Handbook On Maintenance of Switch Expansion Joint

CAMTECH/C/04
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
HANDBOOK
ON
MAINTENANCE OF SWITCH
EXPANSION JOINT
FOR L.W.R./C.W.R.
CAMTECH/C/04
December - 1997
Centre
for
Advanced
Maintenance
Excellence in Maintenance
TECHnology
Maharajpur, GWALIOR - 474 020
Handbook on Maintenance of Switch Expansion Joint
Dec, 97
CAMTECH/C/04
HANDBOOK
ON
MAINTENANCE OF
SWITCH EXPANSION
JOINT
Dec, 97
CAMTECH/C/04
CONTENTS
S.No.
Description
Page
1.
INTRODUCTION
2.
MAINTENANCE OF SEJ.
3.
GAPS AT SEJ.
4.
DAMAGE TO SEJ.
5.
BUCKLING OF TRACK
6.
GAPS OF SEJ FOR VARIOUS

TEMPERATURE AND VARIOUS
TYPE TRACK STRUCTURE.
i.
B.G. 60 Kg PRC sleeper, 1660 nos/km,

r = 13.74 kg/ cm/ rail.
11
ii.
B.G. 60 Kg PRC sleeper, 1540 nos/ km,

12
r = 13.28 kg/cm /rail.
Dec, 97
CAMTECH/C/04
S.No.
Description
Page
iii.
B.G. 60 Kg ST sleeper, 1540 nos/ km,

r = 12.14kg/ cm/ rail.
13
iv.

r = 13.74 kg/ cm/ rail.
14
v.

r = 13.28 kg/ cm/ rail.
15
vi.
B.G. 52 Kg ST sleeper, 1540 nos/ km,

r = 12.14 kg/ cm/ rail.
16
vii.
B.G. 52 Kg CST-9 sleeper, 1540 nos/ km,

r = 10.65 kg/ cm/ rail.
17
viii.
B.G. 90 R PRC sleeper, 1540 nos/ km,

r = 13.28 kg/ cm/ rail.
18
ix.
B.G. 90 R ST sleeper, 1540 nos/ km,

r = 12.14 kg/ cm/ rail.
19
x.
B.G. 90 R CST-9 sleeper, 1540 nos/ km,

r = 10.65 kg/ cm/ rail.
20
xi.
M.G. 90 R ST sleeper, 1540 nos/ km,

r = 3.86 kg/ cm/ rail.
21
xii.
M.G. 90 R CST-9 sleeper, 1540 nos/ km,

22
xiii.
M.G. 90 R ST sleeper, 1540 nos/ km,

23
xiv.
M.G. 90 R CST-9 sleeper, 1540 nos/ km,

24
Dec, 97
CAMTECH/C/04
PREFACE
The track structure on Indian Rlys has now been modernised to
a great extent. The old concept of Rail Joint being a
necessary evil no longer holds true. Rails are now being welded
as long continuous welded rails to provide joint less track with
smooth side.
The officers and supervisors staff of civil engineering
department have since long felt book for maintenance of switch
expansion joints for long welded rails and continuous welded
rails.
Most of the data, sketch and information are available
in some form or other in various books or other printed matter
of various railways. The objective of this handbook is to serve
as a ready reckoner for day to day problems on field with all
standard practices schedules.
A lot of initiative was shown enormous assistance was
received from all technical staff of civil wing.
I shall be grateful to the readers for pointing out errors
if any and invite their valuable suggestions for improving this
handbook in order to enhance its utility.
Gwalior
Date : 10 July,98
R.S.Dubey
Joint Director (Civil)
Dec, 97
CAMTECH/C/04
FOREWORD
Indian Railways have a running track of about 81,000 Kms. As
on 31.03.97, 60618 Kms. has been modernised into Welded
Track out of which 31,914 Kms. is with long Continuous
Welded Rails and 28,704 Kms. is with Short Welded Rails.
Due to continuous increase in the amount of LWR and
CWR, the proper maintenance of SEJs has assumed great
importance in the interest of safe and punctual running of
trains.
This handbook has been prepared for the assistance of
field staff by Centre for Advanced Maintenance Technology in
order to consolidate and put together all information related to
maintenance of Switch Expansion Joints. The tables for SEJs
gaps at various temperatures for varying sleeper density and
ballast resistance have been systematically compiled and
produced in the handbook to serve as a useful ready reckoner
for proper maintenance of SEJ.
Gwalior
Date : 20th July, 1998
D. K. Saraf
Director
Dec, 97
CAMTECH/C/04
SWITCH EXPANSION JOINT(SEJ)

