Corrected upto ACS-6

1 Page 1 of 419 Corrected upto ACS-7 Page 2 of 419 GOVERNMENT OF INDIA MINISTRY OF RAILWAYS (RAILWAY BOARD) INDIAN RAILWAYS PERMANENT WAY MANUALC orrected upto ACS-7 June, 2020 Published by : Indian Railways Institute of Civil Engineering, Pune For Government of India Ministry of Railways (Railway Board), New Delhi Page 3 of 419 FOREWORD TO REDRAFTED IRPWM (2020) Indian Railways Permanent Way Manual was published in the year 1986, as per the recommendations of the 49th track Standards Committee. Thereafter, it was reprinted on different occasions incorporating Advance Correction Slips issued from time to time. There was need to issue updated Manual in view of various technological advancements which have taken place over the years. Description of obsolete materials like 90R Rails, Wooden Sleepers, Steel sleepers, etc. which are no longer in use have been removed. Meter Gauge and Narrow Gauge have been omitted in this IRPWM.

2 For these, provisions of old IRPWM shall continue to hold. Reference to all relevant drawings & specifications have also been provided in this manual, making it simple and more useful. The contents are reorganised, grouping similar topics in one chapter. In the beginning abbreviation and terminology has been added for ready reference. There is a total reduction of about 20% in volume. The IRPWM and LWR manuals have been merged. Now in place of two manuals related to track , only one manual needs to be referred by field officials. All relevant provisions have been placed in logical sequence. The redrafted manual has passed through several rounds of scrutiny by IRICEN faculty, two member committees for each chapter, deliberation in 88thTSC, sub-committee of six SAG officers, RDSO and Railway Board before its final approval. It is hoped that this updated manual will help the Permanent Way men, in easy understanding the provisions and implementing them in the field in their day to day working.

3 (Vishwesh Chaube) New Delhi Member Engineering June, 2020 Railway Board Page 4 of 419 PREFACE TO THE REDRAFTED IRPWM (2020) The Indian Railways Permanent Way Manual (IRPWM) was first published in the year 1986 after recommendation of 49th TSC. It has been reprinted later in the years 1999 and 2004 to incorporate Advance Correction Slips issued from time to time. The third and the last reprint of this Manual in July 2019 was inclusive of the Correction Slips up to No. 149. Railway Board vide letter No. 2013/CE-II/TK/IRPWM dated 24/09/2019 asked IRICEN to redraft IRPWM with a view to remove obsolete topics and material components which are not in use now and make it for only Broad Gauge by adding recent developments in P. Way for the guidance of field officials. Accordingly, Shri Ajay Goyal, the then Director, IRICEN along with a team of faculty members finalised the first draft of IRPWM keeping in view the mandate given by Railway Board.

4 Thereafter Rly Bd vide letter No. 2013/CEII/TK/IRPWM dated 02/12/2019 nominated two members committee as under: S. No Faculty from IRICEN Shri. 2nd Member Shri. Chapter(s) assigned. 1 Sharma, SPT-1S. C. Srivastava, PED/TM/RDSO5 2 R K Bajpai, SPT-2 B P Awasthi, ED/TM/Rly Bd and Manoj Arora, CTE/WR 3 (welding), 4 and 6 3 Anil Choudhary, SPTM P K Garg, CTE/CR and Submoy Mitra, CTE/SER 7 & 8 4 S K Agarwal, PB-1 J. Parida, CTE/ECoR andP S Gupta, ED/CE/G/Rly Bd11 & 12 5 G S Yadav, PB-2 A K Jha, CTE/SCR 9, 10 6 P. Upadhyaya, PT-2P K Garg, CTE/CR 1 7 N K Mishra, PT-1 P S Gupta, EDCE/G/Rly Bd 14 8 A. Siva Kumar, PWA M Rizvi, ED/TR-2/RDSO and D. K Pandey, CE/TMS2,13 & Part 3 LWR portion Each committee then finalised the nominated chapters which were compiled by IRICEN and presented to TSC meeting held in Jan, 2020 at PURI. On recommendation of TSC, Rly Bd nominated a sub Committee comprising of Shri R.

5 K. Bajpai, Sr Professor track -1/IRICEN (Member and Convenor), Shri P K Garg, CTE/CR, Shri A K Jha, CTE/SCR, Shri Ashish Bansal, CTE/NR, Shri S. Mitra, CTE/SER, and Shri A M Rizvi, ED track -2/RDSO as members to examine and submit the final draft. The final draft after initial vetting by RDSO was sent to Railway Board. Rly Bd suggested certain changes which were examined and incorporated by IRICEN. After final vetting by RDSO the redrafted IRPWM is approved by Railway Board (Member Engineering). The provisions of the LWR manual have also been amalgamated herein to make this Manual, a one stop source for all P. Way related matters. The Chapters have been logically re-arranged so as to cater for the day-to-day needs of the field officials. For Metre Gauge and Narrow Gauge track one can refer old IRPWM which was reprinted on July 2019. While revising the Manual, the provisions in the Indian Railway General Rules 1976, Indian Railways Code for the Engineering Department and Indian Railway schedule of Dimensions have been taken in to account.

6 This redrafted edition incorporates all Advance Correction Slips up to No. 155 of the earlier Manual. The hitherto obsolete designations have been done away with and current designations of officials have been incorporated, viz. Gangman as track Maintainer, Permanent Way Supervisor / Permanent Mistry (PWS/PWM) as JE( ), PWI/PWI (In-charge) as JE/SSE( ) Sectional or SSE( ) In-charge. In a volume of this type, it is not possible to provide for every contingency that may arise during the course of the working, though every effort has been made to make the instructions comprehensive. The Principal Chief Engineers of Zonal Page 5 of 419 Railways may therefore supplement, where necessary, the practices and procedures contained herein with such further instructions/orders, as would suit local circumstances on their Railway. Such instructions must not of course contravene any of the provision in this manual, the codes of the various departments of the Railways, General Rules, or any of the statutory regulations in force.

