CE's CIRCULAR No.

2/98
Sub: Improving performance of grooved rubber pads.
$$$$$
Investigations conducted on the present design of 6 mm rubber pad have revealed that
adequate life of rubber pad can be achieved where the rubber pad does not get shifted from its
proper rail seat position. An analysis on the premature failure of the rubber pad has indicated that
the following are the major reasons.
1. A major portion of the rubber pad gets shifted from the sleeper seat in service thereby resulting in
stress concentration on smaller area which leads to crushing of the rubber pad.
2. Due to the ingress of gritty particles between the rubber pad rail foot and sleeper and rubber
pad.
3.

Ingress of oily/gritty matter which affects the rubber.

4. Due to imperfections in the surface of concrete sleepers at rail seat, i.e. having humps/surface
irregularities.
All the above factors indicate that gap is produced between rubber pad and the rail foot and
rubber pad and the sleeper resulting in instantaneous loss of contact between the rubber pads and
the rail foot and the sleeper.
In order to check the above problems, the following steps are to be taken in the field.
a) The toe load of the ERC should be measured by the field staff as per the specified periodicity
and the ERC should be replaced in accordance with the specified norms. The details are given in
Annexure No.1
b) All the Concrete Sleeper Plants should be instructed to maintain the high standards of surface
finish specially in rail seat area to avoid any hump/depression conforming to para 4.7 and 5.3.1.1 of
IRS specification for pretensioned PSC sleepers No.T.39-85 of 1996.
c) Adequate precautions should be carried out by field staff at the time of relaying/maintenance so
that extraneous material like grit does not get entrapped in the rail seat area. The rail seat should be
cleaned properly during replacement of rubber pad.

d) Rubber pad should not be kept in the stores after receipt for unduly longer period.
As the rubber continues to be deteriorated even in storage, it is advisable to use rubber pads
within two years of its manufacture. Storage beyond initial period of 2 years is likely to reduce the
effective service life of the rubber pad depending on the conditions of extra storage. Hence
adequate precautions should be taken to avoid storage of rubber pad beyond two years by using
them on "first in first out basis".
e) Guidelines on the storage of rubber pads are enclosed as Annexure II.

Encl: As above.
for CHIEF ENGINEER
SOUTHERN RAILWAY
No.W.506/14/Circular
Headquarters Office
Works Branch
Chennai - 600 003.
16.03.98

Annexure - I
Periodicity of Measurement of Performance of Elastic Fastening
Components (abstract of CT/EF/POLICY of 15.9.97 addressed to all CE's)
I. SAMPLE SIZE AND TESTING FREQUENCY
i) SAMPLE SIZE: Toe load of elastic rail clip is to be measured on 1% of ERCs randomly on
every 100 sleepers (all 4 ERCs to be measured on one sleeper)
ii) TESTING FREQUENCY: Initial testing of ERCs is to be after four years or passage of 200
GMT of traffic, whichever is earlier. In corrosion prone area, the initial testing of ERC is to be done
after two years or passage of 100 GMT, whichever is earlier. For frequency of subsequent testing,
para (b) below may be referred.
b) Subsequent testing will be done every four years/200 GMT in normal areas and two years/100
GMT (earlier of the two) in corrosion prone areas. However, if 20% or more of sample size
records toe-load below 600 kg, both frequency of inspection and sample size are to be doubled.
II. REPLACEMENT OF ERC
If 20% or more of sample size records toe-load below 400 kg which is to be confirmed by 5%
sample size, proposal of through fastening renewal (TFR) should be initiated.
The provisions given in I and II above are only for guidance of Railways. The large scale
replacement of the fastening should be undertaken by the Railways on the basis of the overall
condition of track, pattern of traffic and the required level of maintenance.
Further, as the loss of toe load is reflective of conditions of other elastic fastening components
like groove rubber sole plate, GFN/Metal liners etc. as well, the Railways may also record condition
of these components along with measuring toe loads for elastic rail clips.

ANNEXURE - II
LIFE AND STORAGE OF RUBBER COMPONENTS
The rubbers whether under storage or in use continue to deteriorate, and ultimately may become
unserviceable. The deterioration may be the result of one particular factor or a combination of
factors viz., the action of oxygen, ozone, light, heat, humidity, etc. The deleterious effects of these
factors may, however, be minimised by adopting appropriate conditions of storing and duration of
storage. This guideline provides suitable conditions for the storage of rubbers in all forms.
i) The rubber components should be stored in a cool place as far as practicable, preferably below
300 C.
ii) They should be kept away from direct sunlight preferably in
causes much faster degradation of the rubber components.

a dark place. Direct sunlight

iii) The humidity of the storage condition should not be such that condensation of moisture takes
place on the surface of the components.
iv) In the vicinity of these components, any loose electrical connections should be avoided, as
these cause production of ozone which adversely affects rubber.
v) They should be stored away from contact with materials containing copper and manganese
which act as poisoning agents and resulting in their faster degradation.
vi) Under no circumstances rubber components should be stressed during storage. The portion
under stress undergoes deformations with permanent set leading to degradation. They should be
stacked in such a way so that any super imposed stresses are substantially avoided.
vii) Any contact with grease or oil should be avoided as these cause swelling, softening and
deterioration of rubbers.
viii) French chalk or soapstone or mica should liberally be applied on the surface of rubber
components.
ix) Great care is to be exercised so that the material is used in the order of their receipt in the
stores i.e. 'first- come-first issue basis. The rubbers whether under storage or in use continue to
deteriorate. The only difference is that under service conditions, deterioration is much faster. Every
moment of storing is at the cost of useful life and prolonged storage of the material may render it
unserviceable due to progressive deterioration.