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AALRT

AALRT Enterprise Standards

Line Facilities Maintenance Regulations

Approved by:

()
Checked by (Law):

()
Checked by (English):

()
Checked by (Chinese):

Reviewed by: Sun Hongyu

2015.08.20
Date: August 20, 2015


Prepared by: Gong Chengguang

Dept.: Maintenance Center

2015.04.30
Date: May 30, 2015

A
Version: A

Revised by:

Revised on:

Controlled State: Internal


Control

Issue No.:

2015.08.30
Issued On: August 30, 2015

2015.11.20
Implemented on: Nov.20,2015

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Contents
1

1 Scope

2. Normative reference

3 Organization of track equipments maintenance work

4 Inspection of track equipment

15

5. Operation requirements for main maintenance items of track

15

21

6 Appendix

21

22

Appendix A: Management system of track inspection

22

23

Appendix B: Notification on clearing the relevant four haves and three-in-one regulation on track
profession
23
C

37

Appendix C: Common tables

37

60

Appendix D: Wording instruction in this specification

60

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Maintenance Regulations of Line Facilities


1
1 Scope
1.1
1.1 This Regulation stipulates the requirements, methods, procedures, contents and standards for
maintenance of track equipments of Addis Ababa Light Rail Transit.
1.2 1435mm 80
/h
1.2 This Regulations is applied for maintenance and management of the track equipments for lines with
standard track gauge of 1435m and running speed 80 /h, the work of which is conducted by track
workers on east-west line and north-south line of Addis Ababa Light Rail Transit.
2
2. Normative reference
2.1
2.1 PRC national standard of Code for Construction and Acceptance of Metro Engineering
2.2
2.2 Rules for Maintenance of Railway Line of Ministry of Railways of the Peoples Republic of China.
3
3 Organization of track equipments maintenance work
3.1
3.1 Content of maintenance work
3.1.1
3.1.1 Track equipments maintenance can be divided into comprehensive maintenance, regular
maintenance and temporary maintenance.
3.1.2

3.1.2 Comprehensive maintenance is periodically conducted to the track as planned according to the
tracks change rules and characteristics, focusing on comprehensively improving the track elasticity,
adjusting the tracks physical dimension, and replace and repair the invalid parts and components, so
as to recover the good technical state of the track.
3.1.3

3.1.3 Regular maintenance refers to conducting monthly, focused and planned maintenance to the track
equipments according to the lines change, so as to keep the track equipments in good condition.
3.1.4

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3.1.4 Temporary maintenance refers to timely repairing the faults that are beyond the allowable
deviation management value of temporary maintenance as well as temporarily repairing other abnormal
parts, so as to guarantee steady and safe traveling.
3.1.5
3.1.5 Major repair work cycle for track equipments
1)

1) At present, there is no fixed work cycle for comprehensive track maintenance of Addis Ababa Light
Rail Transit, so relevant maintenance task should be established according to the characteristics of
tracks change as well as the current quality condition of the track equipments.
2)
2) Regular maintenance cycle: Normally this kind of maintenance is conducted monthly with plan.
3)
3) Temporary maintenance cycle: Temporary maintenance has no fixed work cycle and shall be carried
out according to the extent of the influence of the line faults to the traveling; generally it will be carried
out after monthly check.
4)
4) The tracks static check cycle: The whole line will be checked monthly.
5) 1

5) The tracks routing inspection cycle: Routing inspection is arranged by professional line crew and
shall be conducted no less than once every day (adjusted according to the facts in important holidays
when there is no route plan).
6) 1 400m
2 C1
6) The tracks manual oiling cycle: The slide plate in the turnout area shall be oiled once every month or
more according to the condition of the equipments. The steel rail with radius less than 400m shall be
oiled no less than twice every month and more for special section. See Track Oiling Record (appendix
C1) for oiling record.
7)
7) The main track curve versine check shall be conducted once every year, and the rail yard shall be
checked once every half year, and they can be combined with monthly check.
3.1.6
3.1.6 Basic work content of comprehensive line and turnout maintenance
1)
1) Adjust the physical dimension of the track to meet the acceptance standard for maintenance
operation.
2)
2) Replace the damaged steel rail, turnout parts and invalid connection parts, and weld the broken rail
well.
3) T
3) Oil the fastening bolts in segments, and clean the T-type fastening bolts.
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4)

