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TechnicalStandardsofTrackStructureforMetroRailways/MRTS
1. Scope:
Tostipulatethedesirabletechnicalstandards/specificationsfortrackstructurefor
MetroRailways/MRTSSystemsinthecountry.
2. OperatingEnvironment:
TrackStructureshouldfulfilgenerallythefollowingconditions:
2.1GaugeBroadgauge1676/1673mm(nominal)andstandardgauge1435mm.
2.2 RailSeatinclination(slope):1in20
2.3Speedpotential110kmph(max.)
2.4Staticaxleload20T(max.)
2.5 Designrailtemperaturerange()10degreeCelsiusto(+)70degreeCelsius
2.6 MaximumCurvatureandrulinggradientAsspecifiedinSOD
3. TrackStructure:
3.1 General:Thetrackstructureshouldfulfilthefollowingrequirements:
3.1.1Thetrackstructureshouldconformto/satisfyScheduleofDimensionrequirement
andothermaintenanceinstructionsofMetrosystems.
3.1.2Ridecomfortandrunningsafetyoftrackvehicledynamicsshouldbesatisfied.
3.1.3ThetrackstructureshouldbedesignedwithLongwelded/Continuouslywelded
railonmainlinetrackincaseofballastedaswellasballastlesstrack.
3.1.4 The horizontal alignment shall consist of a series of straights joined to circular
curves generally with transition curves. Curvature and cant shall be calculated
based on the train speed for each train type on the section. Compound and
reverse curves are acceptable, provided they are connected by an adequate
transitioncurve.
3.1.5 The vertical alignment should be designed to achieve a smooth profile line with
gradual changes. Changes in the profile should be connected by vertical curves,
which shall be as generous in length as the location allows. Vertical curves
including its transition shall not be located at stations within the length of
platform.AverticalcurvewithinthelengthoftransitionandTurnoutsisalsonot
desirable. Vertical curve radius is constrained by the need to limit the vertical
accelerationforpassengerridecomfort.
3.2ThetechnicalstandardsforTrackstructuredealswiththefollowingcomponents
(i) RailandWelding
(ii) Sleeperandfasteningforballastedtrack
(iii) Trackslabforballastlesstrack
(iv) Fasteningsystemforballastlesstrack
(v) InsulatedGluedjoint
(vi) Turnout,scissorscrossover
(vii) SwitchExpansionJoints
AnnexureIVpage1of11
4. RailsandRailWelding:
4.1 Rails:
4.1.1 ForMainlineTrack:
4.1.1.1 TherailusedonmainlineoncurvesandapproachesofStationsshallbe60E1
(UIC60),1080gradeHeadHardened.
4.1.1.2 Atotherlocationsonstraightlineofmainline,theuseof60E1(UIC60),1080
gradeHH/60E1(UIC60), 880graderailshallbe decidedbyMetroRailway
dependinguponspeed,axleloadandotherfactorspertainingtosafetyand
lifeofrail.Howeveroncurveswithsmallstraighttrackinbetween,the60E1
(UIC 60), 1080 grade Head hardened rail should be continued on straight
patchesalso.
4.1.1.3 Itisessentialtohavepreventiverailgrindingarrangementsincase60E1(UIC
60),1080HHrailsareused.
4.1.2 ForDepotlines:
Therailusedondepotlinescanbenonheadhardenedandshallbe60E1(UIC
60),880grade.
4.1.3 Specification:
4.1.3.1 The rail shall be class A rails as per IRST122009 specification with latest
amendments. However, any suitable length of rail more than 13 m
considered appropriate by metro on consideration of transportation and
handling can be adopted, providedthe rails are ultimately welded into long
weldedrails.
4.2 Weldingofrail:
4.2.1 The welding of rails should conform to Indian Railway specifications and
technicalinstructionsissuedfromtimetotime.
4.2.2 Thepresentinstructionsarecontainedinfollowingdocuments:
4.2.2.1 AluminoThermitWelding:
(i) Indian Railway Standard specifications for Alumino Thermit Welding of
Rails(IRS/T19withlatestamendments)
4.2.2.2 FlashButtWelding:
AnnexureIVpage2of11
ManualforFlashButtWeldingofRails,January2012withlatestamendments.
5.2Fasteningsystem:
TheelasticfasteningsystemprevalentonIndianRailwaysshallbeuseddulyensuring
theInspectionprotocolforfasteningcomponentslaiddownforIR.
In case of use of elastic fastening other than in use on IR, prior approval shall be
obtainedfromRailways.