1.
INTRODUCTION
Switch expansion Joint is an expansion joint installed at each
end of LWR CWR to permit expansion contraction of the
adjoining breathing lengths due to temperature variations.
2.
3.
MAINTENANCE OF SEJs
Once in a fortnight SEJs shall be checked by PWI.
Packing & Alignment on SEJ shall be corrected

regularly in every fortnight.
Oiling & greasing of stock rails & tongue rail of SEJ

shall be done..
Tightening or fastening shall be done regularly.
Movement of SEJ shall be checked in every fortnight

if found any abnormal behavior action taken for
destressing of LWR.
GAPS AT SEJ
Gaps at SEJ shall be adjusted at the time of laying/
subsequent destressing of LWR/CWR.
Rail section laid
52 kg/60kg
others
Gap to be provided at td
40mm
60mm
Dec, 97
CAMTECH/C/04
The gaps at SEJ at various rail temperatures shall not differ

by more than +/- 20mm from the theoretical range
Where fishplated or SWP track is joined on one side of SEJ,
the gap between the reference mark and tongue rail tip/ stock
rail corner on LWR/CWR side shall not differ by more than
+/- 10mm from half the theoretical range.
4.
DAMAGE TO SWITCH EXPANSION JOINT

The damaged/broken SEJ shall be replaced. The new SEJ
shall be adjusted as per para 3. Traffic may be allowed if
necessary at a restricted speed and thereafter restriction
relaxed progressively.
If damaged SEJ is not available for replacement, both the
damaged SEJ and the undamaged SEJ on the opposite rail at
the same location, shall be replaced by a closure rail and
connected to LWR/CWR with special clamps and fish
plates.
The traffic over the clamped joints may be permitted at the
restricted speed. The restriction may be relaxed only after the
new SEJ has been inserted in the correct position and the
clamped joint has been replaced with in-situweld.
Dec, 97
CAMTECH/C/04
5.
BUCKLING OF TRACK
General
Buckling or a tendency towards buckling may occur, among
others, in the following circumstances :-
Failure to adhere to the temperature ranges specified

for operation on LWR/CWR.
Inadequate resistance to longitudinal, lateral and

vertical movement of track due to deficiencies in
ballast section or/ and inadequate ballast
consolidation.
Use of ineffective fastenings or missing fastening

resulting in loss of creep resistance and torsional
resistance.
Excessive settlement of formation.
Improper functioning of SEJ.
*****
Dec, 97
CAMTECH/C/04
GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE

AND TRACK STRUCTURE
1.
Gaps at SEJ depends on following factors :(a)

(b)
(c)
(d)
(e)
(f)
2.
Longitudinal Ballast Resistance of sleepers

Area of rail section
Modulous of Elasticity (E) for rail steel
Coefficient of linear expansion ( a ) for rail steel
Destressing temperature of the section where
gap at SEJ is required
Initial gap at SEJ at destressing temperature
Values of above variable for Indian Conditions are

tabulated below:
Table - I
PARAMETERS FOR STANDARD I.R. RAIL SECTIONS
(/)
Rail Section
Area
(cm2)
E
(Kg/cm2)
60 Kg (UIC)
78.86
2.15 x 106
1.152 x 10-5
52 Kg
66.15
- do -
- do -
90 R
56.95
- do -
- do -
75 R
47.37
- do -
- do -
Dec, 97
CAMTECH/C/04
Table - II
LONGITUDINAL BALLAST RESISTENCE (R) FOR
VARIOUS SLEEPERS AND SLEEPER DENSITY.
Type of sleeper
Longitudinal Ballast Resistance in Kg/cm/rail