4) The track shall be properly raised according to the line status, and the heighten base plate in
concrete sleeper section shall be removed, with comprehensive or focused tamping; crushed rubber
mat shall be replaced in the whole track bed section.
5)
5) Adjust the rail gap, rebuilt, replace and supplement track reinforcement equipment, repair the track
creeping, and lock the turnout of the line.
6)
6) Repair the road shoulder, clear the weeds on the track bed and the road shoulder, and keep the
whole track bed clean.
7)
7) Repair the crossing and drainage ditch, repair, supplement and Refurbish the symbol, and recycle
the used materials along the line.
3.1.7
3.1.7 Basic work content of regular line and turnout maintenance.
1)
1) Repair the line with the tracks physical dimension beyond the allowable deviation management
value of regular maintenance.
2)
2) Repair the track bed which has rising soils, even the track ballast and clean the track bed.
3)
3) Replace the invalid sleeper and turnout sleeper in single piece, and replace individual invalid
fastener.
4)
4) Adjust the rail gap, and lock the line.
5)
5) Repair track reinforcement equipment
6)
6) Repair the damaged joint.
7)
7) Grind the fat edges of the steel rail.
8)
8) Repair the fasteners, and oil the fasteners, joint bolts and slide plate.
9)
9) Refurbish the symbol of the rail track, and fasten the route sign.
10)
10) Repair the road shoulder, and dredge the drainage facilities.
11)
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11) Clear weeds and wastes on track bed and road shoulder as well as and other matters influencing
the appearance of the line.
12)
12) Keep the whole track bed in turnout area clean.
3.1.8
3.1.8 Basic work content of urgent line and turnout repair.
1)
1) Rebuilt the place with the tracks physical dimension beyond the allowable deviation of temporary
maintenance.
2)
2) Replace seriously damaged steel rail.
3)
3) Replace the damaged plywood, broken joint bolt and guardrail bolt.
4)
4) Adjust seriously abnormal track gauge.
5)
5) Dispose of the broken and seriously damaged rail and seriously damaged weld joint in seamless
track area.
6)
6) Check the drainage facility sections that are prone to be silted, and repair the road and track bed that
have been seriously eroded (ballast track bed)
7)
4
4 Inspection of track equipment
4.1
4.1 Track inspection
4.1.1
4.1.1 Track inspection

Track inspection refers to routine inspection work for track equipment in which track equipment is
inspected during train outage time at night (yard track is determined according to actual conditions),
clearance limit obstacles are handled and small repair in inspection is done well to ensure traffic safety.
Appropriate personnel shall be arranged for track inspection work by each track shift.

Inspection for key sections shall be strengthened.


1)

1) Tour diagram or inspection plan shall be prepared by each division according to requirements of
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higher level and specific conditions of track equipment; and tour diagram shall be amended
correspondingly according to track equipment and traffic requirements.
2)
2) The tour diagram stipulates commencement date and dead track, inspection time, tour route, startstop sections, key inspection parts, requirements of shift change and other contents.
3)
3) The inspectors shall possess high responsibility, enjoy good health, good vision and hearing senses
with certain professional skills and take up their quarters after passing through training.
4)

4) The inspectors shall possess the following conditions and ability: be familiar with relevant rules and
regulations and track business; understand limit knowledge of stacking materials and tools near to the
track, damage determination and marking method for rail and connecting parts, defect identification
knowledge of spare and accessory parts, emergency treatment knowledge for broken rail of gapless
track and track buckling, and have ability to separately to handle relevant faults; be capable to measure
and inspect equipment damage conditions and do small repair in inspection.
4.1.2
4.1.2 Main contents for inspection of track equipment
1)
1) Rail inspection: inspect whether the marked damage is aggravated and determine the rail according
to damage standards.
2)