6. TrackslabforBallastlesstrack
6.1Trackshallbelaidoncastinsitu/precastreinforcedplinthorslab,hereinreferredtoas
thetrackslab.Thetrackslabshallbedesignedasplinthbeamorslabtypeballastless
track structure with derailment guards. It shall accommodate the base plates of the
fasteningsystem.
6.2Ingeneral,trackslab(includingsleeper,ifany)onwhichthefasteningandrailaretobe
fittedshallperformthefollowingfunctions:
i) Resistthetrackforces.(Staticanddynamic)
ii) Have adequate edge distance of concrete beyond the anchor bolts to provide
resistanceagainstedgefailure
iii) Providealevelbaseforuniformtransmissionoftrack/railforces.
iv) Havegeometricalaccuracyandenableinstallationoftracktothetoleranceslaid
down.
v) Ensuredrainage.
vi) Resistweathering.
AnnexureIVpage3of11
8.2 The lateral clearance between the running rail and the derailment guard shall be 210
30mm.Itshallnotbelowerthan25mmbelowthetopoftherunningrailandshould
beclearoftherailfasteningstopermitinstallation,replacementandmaintenance.
8.3Derailmentguardshallbedesignedsuchthatincaseofderailment:
(i) Thewheelsofaderailedvehicleundercrushload,movingatmaximumspeed
areretainedontheviaductortunnel.
(ii) Damagetotrackandsupportingstructuresisminimum.
AnnexureIVpage4of11
The detailed design calculations of derailment guards along with detailed structural
drawingsshallbefurnishedforrecord.
9. GluedInsulatedRailjoint
9.1Normallygluedjointshouldbeavoided.
9.2Whereverinescapable,G3(L)typeofgluedinsulatedrailjointshallbeusedasperRDSO
drawing no.T5843. The glued joints shall be manufactured and tested in accordance
withRDSOsManualforGluedInsulatedRailJoints1998withallamendments.
10.Turnouts,ScissorsCrossover
10.1 StandardsofTurnout:
10.1.1 Mainlines:
On main lines, the turnouts and diamond crossing shall be of the following
standards:
(i) StandardGauge
a) 1in9typeorflatterturnout(desirable)
b) 1in7typeturnout(minimum)
c) Scissors crossover of 1 in 9 / 1 in 7 type consisting of 4 turnouts and 1
diamondcrossing
(ii) BroadGauge
a) 1in12typeturnout
b) 1in8.5typeturnout
c) Scissorscrossoverof1in12typeconsistingof4turnoutsand1diamond
crossing
10.1.2DepotsandNonrunninglines:
Ondepotandothernonrunninglines,theturnoutsanddiamondcrossingshallbeof
thefollowingstandards:
(i) StandardGauge
a) 1in7typeorflatterturnout
b) Scissors crossover of 1 in 7 type consisting of 4 turnouts and 1 diamond
crossing
c) 1in7derailingswitches/1in7typesymmetricalsplitturnout
(ii) BroadGauge
a) 1in8.5typeturnout
b) Scissorscrossoverof1in8.5typeconsistingof4turnoutsand1diamond
crossing
c) 1in8.5derailingswitches/1in8.5typesymmetricalsplitturnout
10.1.3 If any Metro railway decides to use sharper angle layout, they should establish the
adequacyofthespeedpotentialoftheturnoutforthepurposeforwhichitisused
andthenegotiabilityoftheturnoutbytherollingstockwithasafetymargin.
10.1.4Therequirementforturnoutsasspecifiedinthefollowingclausesshallincludeswitch
devices,crossingsandassociatedcheckandleadrailsasappropriate.
AnnexureIVpage5of11
(a) Turnouts(switches,lead,crossingsandassociatedclosure&checkrails)shallbe
suitableforinstallationonPSCsleepersforballastedtrackorconcreteslabfor
ballastlesstrack.
(b) Turnoutsshallbemanufacturedtoallowforinstallationofcontinuouslywelded
track.
(c) Turnout shall be compatible with proposed rolling stock and its operational
characteristics.
(d) The assembly must ensure continuous electrical contact with the train and all
thepointsshallbeoperatedbyelectricmotors.
(e) The CMS crossing to be used on mainline shall be subjected to explosive
hardening.
(f) Allturnoutsshallbelaidwithcantwitharailslopeasthatofmainlinetowards
centreoftrack.
(g) All turnouts and their components shall be designed to minimize electrical
leakagefromrunningrailstotheground.
(h)ScissorcrossovershouldbedesignedforTrackcentresnotinfringingSOD.