Broad Gauge
Metre Gauge
1310 sle- 1540 sleepers/km epers/km

PRC
ST
CST-9
Wooden
12.93
11.48
9.92
7.58
13.28
12.14
10.65
7.97
1660 sleepers/km
13.74
12.68
11.04
8.06
1540 sleeper/ km
-3.86
3.47
5.0
Note : The value given are indicative and can vary

as per site conditions.
Table - III
INITIAL GAP TO BE PROVIDED AT DESTRESSING
TEMPERATURE (td)
Rail Section
Intial gap at Td (mm)
60 Kg(UIC)/ 52 Kg
Other
EXAMPLE
40 mm
60 mm
Dec, 97
CAMTECH/C/04
To find out the gap at SEJ at rail temperature of 58C with

the following data :
i)
ii)
iii)
iv)
v)
vi)
Rail section
Type of sleeper
Sleeper density
Temp. zone
Destressing temp.
Gap at SEJ at td
52 kg/m
PRC
1540 sleeper/ km
IV
td = 48C
40 mm
First of all hysteresis curve of movement of tongue/ stock

rail of SEJ will be drawn at different temperatures.
1. Movement of tongue/ stock rail from the stage of

destressing temperature (point O) to the stage of maximum
temperature (point A) for rising trend of temperature will be
= A E2 t2/ 2R
Dec, 97
CAMTECH/C/04
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 48)2 / 2 x

13.28
= 0.557 cm
= 5.57 cm
Hence coordinate of maximum temperature (point A) will be
(td + 28, + 5.57)
2.
Movement of tongue/ stock rail from stage of maximum

temperature (point A) to stage of minimum temperature
(point B) for decreasing trend of temperature will be
= A E2 t2/ 4R
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28
= 2.052 cm
= 20.50 mm
Hence coordinate of minimum temperature (point B) will be
(td + 28-76, + 5.57 - 20.52)
3.
Movement of tongue/ stock rail from stage of minimum

temperature (point B) to stage of maximum temperature
(point A) for increasing trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76)2 / 4 x 13.28
= 2.052 cm
= 20.52 mm
Dec, 97
CAMTECH/C/04
Hence coordinate of maximum temperature (point A) will be

(td -48+76, -14.95 + 20.52) or (td + 28, +5.57)
Temperature at which gap at SEJ is required is 58C i.e.
(td +10) C say point P.
4.
Value of movement of tongue/ stock rail at (td + 10) C

point P for falling trend of temperature will be
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 58)2 / 4 x
13.28
= 0.115 cm
= 1.15 mm
Hence coordinate at point P for falling trend of temperature
will be :
(td + 10, +5.57 - 1.15) or (td + 10, +4.42)
5.
In the same way, value of movement of tongue/ stock at

(td + 10) C point P for rising trend of temperature will be :
= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (58)2 / 4 x 13.28
= 1.195 cm
= 11.95 mm
Dec, 97
CAMTECH/C/04
ABC-
GAP AT SEJ AT DISTRESSING TEMPERATURE (td)

GAP AT SEJ AT 38 C (td + 10C) FOR FALLING
TREND OF TEMP.
GAP AT SEJ AT 38C (td + 10C) FOR INCREASING
TREND OF TEMP.
Hence coordinate at point P for rising trend of temperature

will be :
( td + 10, -14.95 + 11.95) or ( td + 10, - 3.0)
Dec, 97
CAMTECH/C/04
10
The calculations done above indicatesthat at temperature td

+ 10C i.e. at 58C, movement of one side of tongue/ stock
rail for decreasing trend of temperature is + 4.42 and for
increasing trend temperature is -3.0 mm.
Hence taking twice of movement of tongue/ stock rail for
each side of SEJ, minimum gap at SEJ for decreasing trend
of temperature at td + 10 i.e. (58C) will be 40 -2 x 4.42 =
31.16 mm and maximum gap at SEJ for increasing trend of
temperature at td + 10 i.e. (58 C) will bw = 40 + 2 x 3.0 =
46 mm.
Note : * value of 40 mm taken as gap at SEJ at destressing
temperature td . In case gap is set as 60 mm value of 60 mm
is to be taken for calculation .
Hence theoretical range of gap at SEJ at 58C shall be
within (31.16 mm to 46 mm). Taking into consideration
allowance as per para 5.6.1 the gap should be (31.16 - 20 =
11.16 mm to 46 + 20 = 66 mm ).
Similarly values of gaps for various temperatures, track
structures, temperature zones etc. can be calculated.
*******
Dec, 97
CAMTECH/C/04
11
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg PRC