2) Inspection of clamp plate and bolt: inspect deformation, flaw, breaking and rail gap of the clamp plate
(including emergency restore device) according to standards; inspect looseness and defect of track
bolt, fastener bolt and gasket.
3)

3) Turnout inspection: inspect crack falling, matching and empty sling of switch rail; inspect frog and
guard rail; inspect connecting parts.
4)

4) Inspection of rail overlapping device: inspect crack falling, matching and empty sling of switch rail
and stock rail; inspect connecting parts; record the expansion amount.
5)
,
5) Inspection of subgrade ballast bed: inspect sinking, falling and collapse of subgrade ballast bed;
inspect damage of sleepers; inspect flooding of subgrade and bed ponding; inspect whether the
drainage ditch is silted up and whether there is crack and damage in the ballast bed.
6)
6) For clearance limit obstacles: move away the clearance limit obstacles and do small repair in
inspection.
7)
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7) Ballast bed and concrete short sleepers: inspect whether there is serious cracking and deformation
in ballast bead and concrete short sleepers.
8)
8) Inspect whether the track sign is firm.
9) :
9) Bumper inspection: clear obstacles within the scope of various bumpers and tighten the bolt timely
as required.
4.1.3
4.1.3 Contents of small repair in inspection: retighten, install and change lose and defective spare and
accessory parts of track and turnout.
4.1.4

4.1.4 Principles of fault handling: the fault which can be eliminated shall be immediately eliminated; if it
cannot be eliminated, it shall be immediately reported to maintenance shift for handling or dispatching.
If the fault endangers traffic safety, active measures shall be taken; if the fault cannot be immediately
handled, it shall be set with protection and immediately reported to train dispatching to show danger
degree and required time.
4.1.5
4.1.5 Regulations and notes for inspection tour
1)
1) Application of start and end shall be registered according to route stipulated by tour diagram and
inspection tour shall be comprehensive examination and key inspection.
2
2) The inspector shall walk in the road center and pay attention to holes in viaduct section.
3 3km/h
3The inspection speed shall not exceed 3km/h.
4/ C11

4 Inspection sign-in box shall be set in starting/ending points of inspection sections and inspection
attendance book shall be put in the box (see Appendix C11). The inspector shall sign in when reaching
sign-in box.
4.1.6 C2
4.1.6 After shift inspection is completed, the inspectors shall carefully fill in Tally Book Of Track
Inspection (see Appendix C2), the shift leader shall endorse it every month.
4.2
4.2 Monthly inspection
4.2.1

25
4.2.1 Monthly inspection is one static equipment inspection with complete items conducted by the track
shift for track equipment under administration every month. The track shift shall comprehensively
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inspect the equipment, make efforts to master change rules of equipment and do well status survey for
preparation of next month track equipment maintenance plan. Inspection dead track is before 25 th of
every month, if any urgent adjustment, notify the track professional skill team.
4.2.2
4.2.2 Main contents and requirements of inspection
1)

C3 C4 C5 C7
1) Offset distance size is inspected for all parts such as track gauge, level, twist of track, guard rail
check gauge, guard rail face gage, turnout with track gauge and offset scale. During inspection, Tally
Book of Track Inspection, Tally Book of Turnout Inspection, Tally Book of Diamond Turnout Inspection,
Tally Book of Routine Maintenance and Inspection for Anti-Drop Guardrail shall be filled in (see
Appendix C3, Appendix C4, Appendix C5, Appendix C7).
2) 10m
C6
2) Curve site versine for main track and roll stock depot curve (or connection curve) is fully measured
with 10m string. Tally Book of Curve Versine Inspection shall be filled in during inspection (see
Appendix C6).
4.2.3