7 It is expected that this updated Manual will be of immense use to the Permanent Way Personnel in easily accessing latest instructions related to track and thereby helping them in maintaining and upkeep of the track more effectively and efficiently. IRICEN will be glad to consider any comments and suggestion from Railway Administrations. Any errors or omissions found in this Edition may be brought to the notice of IRICEN. (Santosh Kumar Agrawal) Pune Director General June, 2020 IRICEN Page 6 of 419 CHAPTERS ABBREVIATIONS AND TERMINOLOGY CHAPTER 1- DUTIES OF PERMANENT WAY OFFICIALSCHAPTER 2- track STRUCTURE AND COMPONENTSCHAPTER 3- INSTALLATION AND maintenance OF WELDEDRAILS CHAPTER 4- CURVES & TURNOUTSCHAPTER 5- track MONITORING& TOLERANCESCHAPTER 6- maintenance OF PERMANENT WAYCHAPTER 7- PERMANENT WAY RENEWALSCHAPTER 8- ENGINEERING RESTRICTIONS & INDICATORS,WORKING OF TROLLIES, LORRIES & MATERIALTRAINS 9- LEVEL CROSSINGS AND GATEMANCHAPTER 10 - PATROLLING OF THE RAILWAY LINE CHAPTER 11 - ACTION DURING ACCIDENTS INCLUDINGBREACHES AND PRE-MONSOONPRECAUTIONARY MEASURES CHAPTER 12 - CRS SANCTION CHAPTER 13 - track MANAGEMENT SYSTEM CHAPTER 14 - TRAINING, COMPETENCY & REFERENCES Page 7 of 419 CONTENTS ABBREVIATIONS AND TERMINOLOGY CHAPTER 1 DUTIES OF PERMANENT WAY OFFICIALS PART A DUTIES OF ASSISTANT DIVISIONAL ENGINEER (ADEN) 101 General.

8 102 Knowledge of Rules and Regulations. 103 Duties of ADEN. PART B DUTIES OF SENIOR SECTION IN OVERALL CHARGE 104 General. 105 Knowledge of Rules and Regulations. 106 Duties of (In-charge). PART C DUTIES OF JUNIOR ENGINEER /SENIOR SECTION ENGINEER (SECTIONAL) 107 General Responsibilities. 108 Knowledge of Rules and Regulations. 109 Duties of JE/ SSE/ (sectional). PART D DUTIES OF JE/SSE/ (OTHER THAN SECTIONAL OR IN-CHARGE) 110 General responsibilities. 111 Knowledge of Rules and regulations. PART E DUTIES OF GANG MATES, KEYMEN, PATROLMEN, GATEMAN AND track MAINTAINER 112 General. 113 Knowledge of Rules and Signals. 114 Important Duties of Gang Mate. 115 Responsibilities of a Keyman. 116 Important Duties of Keyman. 117 Duties of Patrolmen / Stationary Watchmen. 118 Duties of Gateman. 119 Duties of track Maintainer. CHAPTER 2 track STRUCTURE AND COMPONENTS 201 Classification of Lines. 202. track Structure.

9 PART A RAIL AND RAIL FASTENINGS 203 Standard Sections of Rails. 204 Identification of Different Qualities of Rails in the Field. 205 Recommended Rail Section. 206. Rail Fastenings Page 8 of 419 PART B SLEEPERS & FASTENINGS 207 General. 208 Concrete Sleepers. 209 Sleeper Density. 210 Fastenings on PSC sleepers. PART C BALLAST. 211 Ballast Specifications. 212 Ballast Profile/Section/Depth of Cushion. 213 Assessment of Ballast Requirements 214 Collection and Training out of Ballast. 215 Handing over Charge by Assistant Divisional Engineer. 216 Unloading Ballast along the Line. 217 Surplus Ballast along the Line. PART D FORMATION 218 Classification of Formation Requiring Treatment. 219 Nature of Formation Problems. 220 Site Investigation. 221 Soil Investigation and Testing. 222 Remedial Measures Suggested. PART E INSULATED JOINTS & SWITCH EXPANSION JOINTS 223 Insulated Joints. 224 Glued insulated Joints.

10 225 Switch Expansion Joint. PART F track STRUCTURE ON BRIDGES 226 Rail and Rail joints on Bridges. 227 Steel Sleepers on bridges 228 Provision of Guard Rails on Bridges. 229 Provision of side pathways and walkways. CHAPTER 3 INSTALLATION AND maintenance OF WELDED RAILS PART - A ALUMINO-THERMIT WELDING OF RAILS 301 General. 302 Alumino Thermit Welding of Rails. 303 Selection of rails to be welded. 304 Portion for welding. 305 Storage and transportation of Portions. 306 Equipment, staff and Traffic block for welding. 307 Execution of Welding and other precautions. 308 Tolerances on finished welds. 309 Record of joint geometry. 310 Painting of Thermit welds. 311 Acceptance tests. Page 9 of 419 PART - B FLASH-BUTT WELDING OF RAILS 312 General 313 Rail Welding by Stationary Flash Butt Welding plant. 314 Rail Welding by Mobile flash butt welding plant. 315 Suitability of rails for welding. 316 Acceptance Tests.