10.2 Typeandgeometryofturnout
Detailed design of all turnouts, scissors, and crossover should comply the following
geometricalparameters.
(a)StandardGauge
(i) 1in9turnout:
Thedesignshallbetangentialwithaswitchanglenotexceeding02000.It
isdesirablethattheradiusofleadrailofturnoutisnotlessthan300m.Lead
curveof190mradiusmaybelaidasanexception.Allclearancesshallbein
accordancewithrelevantprovisionsofSOD.
(ii) 1in7turnout:
Thedesignshallbetangentialwithaswitchanglenotexceeding02000.It
isdesirablethattheradiusofleadrailofturnoutisnotlessthan190m.Lead
curveof140mradiusmaybelaidasanexception.Allclearancesshallbein
accordancewithrelevantprovisionsofSOD.
(iii) ScissorsCrossover
Thebasicgeometryoftheturnoutsofscissorscrossovershallbesameasthat
ofcorrespondingordinaryturnoutsasmentionedinclause10.2(i)(ii)above.
(b)BroadGauge
(i) 1in12turnout
The design shall be tangential with a switch entry angle not exceeding 00
2000. The radius of lead rail of turnout shall not be less than 410m. All
clearancesshallbeinaccordancewithrelevantprovisionsofSOD.
(ii) 1in8.5turnout
The design shall be tangential with a switch entry angle not exceeding 00
2000. The radius of lead rail of turnout shall not be less than 218m. All
clearancesshallbeinaccordancewithrelevantprovisionsofSOD.
(iii) ScissorsCrossover
AnnexureIVpage6of11
Thebasicgeometryoftheturnoutsofscissorscrossovershallbesameasthat
of corresponding ordinary turnouts as mentioned in clause 10.2 (iv) & (v)
above.
10.3 Operatingrequirementofturnout,scissorcrossover:
Tracklayoutdesign shallpermittrainstooperate atmaximumcapability wherever
possible. Turnouts and crossover shall be selected such that they do not form a
restrictiontotheoperatingspeedonmainline.Switchesandcrossingsshallnotbe
locatedontransitioncurvesorverticalcurves.
Speed:
Theturnoutshallbedesignedforthespeedonmainlinesideequaltothespeedas
onmainlinetrack.
Theminimumspeedpotentialofthevariousturnoutsandscissorscrossoveronthe
Turnoutsideshouldbeasfollows:
StandardGauge
(i)1in9typeturnoutwith300mradius(speedpotentialof45Kmph)
(ii)1in7/1in9typeturnoutwith190mradius(speedpotentialof35Kmph)
(iii)1in7typeturnoutwith140mradius(speedpotentialof25Kmph)
(iv)Scissorscrossover1in9typewith300mradius(speedpotentialof45Kmph)
(v)Scissorscrossover1in9/1in7typewith190mradius(speedpotentialof35Kmph)
(vi)Scissorscrossover1in7typewith140mradius(speedpotentialof25Kmph)
(vii)1in7typesymmetricalsplitturnout(speedpotentialof45Kmph)
BroadGauge
(i) 1in12typeturnout(speedpotentialof50Kmph)
(ii) 1in8.5typeturnout(speedpotentialof30Kmph)
(iii) Scissorscrossover1in12type(speedpotentialof50Kmph)
(iv)Scissorscrossover1in8.5type(speedpotentialof30Kmph)
(v) 1in8.5typesymmetricalsplitturnout(speedpotentialof40Kmph)
10.4 TechnicalSpecification
10.4.1 General
(a)Allthepointsshallbecapableofbeingoperatedbyelectricmotorsinaccordance
withthesignallingspecification.
(b) The top surfaces of PSC sleeper/RCC slab supporting rail seat of turnouts and
scissorscrossovershallbeflatwithoutanycant/slope.
(c) The track form of the turnout shall have uniform resilience as that of the
adjoiningtrackform.
(d) The fixation of turnouts, scissor crossover on track slab shall be through base
plates/bearingplates.
AnnexureIVpage7of11
10.4.2Rails
1.Therailsusedinturnoutsshallbe1080gradeHeadHardened.However,railsused
inturnoutsondepotandothernonrunninglinesmaybeof880grade.
2.Therailsusedformanufacturingofturnoutsshallsatisfythefollowingconditions:
a.TherailsshallbemanufacturedandtestedinaccordancewithIRS/T122009
withlatestamendment.
b.Thesectionofrailsshallbe60E1(UIC60)forstock,leadand60E1A1(ZU160)
/60E1A4forswitchrail.
c.TherailsshallqualifyasClassArailsasperIRS/T122009.
d.Therailsshallbewithendsundrilled.
e.The rails shall be of grade 1080HH and be suitable for being welded by
aluminothermicorflashbuttweldingtechnique.
