inside of rails in severe
corrosion prone locations shall be
done once in a year
4 Painting of rails for severe
corrosion prone area : Once in a
year inside only
3.4.5 (iii) Painting of Rails on out side of rail
in severe corrosion prone locations
and both inside and outside in
moderate corrosion prone
locations need not be done.
However, painting of welds (both
SKV & FBW) shall be done on inside
of track once in a year in moderate
corrosion prone locations.
The para to be deleted
Painting of rails in severe
corrosion area :
Painting of welds (SKV & FBW) on
inside once in a year.
Painting of Rails on both inside
and outside in severe corrosion
prone locations and in moderate
corrosion prone locations need
not be done. However, painting of
welds (both SKV & FBW) shall be
done on inside of track once in a
year in severe and moderate
corrosion prone locations.

You are advised to notify all concerned the above.

(›ê−Öß £ÖÖê´ÖÃÖ / Dani Thomas)

Chief Track Engineer
EÞòiÉä ¨ÉÖJªÉ <ÆVÉÒxÉҪɮú ºÉ¨Éx´ÉªÉ

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email : cte@sr.railnet.gov.in Rly Ph: 22543 BSNL:Tele/Fax 044-2535 1157

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