4.2.3 Measured data of monthly inspection shall be recorded in equipment inspection records as
required. The track shift leader shall be responsible for signature of monthly inspection data for track
equipment under administration, cross and mark the overrun position in inspection records. The data is
divided according to overrun classification. The management value exceeding urgent repair allowable
deviation or overrun position endangering traffic safety shall be immediately handled according to the
principle of handling overrun, first serious and then common and shall not exceed completion of next
construction point at the latest.
4.2.4
4.2.4 After the overrun is eliminated, the operation director shall make mark and sign on the inspection
record.
4.3
4.3 Quarterly inspection

Rail gap of rail shall be inspected in seam track section every quarter and adjusted according to
inspection conditions.
4.4
4.4 Annual inspection

79

Annual inspection and evaluation of track equipment is basic index of inspecting management of track
equipment and evaluating state of track equipment as well as main basis of arranging the next year
work. Annual inspection is arranged in relatively centralized period (generally in July-September) every
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year; seasonal season shall be arranged in high temperature season and rainstorm flood season.
Annual inspection and seasonal inspection shall be arranged by industrial construction division of
maintenance center and organized by track professional skill team.
4.4.1
C8
4.4.1 Annual inspection is to make grade evaluation for equipment after measured investigation
according to evaluation standards of track equipment state and prepare Statistical Report on Track
Equipment State (see Appendix C8).
4.4.2

4.4.2 Seasonal inspection is to make necessary strengthening inspection for key parts of track
equipment when climates happen to influence track equipment (high temperature anti-bulging,
rainstorm flood season) according to characteristics of track equipment characteristics, mainly is open
air track inspection. Starting and ending time of seasonal (high temperature anti-bulging, rainstorm
flood season) inspection shall be determined by the division according to customs and specific
conditions and conducted by division professional engineer or track shift leader and inspection during
daily tour inspection or train crew-adding inspection. Any danger for traffic safety in seasonal inspection
work shall be immediately reported to the division and train dispatching, timely organized and handled.
Other safe potential risk shall be reported timely.
4.4.3
4.4.3 Inspection of high temperature anti-bulging
1)

1) Inspection of high temperature anti-bulging mainly observe direction change of track and curve,
broken bending, looseness of fastener bolt, blockage of joint rail gap, full degree of ballast bed, empty
sling of soft sleepers, gap of ballast and sleeper ballast separation under dynamic load effect and other
conditions.
2)
2) Rail temperature shall be measured for inspection of high temperature anti-bulging.
4.4.4
4.4.4 Inspection of rainstorm flood season

Inspection of rainstorm flood season is mainly to inspect track drainage conditions, ponding and
flooding of ballast bed and subgrade, sinking and falling of ballast bed and subgrade, landslide of
subgrade slope, sinking of track rail surface and track mud-pumping and other conditions.
4.5
4.5 Dynamic inspection
4.5.1
4.5.1 Train crew-adding inspection
1) 1
1
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1) Cycle of train crew-adding inspection: shift leader of main track shall make train crew-adding
inspection not less than once for equipment under his administration; track technicians of each division
shall make train crew-adding inspection not less than once for equipment under its administration;
manager and deputy manager of each division shall make train crew-adding inspection not less than
once for equipment under their administration.
2)
2) Train crew-adding inspection items mainly include driving shaking, rail and wheel touching, abnormal
noise and other conditions.
3)
3) Abnormal driving shaking, abnormal noise of rail and wheel touching found in train crew-adding
inspection shall be notified to shift under administration. The shift shall make actual measurement and
repeated measurement to confirm it after the operation ends.
4)
4) During the rainy season, the personnel shall be arranged once to make electric passenger train
crew-adding inspection to observe change conditions of track equipment.
4.5.2
4.5.2 Inspection of measuring tools
1)
1) Inspection of measuring tools is to regularly check and verify instruments and apparatuses for
inspected track equipment according to relevant standards.
2) AALRT
2) The cycle for inspection of measuring tools can be formulated according to relevant standards. The
terms which have corresponding standards can be determined by AALRT alone.
3)