10.4.3Switches
1.Each switch device shall consist of two stock rails, one left hand and one right
handandtwoswitchrails,onelefthandandonerighthand.
2.The switch rail shall be one piece with no weld or joint within the switch rail
length.
3.Theendoftheasymmetricalswitchrailshallbeforgedto60E1(UIC60)railprofile
withminimumlengthof500mm.Theforgedswitchrailendshallbesuitablefor
weldingorinstallationofinsulatedrailjoint.
4.Slide chairs in the switch portion shall be coated with an appropriate special
coating, so as to reduce the point operating force and to eliminate the
requirementoflubricationofslidingsurfacesduringservice.
5.Switches shall provide suitable flange way clearance between the stock rail and
theswitchrailwiththeswitchrailinopenposition(minimum60mm).The1in12
and 1 in 9 ( with radius of 300 mts) and flatter turnouts shall be provided with
seconddriveorothersuitablearrangementtoensureminimumgapof60mmat
JOHaswellasproperhousingofswitchrailwithstockrailuptoJoH.1in8.5,1in
9 turnout (with radius of 190m) and 1 in 7 and sharper turnouts may not be
providedwithseconddrivearrangement,howeverminimumgapof60mmatJOH
as well as proper housing of switch rail with stock rail up to JoH should be
ensured.Thenormalopeningofswitchattoeofswitchshallbekeptas160mm.
6.The switch manufacturer shall include provision for all holes required to main
drivemachines,stretcherbarsanddetectionequipmenttosuittherequirements
of the signalling and switch operating system duly chamfered to avoid stress
concentrationattheedgeoftheholes.
7.Theswitchesshallbedesignedwithananticreepdeviceattheheelofswitchto
withstandthermalforcesoftheCWRtrack.
8.The switches and all slide chairs shall be same for ballasted and ballastless
turnouts.
10.4.4Crossings
1.Allcrossingsshallbecastmanganesesteel(CMS)crossingswithweldablerailsof
minimum1.2mlengthundrilledforweldingintotheoverallturnout.
AnnexureIVpage8of11
2. TheCMScrossingsshallbemanufacturedfromAusteniticManganesesteelasper
UIC866.
3.AllCMScrossingsshallhaveweldedlegextensionsof60E1(UIC60)rails.Thisshall
be achieved by flash butt welding of buffer transition rail piece of suitable
thicknesstoCMScrossingsandraillegextension.
4.AllCMScrossingsonmainlineshallhaveaminimuminitialhardnessof340BHN.
5.AllCMScrossings and theirweldedlegextensionsforall scissor crossoversshall
besuitablydimensionedsoastoeliminatethenecessityofprovidingsmallcutrail
pieces for the purpose of interconnection. However, the need for providing
insulated glued joints from signalling requirement point of view shall be taken
careofinthedesign,ifrequired.
6.The provision of rail cant shall be taken care of on the top surface of the CMS
crossingandthebottomsurfaceofallCMScrossingshallbeflat.
10.4.5CheckRails
1.Thecheckrailsectionshallbe33C1(UIC33)orsimilarwithoutanydirect
connectionwithrunningrails.
2.Checkrailsshallhavethefacilityfortheadjustmentofcheckrailclearancesupto
10mmoverandabovetheinitialdesignedclearance.
3. Each check railendshall be flared by machining to haveminimum clearance of
62mmatend.
4.Thecheckrailconnectionsinturnoutsshallbethroughspeciallydesignedbearing
plates/brackets.
5.Allthecheckrailsshallbehigherby25mmaboverunningrails.Thelengthsand
positions of the check rail in diamond crossings shall provide safety and be
compatiblewiththeoveralltracklayout.
10.4.6SleeperforTurnouts,Scissorcrossover(BallastedTrack)
10.4.6.1Sleeper shall be of prestressed concrete, monoblock, suitable for
installation in track both with and without signalling circuits and with and
withoutelectrification.
10.4.6.2Sleepers shall be designed to provide a minimum service life of fifty years
undernominalaxleloadasthatofmainlinefortheMetrosystem.Railseat
padsandrailclipetcshallbedesignedtoprovideaminimumservicelifeof
15years.
10.4.6.3Thesleeperbasesurfaceshallberoughcastwhilethetopandsidesurface
shallbesmoothtopreventretentionofmoistureandforeignmaterials.