SLEEPER, 1660 Nos/Km, VALUE OF r (BALLAST RESISTANCE) ASSUMED
= 13.74 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg. rails and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
--
28
td + 25
--
--
30
28 to 31
td + 20
--
34
30 to 35
28 to 31
td + 15
36
34 to 38
31 to 40
29 to 42
td + 10
37 to 40
34 to 42
32 to 45
30 to 47
td + 05
37 to 44
35 to 46
33 to 49
32 to 51
td
38 to 47
37 to 50
35 to 53
34 to 55
td - 05
40 to 49
39 to 53
37 to 56
36 to 59
td - 10
41 to 51
41 to 55
40 to 59
39 to 62
td - 15
44 to 53
43 to 57
43 to 62
42 to 65
td - 20
46 to 55
46 to 59
46 to 64
46 to 67
td - 25
49 to 56
50 to 61
50 to 66
50 to 69
td - 30
53 to 56
54 to 62
54 to 67
54 to 71
td - 35
56
58 to 62
59 to 68
59 to 71
td - 40
--
62
64 to 69
64 to 73
td - 45
--
--
69
70 to 74
td - 48
--
--
--
74
Note :
The above values have been calculated with initial setting of gaps at SEJ as 40 mm.
Where initial setting of SEJ is 60 mm, 20 mm should be added to each of above
values for comparioson of gaps at site.
Dec, 97
CAMTECH/C/04
12

SLEEPER, 1540 Nos/Km, VALUE OF R (BALLAST RESISTANCE) ASSUMED
= 13.28 kg/cm/rail AND td = tm + 5 C to tm + 10C for 52 kg and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
--
27
td + 25
--
--
30
27 to 28
td + 20
--
33
30 to 35
27 to 31
td + 15
36
34 to 38
31 to 40
28 to 37
td + 10
36 to 40
34 to 43
32 to 45
30 to 42
td + 05
37 to 44
35 to 46
33 to 50
32 to 52
td
38 to 47
37 to 50
35 to 53
34 to 56
td - 05
40 to 50
39 to 53
37 to 57
36 to 60
td - 10
41 to 52
41 to 56
40 to 60
39 to 63
td - 15
44 to 54
44 to 58
43 to 63
42 to 66
td - 20
46 to 55
47 to 60
46 to 65
46 to 67
td - 25
50 to 56
50 to 61
50 to 67
50 to 70
td - 30
53 to 57
54 to 62
55 to 68
55 to 72
59 to 69
60 to 73
td - 35
57
56 to 63
td - 40
--
63
65 to 70
65 to 74
td - 45
--
--
70
72 to 75
td - 48
--
--
--
75
Note :
Dec, 97
CAMTECH/C/04
13
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 60 kg ST

= 12.14 kg/cm/rail AND td = tm + 5C to tm + 10C kg and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
--
26
td + 25
--
--
29
26 to 30
td + 20
--
33
29 to 35
26 to 36
td + 15
36
33 to 38
30 to 40
27 to 42
td + 10
36 to 40
34 to 43
31 to 46
29 to 48
td + 05
37 to 44
35 to 47
32 to 50
31 to 53
td
38 to 47
36 to 51
34 to 55
33 to 57
td - 05
40 to 50
38 to 54
37 to 59
36 to 61
td - 10
41 to 53
41 to 57
42 to 62
39 to 65
td - 15
44 to 55
44 to 60
43 to 65
43 to 68
td - 20
47 to 56
47 to 62
46 to 67
47 to 71
td - 25
50 to 58
51 to 63
51 to 69
51 to 73
td - 30
54 to 58
55 to 64
56 to 71
56 to 75
td - 35
58
61 to 72
72 to 77
td - 40
--
65
67 to 73
68 to 77
td - 45
--
--
73
74 to 78
td - 48
--
--
--
78
Note :
60 to 65
Dec, 97
CAMTECH/C/04
14