3) The instruments and apparatuses listed within the scope of measuring tools inspection include
gauging rule, offset scale, square rule, torsional moment wrench, thermo detector, abrasion inspection
rule, flaw detector and pressure gauge, etc.
4)
4) Inspection of measuring tools shall meet requirements of relevant metrology testing system.
5)
5) The measuring tools pass through detection shall be pasted with signs meeting requirements. The
measuring tools without signs or exceeding period of validity shall be strictly prohibited.
6)
6) The measuring tools shall be stored by the shift uniformly.
4.6
4.6 Inspection of rail damage
4.6.1
3 C11
4.6. If any damage is found in rail ultrasonic inspection, the operators shall make grade determination
according to damage degree and propose handling suggestion, make records and signs, as shown in
Table 3. Monthly Report on Damaged Rail shall be prepared well (see Appendix C11).
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3
Table 3 Rail damage signs

Type of damage

Damage range and signs

Description

Continuous damage

A little position

Minor damage

Signed with white paint

Minor damage
which will be
aggravated

Ditto

Serious damage

Ditto

4.6.2
4.6.2. The damage endangering traffic safety shall be immediately notified to shift and reported to
dispatching. Measures shall be timely taken.
4.7
4.7 Inspection of bumper equipment
1)
1) During daily track inspection, obstacles within the scope of various bumpers shall be cleared. For
example, the loose blot shall be timely tightened;
2 C10
2) One comprehensive inspection is made for various bumpers every year (see attached table C10),
the inspection results are listed in annual inspection.
3)
3) The stop buffer shall be inspected and reset according to the following methods after it is hit

Inspect whether there are bending, open welding and crack phenomena in main body of stop buffer.
For hydraulic damping device, inspect whether there is leakage and damage. If main body is seriously
damaged or the hydraulic damping device is leaked and damaged and the users cannot recover it
alone, please contact the manufacturer. The manufacturer shall assign professional staff to make
technical evaluation and assist users to recover it.

After ensuring no damage deformation in main body and no leakage and damage in hydraulic
damping device, inspect the internal structure according to the manual. If any damage, change the stop
buffer.
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After inspection, move back the stop buffer to original position, and install it again according to
installation steps and methods of manual for various types and recheck the relevant technical
parameters (including height of round hole center of bumper plate away from rail surface, inner-side
distance of round hole center of bumper plate away from left rail surface, etc. as required).
4
4) For bumper types not listed in the regulations, please refer to relevant technical data and manuals of
bumper for maintenance.
4.7.1 CDH-Y/720/S
4.7.1 CDH-Y/720/S type hydraulic buffer sliding stop buffer
1)
1) The stop buffer shall be often kept in good state. Obstacles and greasy dirt on rail within sliding
range of stop buffer shall be timely cleaned during daily use.
2)

2) In order to make the stop buffer give full play to its ability, good track conditions shall be kept. The
track shall be regularly maintained according to standards to ensure the track gauge and other
parameters are in prescribed limit. The sleeper bolts shall be completed and effective and the nuts are
tightened to reach prescribed torque.
3)

3) One comprehensive inspection is made for the stop buffer every month. The contents shall include:
whether there is corrosion an damage in plunger, whether parts in each part is lost, whether the
reflective paint (film) is fallen, whether the pressure valve cover keeps original tightening state, whether
the main body frame is deformed and damaged, whether the position of damper is correct, whether the
wedge-like splitter is loose, etc. If any abnormal condition, handle it timely and contact the manufacturer
if necessary.
4) 45
4) Hydraulic oil is changed once every 4-5 years (determined according to environment temperature
and deterioration of oil product).
4.7.2 CDH/720
4.7.2 CDH/720 type sliding stop buffer
1)
150 Nm
1) During daily track inspection, obstacles within the scope of sliding shall be cleared and the loose blot
shall be timely tightened. All lock bolts shall be pre-tightened with special torque wrench as required
and the braking rail clamp shall be pre-tightened in 150 Nm.
2) 150Nm
2) All fasteners shall be inspected once every half year. The loose bolts shall be timely tightened. Pretightening torque of lock bolt is 150Nm
3)
3) After all lock bolts are completely loosened every year, the lock bolts shall be pre-tightened once
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according to pre-tightening requirements and rust preventive oil shall be painted once for the bolts.
4)
4) Grease oil and obstacles on rail head part of standard rail in the sliding direction of stop buffer shall
be timely eliminated during routine inspection;
5)

