SPECIFICATION FOR TRACK BALLAST

SCOPE: These specifications will-be applicable for stone ballast to be used for all
types of sleepers on normal track, turnouts, tunnels and deck slabs etc on all routes.

DETAILED SPECIFICATIONS:

2.1 GENERAL

2.1.1 Basic Quality: Ballast should be hard durable and as far as possible angular along
edges/comers: free from weathe'red portions of parent rock, organic impurities and
inorganic residues.

Particle sbape: Ballast should be cubical in shape as far as possible. Individual

pieces should not be flaky and should have generaUy flat faces with not more than tw£
roundedl sub rounded faces .
.:=

2.1.3 Mode of manufacture: Ballast for all BG main lines and running lines, except on 'E'
-;Ooutes but including IE; special routes, shall be machine cru~hed. For other BG Jines
and MGING routes planned/s~nctioned for conversion, the ballast shall preferably be
machine crushed. Hand broken ballast can be used in exceptional cases with prior
approval of Chief Track Engineer/CAO/e. Such approval shall be obtained prior to
invitation oftenders.

On other MG and NG routes not planned/sanctioned for conversion hand broken

ballast can be used for which no approval shall be required.

2.2 PHYSICAL 'PROPERTIES

2.2.1 Ballast sample should satisty the following physical properties in accordance with
IS:2386 Pt.IV-I963 when tested as per the procedure given in Annexure-I & II.

BG, MG & NG(plannedlsanctioned NG & MG(other than those

For conversion) planned for conversion)

Aggregate 30% Max.* 35% Max.

Abrasion value

Aggregate 20% Max. * 30% Max.

Impact value

* In exceptional cases, on technical andlor economic grounds relaxable upto 35% and
25%respectively by CTE in open line and CAO/C for construction projects. The
relaxation in Abrasion and Impact values shall be given prior to invitation of tender
and should be in'corporated in the Tender document.
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The 'Water Absorption t tested as per IS 2386 Pt.III-1963 following the procedure

given· in Annexure III should not be more than I%. This test however, /0 be

prescribed at the discretion of CE/CTE in open line and CAO/Con. For conslrue/ion .

projects.

SIZE AND GRADATION

Ballast sbould satisfy the following size and gradation:

a) Retained on 65mm Sq.mesh sieve

5% Maximum \ "'IS - 1.-0
b) Retained on 40mm Sq.mesh sieve* 40%-60% -+0 - ~ -0
c) Retained.on 20mm Sq.mesh sieve Not less than 98% for machine crushed ~ ~ R­
Not less than 95% for hand broken

* For machin~ crushed ballast only,

Oversize ballast

i) Retention on 65mm square mesh siev~.

!
A maximum of 5% ballast retained on 65 mm sieve shall be allowed widloUt
deduction in payment._ .

tIn case ballast retained on 65mm sieve exceeds 5% but does not exceed
10%, payment at 5% reduction in contracted rate shall be made for the full
stack, Stacks having more than 10% retention of ballast on 65mm sieve shall
be rejected.)

it) In case ballast retained on 40mm square mesh sieve (machine crushed case
only) exceeds 60% limit prescribed in 2.3.1 (b) above. payment at the
following reduced rates shall be made for the fulJ stack in addition to the
reduc,tion worked out at i) above.

• 5% reduction in contracted rates if retention on 40mm square mesh sieve is

between 60% (excluding) and 65% (including).

• 10% reduction in contracted rates if retention on 40mm square mesh sieve

is between 65% (excluding) and 70% (including),

iii) In case retention on 40mm square mesh sieve exceeds 70%, the stack shall be
rejected.

iv) In case of hand broken ballast supply, 40mm sieve analysis may not be carried
out. The executive may however ensure that the ballast is well graded between
65mm and 20mm size.
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Under Size Ballast: The Ballast shall be treated as unde~ize._a!'!!!~!l{tJLb~Lej~~t~Jr-
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i) Retention on 40mm Sq. Mesh sieve is less than 40%.

ii) Retention on 20mm square mesh sieve is less than 98% (for machine crushed)
or 95% (for hand broken).

2.3.4 Method of Sieve Analysis:

i) Sieve sizes mentioned in this specification are nominal sizes. The following
tolerances in the size of holes for 65, 40 and 20mm nominal sieves sizes shall
be perm itted.
65mm Square Mesh Sieve Plus Minus 1.5mm ¥
40mm Square Mesh Sieve Plus Minus I.5mm *
20mm Square Mesh Sieve Plus Minus I.Omm 'It ~
Mesh sizes of the sieves should be checked before actual measurement.
The screen for sieving the ballast shall be of square mes1!.and shall not be less

ii)
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than IOOcm in length. 70cm in breadth and IOem in height on sides.

While carrying out sieve analysis, the screen shall not be kept inclined, but
held horizontally and shaken vigorously. The pieces of ballast retained on the
screen can be turned with hand to see if they pass through but should not be
pushed through the sieve.

iii) The percentage passing through or retained on the sieve shall be detennined by
weight. .

3, CONDITIONS FOR SUBMISSION OF TENDER

3.1 Each tenderer at the time. of tendering shall submit· the test report of Impact Value.
Abrasion Value, Water Absorption Value from approved laboratories and the list of
these laboratories shall be mentioned in the tender documents.

3.2 The tenderer shall also furnish an undertaking as incorporated in the tender document
that the ballast supply at all times will conform to Specifications for Track Ballast as
specified by Railway.

4. METHOD OF MEASUREMENT

4.1 Stack Measurement

Stacking shall be done on a neat, plain and finn ground with good drainage. 1:!!!L,
hei ht of stack shall not be less than 1m exee t in hilly areas where it may be O.5m.
r,,<. he .heigbtshall not e more than 2.0m. op wi 0 ..stack shall not be ess an

COm. 'Top of stack shall be kept pataneI to the grol,lnd plane. The side slopes of stack.

should not be flatter than 1.5: 1 (Horizontal: Vertical). CubicaI content of each stack

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Sllall normally be no"fliiss tfuiri 30 cum in plain areas and 15 cum in hiJIyareas.