= 13.74 kg/cm/rail AND td = tm + 5C to tm + 10 C for 52 kg and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
--
29
td + 25
--
--
31
29 to 32
td + 20
--
35
32 to 36
30 to 37
td + 15
37
35 to 39
32 to 40
30 to 42
td + 10
37 to 40
35 to 42
33 to 44
32 to 46
td + 05
38 to 43
36 to 45
34 to 48
33 to 50
td
39 to 46
37 to 48
36 to 51
35 to 53
td - 05
40 to 48
39 to 51
38 to 54
37 to 56
td - 10
41 to 50
41 to 53
40 to 57
39 to 59
td - 15
43 to 51
43 to 55
42 to 59
42 to 61
td - 20
45 to 53
46 to 57
45 to 61
45 to 64
td - 25
48 to 53
48 to 58
49 to 62
49 to 65
td - 30
51 to 54
52 to 59
52 to 64
52 to 67
55 to 59
56 to 64
57 to 68
td - 35
54
td - 40
--
59
60 to 65
61 to 69
td - 45
--
--
65
66 to 69
td - 48
--
--
--
69
Note :
values for comparison of gaps at site.
Dec, 97
CAMTECH/C/04
15

= 13.28 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
-- 29
td + 25
--
--
31
29 to 32
td + 20
--
34
31 to 36
29 to 37
td + 15
37
34 to 38
32 to 40
30 to 42
td + 10
37 to 40
35 to 42
33 to 44
31 to 46
td + 05
38 to 43
36 to 46
34 to 48
33 to 50
td
39 to 46
37 to 49
36 to 52
34 to 54
td - 05
40 to 48
39 to 51
38 to 55
37 to 57
td - 10
41 to 50
41 to 54
40 to 57
39 to 60
td - 15
43 to 52
43 to 55
42 to 60
42 to 62
td - 20
46 to 53
46 to 57
46 to 62
45 to 64
td - 25
48 to 54
49 to 58
50 to 63
49 to 66
td - 30
51 to 54
52 to 59
53 to 64
53 to 68
56 to 60
57 to 65
57 to 69
td - 35
55
td - 40
--
60
61 to 66
td - 45
--
--
66
td - 48
--
--
--
Note :
62 to 69
67 to 70
70
Dec, 97
CAMTECH/C/04
16
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg ST

Temperaure
Zone I
Zone II
Zone III
Zone IV
28
td + 28
--
--
--
td + 25
--
--
30
td + 20
--
34
30 to 36
28 to 37
td + 15
37
34 to 38
31 to 40
29 to 42
28 to 31
td + 10
37 to 40
35 to 42
32 to 45
30 to 47
td + 05
37 to 44
36 to 46
33 to 49
32 to 51
td
38 to 46
37 to 49
35 to 53
34 to 55
td - 05
40 to 49
39 to 52
37 to 56
36 to 58
td - 10
41 to 51
41 to 55
40 to 59
39 to 62
td - 15
44 to 53
43 to 57
43 to 61
40 to 64
td - 20
46 to 54
46 to 59
46 to 64
46 to 67
td - 25
49 to 55
50 to 60
50 to 65
52 to 69
td - 30
52 to 56
53 to 61
54 to 67
54 to 70
td - 35
56
58 to 68
59 to 71
td - 40
--
62
63 to 68
64 to 72
td - 45
--
--
68
69 to 73
td - 48
--
--
--
73
Note :
57 to 62
Dec, 97
CAMTECH/C/04
17
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 52 kg CST-9

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 28
--
--
--
26
td + 25
--
--
29
26 to 30
td + 20
--
33
29 to 35
27 to 36
td + 15
36
33 to 38
30 to 40
28 to 42
td + 10
36 to 40
34 to 43
31 to 46
td + 05
37 to 44
35 to 47
32 to 50
30 to 52
td
38 to 47
36 to 51
34 to 54
33 to 57
td - 05
40 to 50
38 to 54
37 to 58
36 to 61
td - 10
42 to 53
41 to 57
42 to 61
39 to 65
td - 15
44 to 55
44 to 59
43 to 64
43 to 68
td - 20
47 to 56
47 to 61
47 to 67
47 to 70
td - 25
50 to 57
51 to 63
51 to 69
51 to 73
td - 30
54 to 58
55 to 64
56 to 70
56 to 74
td - 35
58
61 to 71
61 to 76
td - 40
--
65
66 to 72
td - 45
--
--
72
73 to 77
td - 48
--
--
--
77
Note :
62 to 65
29 to 48
67 to 77
Dec, 97
CAMTECH/C/04
18
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R PRC