5) If the stop buffer shifting is found in routine inspection, it shall be timely reported to relevant
administrative department, and the stop buffer shall be inspected comprehensively. The stop buffer can
be installed and used again when no part and component are damaged.
4.7.3
4.7.3 Crescent type fixed stop buffer
1

1) The stop buffer shall often keep good operating state; one inspection shall be made for it every
month to ensure there is no shift, deformation and bolt looseness. When any abnormal state,
immediately handle it.
2
2) The obstacles on rail surface in the sliding direction of stop buffer shall be eliminated daily and super
elevation spike and sleeper bolt shall be handled well.
3
3) Rust preventive oil shall be painted once for the stop buffer every two years.

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5
5. Operation requirements for main maintenance items of track
5.1
5.1 Track lifting operation
5.1.1

40mm
5.1.1 If the track state is better and quality is basically steady in ballast bed section, key track lifting can
be adopted; if hollows in the track are more and accumulated sinkage amount is more, comprehensive
planned track lifting shall be adopted. During comprehensive track lifting, extension and track lifting
amount shall be reasonably determined combined with track slope and grade change point. When the
track lifting exceeds 40mm, leveling peg shall be set generally with instrument and the track lifting is
conducted by leveling peg.
5.1.2
450mm
5.1.2 In the concrete sleeper section, comprehensive tamping shall be conducted for track lifting section
and comprehensive tamping or key tamping shall be conducted for non-track lifting section. During
tamping, the ballast bed shall be tamped evenly within 450mm scope of both rail sides. The ballast bed
below the sleepers near to tamping range shall be filled full.
5.1.3
5.1.3 After the operation, the track shall be returned to normal condition. The tools and personnel shall
be removed.
5.2
5.2 Track lining and gaging of track
5.2.1

5.2.1 Poor track direction of ballast bed and straight-line segment can be corrected by visual inspection.
Poor track direction of curve segment can be measured, calculated and corrected by string lining of
curve. Refer to Rule on Maintenance of Rail Track by Ministry of Railways of the People's Republic of
China for specific implementation process. The head and tail position of curve, length of transition curve
and radius of circular curve shall be measured and changed with instrument. When correction cannot
be conducted as per due position due to the influence of other equipments on track, an instrument shall
be used to measure and rectify. The midline of track shall be used as the principle to adjust the position
and dimension of other equipments. Under difficult condition, the position of track midline can be
adjusted through measurement.
5.2.2

5.2.2 When gaging of track is conducted for turnout switch part, the bending size of stock rail of curve
track and the lateral bending of switch rail, which will affect the gauge standard, shall be repaired.
When gaging of track is conducted for frog, the relationship between check gage, guard rail face gage
and wing rail, guard rail groove shall be well processed.
5.2.3
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5.2.3 After the operation, the track shall be returned to normal condition. The tools and personnel shall
be removed.
5.3
5.3 Operation of gapless track
5.3.1

