Summer Internship AT North Western Railways

SUMMER INTERNSHIP
AT
NORTH WESTERN RAILWAYS
Submitted by- Submitted to-

Rajkumar Meena 2016UCE1266 Dr. Arun Gaur
Tarun Goyal 2016UCE1230 Dr. Mahendra Chaudhary
Ashish Kumar Gautam 2016UCE1234 (Civil Engineering Dept.)
1/32
PROJECT-
 CONSTRUCTION OF NEW PLATFORM
 DISMENTALING OF MG TRACK
 LAYING OF BROAD GAUGE TRACK
 SPREADING OF BALLAST
AUTHORIZED BY-NORTH WESTERN RAILWAY

DESIGNED BY-GIRVAR ARCHITECTS LIMITED
CONSTRUCTED BY-SANJEEV BROTHERS
ESTIMATED COST- 500 CRORE
SITE: - JAIPUR JUNCTION 2/32

PLATFORM- 6,7&VIP
• Platform 6,7 Length= 603m
• Platform 6,7 = Island Platform
• Platform VIP Length=150m
• Platform final level from rail top level=800mm
• Distance b/w platform and rail section =840mm
3/32
CEMENT CONCRETE APRON:-
• Prevent entry of water into subgrade so swelling of soil is prevented

that further prevents in change in alignment of track.
4/32
• Reinforcement is provided in top & bottom layers.
• M30 design mix is used.
• Nominal cover – 45mm
• Diameter of Bars = 12mm.
• Spacing of main reinforcement – 150mm
• Spacing of secondary reinforcement – 300mm
• Depth of CC Apron slab – 300mm.
• The concrete is cured for 7 days by ponding.
5/32
AGGREGATE TESTS:-
1.SIEVE ANALYSIS [Confirming IS: 2386-1 (1963)]
• Location of Sample – Jaipur Yard

• Sample Taken = 3000gm
CUM WEIGHT IS LIMIT

SIEVE WEIGHT RETAINED ( CUM % %
SIZE RETAINED(gms) gms ) WEIGHT % PASSING PASSING
40 mm 0 0 0 100 100
20 mm 169 169 5.63 94.37 85-100
10 mm 2547 2716 90.53 9.47 0-20
4.75 mm 215 2931 97.70 2.3 0-5
PAN 69 3000 100.00 0
Result – Nominal Size of Aggregate is 20mm 6/32

2.IMPACT VALUE TEST [Confirming IS 2386(Part 4):1963]
• Measure of resistance to sudden impact or shock.

• Apparatus:-
Source:-http://www.iricen.gov.in 7/32
UNIT
Size of Aggregate 20 mm
Weight of Empty Measure 1.519 kg
Weight of Filled Measure 2.151 kg
Weight of Aggregate and Measure (A) 0.632 kg
Weight of Aggregate passing 2.36 mm (B) 0.109 kg
Weight of Aggregate retained on 2.36 mm 0.532 kg
Aggregate Impact Value = (B/A)*100 17.25
• Classification of Aggregate – Strong (10-20%)
8/32
Concrete:-
Compressive Strength Test [confirming IS 516 (1959)]
• Cube size=15×15×15 cm3

• Tested in UTM
• 3 specimens for 7 days
• 3 specimens for 28 days.
• Stress applied at rate of 140
kg/cm2/minute on specimen.
9/32
Concrete:-
Compressive Strength Test [confirming IS 516 (1959)]
7 days Avg. 7 28 days

Date of No. of Date of Comp. days Comp. Avg 28
Concrete Mix Cube Testing st. Strength st. days st.
27-05-19 M30 1 25.88
2 03-06-19 26.22 25.99
3 25.88
4 33.77
5 24-06-19 34.66 34.95
6 36.44
If strength of any specimen varies by more than 15 percent of average strength,

results of such specimen should be rejected. 10/32
Slump Test of Concrete:-[confirming Is 1199 (1959)]
• For measurement of workability.

• Slump cone height = 300mm
• Base Diameter = 200mm
• Top Diameter = 100mm
Test Result:-
• Slump obtained on the Jaipur
Junction site for the Concrete work
for M30 concrete is 80mm.
• Medium Workable. 11/32

SLEEPER:-
• Support for rails
• Mono-block pre stressed

sleepers
• Length =2730 mm
• Spacing=640mm
• Density of sleeper=21
• Adzing 1in 20
12/32
RAIL SECTION:-
• 60 kg/m rail
• Flat Footed Rail
Source:-Satish Chandra’s book. 13/32

Fastening:-
Pandrol Clips:-
• Elastic Fastening
• Hold rail to the sleeper

with the help of MCI
insert fixed in the sleeper
• Made from Spring Steel

bar of 20.6 mm.
• Used PR-401pandrol clip
14/32
Rubber Pad:-
• Prevents abrasion and

damage of concrete sleeper
by the sharp edges and
vibrations of rail.
• Size of rubber bad -

270x234x10mm
• Rubber pad is grooved

which provides grip between
rail and sleeper
• Laid in such a way that

grooves are parallel to rail .
15/32
Elastic Liners:-
• Used between Pandrol clip and

Rail.
• Reduce wear and tear of rails.
• Insulated Liners.
• Provided on Track circuited

areas.
• Glass Filled Nylon Liners.
16/32
FISH PLATE:-
• A kind of rail-to-rail
fastenings.
• 22 mm dia. Of fish bolt are

used.
• Keep adjoining ends of rail in

correct position.
• To allow contraction and

expansion of rails.
17/32
Plain Concrete Cement (PCC):-
• Provided for fast drainage.