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
47
td + 30
--
--
49 47 to 49
td + 25
--
52
td + 20
55
49 to 53
53 to 56
50 to 57
47 to 54
48 to 58
td + 15
55 to 58
53 to 59
50 to 60
49 to 61
td + 10
56 to 60
54 to 62
51 to 64
50 to 65
td + 05
57 to 63
55 to 65
53 to 67
51 to 68
td
58 to 65
56 to 67
54 to 69
53 to 71
td - 05
59 to 67
58 to 69
56 to 71
56 to 73
td - 10
61 to 68
60 to 71
59 to 73
58 to 75
td - 15
63 to 69
62 to 72
61 to 75
61 to 77
td - 20
65 to 70
65 to 73
64 to 77
64 to 79
td - 25
67 to 70
67 to 74
67 to 78
67 to 80
td - 30
70
71 to 74
71 to 78
71 to 81
td - 35
--
74
75 to 79
75 to 82
td - 40
--
62
79
79 to 82
td - 43
--
--
--
82
Dec, 97
CAMTECH/C/04
19
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R ST

= 12.14 kg/cm/rail AND td = tm + 5 C to tm + 10C for 52 kg and haviour.
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
45
td + 30
--
--
48
45 to 48
td + 25
--
52
48 to 52
46 to 53
td + 20
55
52 to 55
49 to 57
47 to 58
td + 15
55 to 58
52 to 59
49 to 61
48 to 62
td + 10
55 to 61
53 to 62
51 to 64
49 to 65
td + 05
56 to 63
54 to 65
52 to 67
51 to 69
td
57 to 65
56 to 68
54 to 70
53 to 72
td - 05
59 to 67
58 to 70
56 to 73
55 to 74
td - 10
61 to 69
60 to 72
59 to 75
58 to 77
td - 15
63 to 70
62 to 73
62 to 77
61 to 79
td - 20
65 to 71
65 to 74
65 to 78
64 to 81
td - 25
68 to 71
68 to 75
68 to 79
68 to 82
td - 30
71
72 to 80
72 to 83
td - 35
--
76
76 to 81
76 to 84
td - 40
--
--
81
81 to 84
td - 43
--
--
--
84
72 to 76
Dec, 97
CAMTECH/C/04
20
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR BG 90 R CST - 9

= 10.65 kg/cm/rail AND td = tm + 5C to tm + 10C for 52 kg and haviour
Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
43
td + 30
--
--
46
43 to 47
td + 25
--
50
46 to 51
44 to 52
td + 20
54
51 to 55
47 to 56
45 to 57
td + 15
54 to 58
51 to 59
48 to 61
46 to 62
td + 10
55 to 61
52 to 62
49 to 65
47 to 66
td + 05
56 to 64
54 to 66
51 to 68
49 to 70
td
57 to 66
55 to 69
53 to 71
52 to 73
td - 05
59 to 68
56 to 74
54 to 76
td - 10
61 to 70
61 to 73
58 to 77
57 to 79
td - 15
63 to 71
63 to 75
62 to 79
61 to 81
td - 20
66 to 72
66 to 76
65 to 81
65 to 83
td - 25
69 to 73
69 to 77
69 to 82
69 to 85
td - 30
73
73 to 83
73 to 86
td - 35
--
78
79 to 83
79 to 87
td - 40
--
--
84
84 to 87
td - 43
--
--
--
87
57 to 71
73 to 78
Dec, 97
CAMTECH/C/04
21
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
14
td + 30
--
--
22
14 to 24
td + 25
--
34
23 to 36
16 to 38
td + 20
43
34 to 46
24 to 49
18 to 52
td + 15
44 to 53
36 to 57
27 to 62
21 to 65
td + 10
45 to 62
38 to 67
31 to 73
25 to 77
td + 05
48 to 70
42 to 76
35 to 83
31 to 87
td
52 to 77
47 to 84
41 to 92
37 to 97
td - 05
56 to 83
53 to 91
48 to 99
45 to 105
td - 10
62 to 87
59 to 96
56 to 106
53 to 113
td - 15
69 to 91
67 to 101
65 to 112
63 to 119
td - 20
77 to 94
76 to 105
75 to 117
73 to 125
td - 25
86 to 95
86 to 107
86 to 121
85 to 129
td - 30
96
97 to 109
98 to 123
98 to 132
td - 35
--
109
111 to 125
111 to 134
td - 40
td - 43
--
--
125
127 to 136
--
--
--
136
Dec, 97
CAMTECH/C/04
22
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
td + 30
--
--
18
9 to 24
td + 25
--
31
18 to 34
11 to 36
td + 20
41
31 to 44
20 to 48
13 to 51
td + 15
42 to 52
33 to 56
23 to 62
17 to 65
td + 10
44 to 62
36 to 68
27 to 74
21 to 78
td + 05
47 to 71
40 to 78
32 to 85
27 to 90
td
51 to 79
45 to 86
39 to 95
35 to 101
td - 05
56 to 85
52 to 94
47 to 104
43 to 110
td - 10
62 to 90
59 to 100
55 to 112
52 to 119
td - 15
70 to 95
68 to 106
65 to 118
63 to 126
td - 20
79 to 97
78 to 110
76 to 123
75 to 132
td - 25
89 to 99
89 to 113
89 to 127
88 to 137
102 to 114
102 to 130
102 to 140
td - 30
100
td - 35
--
115
117 to 132
117 to 143
td - 40
--
--
133
134 to 144
td - 43
--
--
--
144
Dec, 97
CAMTECH/C/04
23
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R ST