10.4.6.4Sleepers must be suitable for installation by track laying machines and
sleeperinsertionequipmentofatypeusedforisolatedsleeperlaying.
10.4.6.5Thesleepermustbeabletotransferalltherelevanttrackforcesgenerated
bytrainoperationsandtheforcesofrailexpansionandcontractiontothe
ballast.
10.4.6.6DesignRequirementsforPSCSleepers:
(A) Thesleepersshouldsatisfythefollowingdesignrequirement:
AnnexureIVpage9of11
DesignParameters
(i) RailsleeperfasteningElasticresilienttype
(ii) Spacingofsleepers600mm(max)formainlineand650mm(max)forDepots
andothernonrunninglines,exceptatfewlocationssuchasnearpointmachine
locationswhereitmaybevariedtomeetthedesignrequirements.
(iii) Ballastcushion300mmformainlineand250mmforDepotsandsidings
(iv)BallastprofilesuitableforLWR/CWR.
SpecificationsandDrawings(Withlatestamendment)
(i) SpecialCementIRST401985
(ii) HTSwireplainandstrandBIS1785(Pt1)1983andBIS6006
(iii)PolyethylenedowelsProvisional1997Drg.No.RDSO3002Alt3
(iv)IRSSpecificationforTurnoutSleeperT451996
(v) IRSBridgecode1982
(vi)CodeofPracticeforPrestressedConcreteIS1343
(B)Thedesignshouldsatisfythefollowingadditionalrequirements
(i) The connections of the slide chairs and bearing plates/special bearing
plates/bracketsshallbedesignedforeasyinstallationandmaintenance.Allthe
fittings shall be suitably designed to ensure full compatibility & also to ensure
interchangeabilityofslidechairsbetweenballastedandballastlessturnouts.
(ii) For attaining suitable cant of the rail, as provided on mainline, (excluding
crossing and switch portion), suitably designed pads of appropriate material
shallbeprovidedbetweenrailpad&PSCsleeper.Alsofasteningsystemshould
bedesignedtogetthedesiredToeLoad.
(iii) The detailed design of Monoblock PSC sleepers for the turnouts along with
structuraldrawingsshallbecheckedandapprovedbymetrorailways.
10.4.7LockingSystem:
AnnexureIVpage10of11
10.4.8MonitoringSystem:
1.Safetyandmaintenancerelevantfunctionsofaturnoutshallbemonitoredbya
monitoringsystem.Incaseofirregularityintrackorlackofmaintenance,the
monitoringsystemshallsendonlinemessagesaboutproblems.
2.Themonitoringsystemshallhaveamodularsystemstructureforbeingeasily
expandable.
3. Itshallautomaticallygenerateerrormessages.
4. Itshallhaveacontinuousdataacquisitionwithfacilityforstorageofdata.
11.SwitchExpansionJoint
1. The SEJ for ballasted track shall be laid on PSC sleepers whereas the SEJs for
ballastlesstrack,ifrequired,shallbelaidonreinforcedconcreteslab.
2.TherailsectionforallSEJsshallbeUIC60,1080HHgradeasperIRST122009.
3. TheSEJforballastedtrackshallbedesignedforamaximumgapof80mm.
4. The SEJ for ballastless track should be designed for the maximum gap required as
perdesign.
5.TheballastedSEJshallbeasperRDSOdrawingT6902&T6922.
6.TheballastedSEJforBGshallbelaidwithPSCsleepersasperRDSOdrawingT4149.
For Standard Gauge, PSC sleeper shall be designed such that SEJ to RDSO drawing
alongwithitsbearingplates/chairsmaybeaccommodatedforinstallationofSEJ.
7.SleepersusedforSEJsshallbeflatandcantwillbeprovidedthroughCIchair.
8.TheSEJshallbesuitablefortwowaydirectionaltraffic.
12.Fasteningsystemforballastlesstrack
TheMetrosystemsmayadoptanysuitablefasteningsystemmeetingtheperformance
criteria.MoR haveapprovedsomefasteningsystem.Metro Railways/MRTSsystem
may adopt one of them. Any other fastening system can be adopted meeting the
performancecriteria.Theperformancecriteriaforfasteningsystemofballastlesstrack
havebeenstipulatedinannexureC2separately.
13. NoiseandVibration
Metro system shall be designed to ensure that noise emitted is well within the
prescribed limits for the particular area. Each Metro system shall specify the
prescribed limits of permissible Noise and vibration parameters as per legal and
statutoryrequirementofIndia.
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AnnexureIVpage11of11