• M30 design mix is used.
{w/c = 0.4, cement=50kg,
sand=76kg, aggregate=58kg(10mm
)& 88kg(20mm) }
• Slope of 1 in 25 is maintained
• Vary depth from 183mm to 45mm
• Compaction by needle vibrator.
• Curing is done by Ponding
Method.
18/32
BALLAST:-
• Distribute load from sleeper to
formation.
• Depth provided = 250mm
• Top Width provided = 3350mm
• Slope of Ballast Cushion – 1.5 :1
• Ballast-min. size(19mm) for

drainage condition.
• Max. size(51mm) for

interlocking
19/32
WELDING OF RAILS:-
Thermit Welding-
• Fusion welding process that makes use of the intense heat.
• Heat is produced when a mixture containing Al and iron oxide is

ignited
• Reduces iron oxide to molten iron and slag.
• The superheated molten metal is poured at the desired place,

which on solidification form the welded joint.
• Gap should be of 1 inch.
• The fuel is oxygen and propane

20/32
• 8 Al + 3 Fe3O4 → 9 Fe + 4 Al2O3 + heat (3000˚C, 35 kJ/kg of mixture)
21/32
Rail Welding Tests:-
Ultrasonic Flaw Detector Test:-
• Sound waves of high frequency are reflected from flaws

and generate clear echo patterns.
• When sound waves bump into a boundary having a

different medium, they are transmitted back.
• The USFD machine is calibrated to 3mm flaw in the rail.
Probe Distance from the center of

weld(mm)
Zero degree probe 0

45 degree probe 172
22/32
23/32
Welding test of column:-
Dye Penetration Test:-
• Used to check surface cracks of welding.
• Principal of DPT is based on capillary action.
• In this test three liquids are used:-

1. Red Dye Penetrant.
2. Penetrant Remover.
3. Developer.
Acceptance Limit:-
Linear ind. L>3B
Round ind. L<3B(5mm)
4 rounded ind. <1.5mm
24/32
Procedure:-
25/32
Finishing of platform:-
1.COPING:-
• It prevents slipping due to grooves.
• Overall Dimensions - 1125mm x

530mm x 100mm thickness.
• Reinforcement =8@150mm c/c

TOR steel.
• Manufactured with M-30 grade

concrete.
• Placed on mortar =1:4
• Depth of mortar = 30mm
26/32
2.KOTA STONE:-
• The final level after Kota stone

finish is 800mm above the rail-
top.
• Square Kota stones of 600mm

are used.
• Thickness= 25mm
• 1:4 mix of cement & sand is

used.
• slope of 1 in 60 is provided.
27/32
Turnout :-
• Divert the train from one track to another track
28/32
Points And Crossings:-
• Crossing angle- 6⁰42′35″( 1 in 8.5)
• Rectangular sleepers.
Width=300mm
Height =220mm
• No cant is provided.
Check Rail
29/32
Versine of Railway Track:-
• The perpendicular distance

of the mid-point of chord
from the arc of the circle.
• Thread is used.
• Measurement is taken at
every 10m distance.
• Versine is measured with

scale.
• Y(2R-Y)= L2 /4 .
30/32
ALIGNMENT CHECKING
 By level gauge.
 Level is checked by position of

bubble.
 Allowable tolerance ±5mm
31/32
32/32

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SUMMER INTERNSHIP

Submitted by- Submitted to-

AUTHORIZED BY-NORTH WESTERN RAILWAY

SITE: - JAIPUR JUNCTION 2/32

• Platform 6,7 Length= 603m

• Platform 6,7 = Island Platform

• Platform VIP Length=150m

• Platform final level from rail top level=800mm

• Distance b/w platform and rail section =840mm

• Prevent entry of water into subgrade so swelling of soil is prevented

• M30 design mix is used.

• Nominal cover – 45mm

• Diameter of Bars = 12mm.

• Spacing of main reinforcement – 150mm

• Spacing of secondary reinforcement – 300mm

• Depth of CC Apron slab – 300mm.

• The concrete is cured for 7 days by ponding.

• Location of Sample – Jaipur Yard

CUM WEIGHT IS LIMIT

20 mm 169 169 5.63 94.37 85-100

10 mm 2547 2716 90.53 9.47 0-20

4.75 mm 215 2931 97.70 2.3 0-5

PAN 69 3000 100.00 0

Result – Nominal Size of Aggregate is 20mm 6/32

• Measure of resistance to sudden impact or shock.

Weight of Aggregate passing 2.36 mm (B) 0.109 kg

Weight of Aggregate retained on 2.36 mm 0.532 kg

Aggregate Impact Value = (B/A)*100 17.25

• Classification of Aggregate – Strong (10-20%)

• Cube size=15×15×15 cm3

7 days Avg. 7 28 days

If strength of any specimen varies by more than 15 percent of average strength,

• For measurement of workability.

• Medium Workable. 11/32

• Support for rails

• Mono-block pre stressed

Source:-Satish Chandra’s book. 13/32

• Hold rail to the sleeper

• Made from Spring Steel

• Used PR-401pandrol clip

• Prevents abrasion and

• Size of rubber bad -

• Rubber pad is grooved

• Laid in such a way that

• Used between Pandrol clip and

• Reduce wear and tear of rails.

• Provided on Track circuited

• Glass Filled Nylon Liners.

• 22 mm dia. Of fish bolt are

• Keep adjoining ends of rail in

• To allow contraction and

• Provided for fast drainage.

• Depth provided = 250mm

• Top Width provided = 3350mm

• Slope of Ballast Cushion – 1.5 :1

• Ballast-min. size(19mm) for

• Max. size(51mm) for

• Heat is produced when a mixture containing Al and iron oxide is