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
22
td + 30
--
--
28
22 to 30
td + 25
--
38
29 to 40
23 to 42
td + 20
46
39 to 48
30 to 51
25 to 54
td + 15
46 to 54
40 to 57
23 to 61
28 to 64
td + 10
48 to 62
42 to 66
35 to 71
31 to 74
td + 05
50 to 68
45 to 73
39 to 79
37 to 83
td
53 to 74
49 to 80
44 to 86
41 to 91
td - 05
57 to 79
54 to 85
50 to 93
47 to 98
td - 10
62 to 83
60 to 90
57 to 99
54 to 104
td - 15
67 to 86
66 to 94
64 to 103
62 to 109
td - 20
74 to 88
74 to 97
72 to 107
71 to 114
td - 25
81 to 99
82 to 99
81 to 110
84 to 117
td - 30
90
92 to 113
91 to 120
td - 35
--
101
102 to 114
103 to 122
td - 40
--
--
125
115 to 123
td - 43
--
--
--
123
91 to 101
Dec, 97
CAMTECH/C/04
24
GAPS OF SEJ FOR VARIOUS TEMPERATURES IN mm FOR MG 90 R CST-9

Temperaure
Zone I
Zone II
Zone III
Zone IV
td + 33
--
--
--
18
td + 30
--
--
25
18 to 26
td + 25
--
36
25 to 38
19 to 40
td + 20
44
36 to 47
27 to 50
21 to 53
td + 15
45 to 54
38 to 57
29 to 61
24 to 65
td + 10
46 to 62
40 to 66
33 to 72
28 to 75
td + 05
49 to 69
43 to 75
37 to 81
33 to 85
td
52 to 76
48 to 82
42 to 89
39 to 94
td - 05
57 to 81
53 to 88
49 to 97
46 to 102
td - 10
62 to 85
60 to 94
56 to 103
54 to 109
td - 15
68 to 89
67 to 98
64 to 108
62 to 115
td - 20
76 to 91
75 to 101
74 to 113
72 to 120
td - 25
84 to 93
84 to 104
84 to 116
83 to 124
td - 30
93
95 to 118
95 to 127
td - 35
--
106
107 to 120
108 to 129
td - 40
--
--
120
121 to 130
td - 43
--
--
--
130
95 to 105
Dec, 97
CAMTECH/C/04
**
25
Movement of rail shall be positive in the direction of

traffic on double lines and in the direction of heavier
traffic on single lines which shall be specified.
(a) and (b) will almost always be positive.
Left and right rails on single lines are determined,
looking in the direction of increasing kilometrage.
The reference line for each SEJ shall be marked by two
rail pieces in such away that it is central with respect to
the tip of the tongue and the edge of the foot of stock
rail where planning ends (a+b) at the time of
destressing done immediately after laying of LWR/
CWR. The following line should not be shifted at any
subsequent destressing.
The reference marks at the centre of LWR/ CWR shall
consist of (a) saw marks on the rail pieces fixed as
reference pillars on the cess and (b) paint marks on the
non-gauge side of the rail heads of the LWR/ CWR
rails. Additional reference pillars may erected to
observe the behaviou of movement of LWR/ CWR.
***
Dec, 97
CAMTECH/C/04
26
NOTES
Dec, 97
CAMTECH/C/04
27
OUR OBJECTIVE
To upgrade Maintenance
Technologies and Methodologies
and achieve improvement in
productivity and performance
of all Railway assets and manpower
which inter-alia would cover
Reliability, Availability,
and Utilisation.
If you have any suggestion & any specific comments,

please write to us :
Contact person
Jt. Director (Civil)
Postal
Address
:
:
Centre for Advanced

Maintenance Technology,
Maharajpur, Gwalior (M.P.)
Pin code 474 020
Phone
Fax
:
:
(0751) - 470869, 470803

(0751) - 470841
Dec, 97

Handbook On Maintenance of Switch Expansion Joint

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Handbook On Maintenance of Switch Expansion Joint

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CAMTECH/C/04

Handbook on Maintenance of Switch Expansion Joint

Handbook on Maintenance of Switch Expansion Joint

GAPS OF SEJ FOR VARIOUS

B.G. 60 Kg PRC sleeper, 1660 nos/km,

B.G. 60 Kg PRC sleeper, 1540 nos/ km,

Handbook on Maintenance of Switch Expansion Joint

B.G. 60 Kg ST sleeper, 1540 nos/ km,

B.G. 52 Kg PRC sleeper, 1660 nos/ km,

B.G. 52 Kg PRC sleeper, 1540 nos/ km,

B.G. 52 Kg ST sleeper, 1540 nos/ km,

B.G. 52 Kg CST-9 sleeper, 1540 nos/ km,

B.G. 90 R PRC sleeper, 1540 nos/ km,

B.G. 90 R ST sleeper, 1540 nos/ km,

B.G. 90 R CST-9 sleeper, 1540 nos/ km,

M.G. 90 R ST sleeper, 1540 nos/ km,

M.G. 90 R CST-9 sleeper, 1540 nos/ km,

M.G. 90 R ST sleeper, 1540 nos/ km,

M.G. 90 R CST-9 sleeper, 1540 nos/ km,

Handbook on Maintenance of Switch Expansion Joint

Handbook on Maintenance of Switch Expansion Joint

Handbook on Maintenance of Switch Expansion Joint

SWITCH EXPANSION JOINT(SEJ)

Once in a fortnight SEJs shall be checked by PWI.

Packing & Alignment on SEJ shall be corrected

Oiling & greasing of stock rails & tongue rail of SEJ

Tightening or fastening shall be done regularly.

Movement of SEJ shall be checked in every fortnight

Handbook on Maintenance of Switch Expansion Joint

The gaps at SEJ at various rail temperatures shall not differ

DAMAGE TO SWITCH EXPANSION JOINT

Handbook on Maintenance of Switch Expansion Joint

Failure to adhere to the temperature ranges specified

Inadequate resistance to longitudinal, lateral and

Use of ineffective fastenings or missing fastening

Excessive settlement of formation.

Improper functioning of SEJ.

Handbook on Maintenance of Switch Expansion Joint

GAPS AT SEJ FOR VARIOUS RAIL TEMPERATURE

Gaps at SEJ depends on following factors :(a)

Longitudinal Ballast Resistance of sleepers

Values of above variable for Indian Conditions are

Handbook on Maintenance of Switch Expansion Joint

Longitudinal Ballast Resistance in Kg/cm/rail

1310 sle- 1540 sleepers/km epers/km

Note : The value given are indicative and can vary

Intial gap at Td (mm)

Handbook on Maintenance of Switch Expansion Joint

To find out the gap at SEJ at rail temperature of 58C with

First of all hysteresis curve of movement of tongue/ stock

1. Movement of tongue/ stock rail from the stage of

Handbook on Maintenance of Switch Expansion Joint

= 66.15 x 2.15 x 106 x (1.152 x 10-5)2 x (76 - 48)2 / 2 x

Movement of tongue/ stock rail from stage of maximum

Movement of tongue/ stock rail from stage of minimum

Handbook on Maintenance of Switch Expansion Joint

Hence coordinate of maximum temperature (point A) will be

Value of movement of tongue/ stock rail at (td + 10) C

In the same way, value of movement of tongue/ stock at

Handbook on Maintenance of Switch Expansion Joint

GAP AT SEJ AT DISTRESSING TEMPERATURE (td)

Hence coordinate at point P for rising trend of temperature

Handbook on Maintenance of Switch Expansion Joint