5.3.1 The annual maintenance plan for gapless track shall be reasonably arranged according to
seasonal characteristics, fastening-down temperature of rail and track status. The comprehensive
maintenance shall be arranged using long rail string as unit. The comprehensive maintenance for
segment with low fastening-down temperature of rail or weak segment shall be arranged in months with
low temperature. The comprehensive maintenance for segment with high fastening-down temperature
of rail can be arranged in months with high temperature. It's better not to arrange comprehensive
maintenance or do work affecting the stability of track in high temperature months. When
comprehensive maintenance or segment maintenance is necessary, destressing shall be conducted
before operation. The destressing and the fastening-down shall be conducted within designed range of
fastening-down temperature of rail. Straightening hard bending of rail, rail grinding and repair welding,
etc. can be arranged in high temperature season. Under lower temperature, if change of rail or bar is
needed, it can be conducted with rail tensor. The infrastructure or subgrade repair that may affect the
stability of gapless track must have technical safety measures and shall be approved by the
headquarters.
5.3.2
5.3.2 The maintenance of gapless track must comply with the following rail temperature conditions:
1)
1) The rail temperature condition for maintenance of concrete tie gapless track shall refer to Rule on
Maintenance of Rail Track by Ministry of Railways of the People's Republic of China.
2) 600800
10 30

2)The rail temperature condition for ballast bed digging, track lifting and track lining in curve section of
concrete tie gapless track: The provision in Rule on Maintenance of Rail Track by Ministry of Railways
of the People's Republic of China shall be narrowed down 10 for section with the radius of 600
800m. When the rail temperature is 30 below the actual fastening-down temperature of rail,
maintenance cannot be conducted in breathing zone and buffer zone (except for changing fastener and
lubricating the fastener).
5.3.3

5.3.3 When maintenance affecting the stability of gapless track is conducted, the rail temperature must
be measured and mastered. The rail displacement shall be checked. The change of fastening-down
temperature of rail shall be analyzed. Work shall be conducted as per rail temperature condition. The
system of "site clearing per half a day in maintenance, site clearing per jimmying in temporary remedy"
and "measuring rail temperature before, during and after operation" shall be strictly executed. The
following shall be paid attention to during operation process:
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1
1) Sufficient ballast is needed upon track lifting. The track direction shall be corrected before track
lifting. The track lifting machine and the track lining machine shall not be placed in a thermit welding
line.
2
2) Run-off elevation tamping shall be conducted for track lifting before the train passes through. The
track shall be lined.
3
3) Timely backfilling and tamping shall be conducted for digged up ballast bed.
4

4) Attention shall be paid to track condition during operation. If the signs of rail expansion, such as easy
track lifting, hard track lining, temporary change of track direction and height, are found, the operation
shall be stopped immediately. The ballast bed shall be backfilled to recover the track. The inspection
and monitoring shall be strengthened. Protective measures shall be conducted in necessity.
5.3.4
5.3.4 Prevention and treatment of track buckling
1 35mm

1) If 35mm continuous bends are found on the track, the patrol shall be strengthened, or a speciallyassigned person shall be sent for monitoring. The change of rail temperature and the direction of track
shall be observed. If the bend continuously expands, emergency treatment shall be conducted.
2 10m
10mm
12mm

2) If poor track direction is found, no matter during or after operation, a string 10m in length shall be
used to measure the track direction deviation between two rails. When the mean reaches 10mm, an
emergency protection must be set up, and measures, such as tamping ballast bed, filling sleeper box
ballast and stacking shoulder, shall be adopted. When the mean of track direction deviation of two rails
reaches 12mm, if the track bend suddenly expands after the train passes under the condition of
unchanged rail temperature, the stop signal must be immediately set up. The station or the train
dispatching shall be timely informed. Emergency measures such as rail cooling shall be adopted. The
train operation can be recovered after the fault is eliminated.
3

3) After track buckling is found, the rail temperature can be reduced through watering. Track lining can
be conducted after the rail temperature is reduced. Jacking rather than pushing shall be conducted in
curve section. After track lining, the ballast bed must be tamped; the train shall be released in limited
speed; and a specially-assigned person shall watch it. When the rail temperature approaches the
fastening-down temperature of rail, the track and normal speed can be recovered.
5.3.5 ,

5.3.5 In terms of destressing of gapless track, the engineering construction subdivision shall investigate
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and propose the plan. The plan shall be reviewed by the engineering construction department, and
submitted to the maintenance center for approval. The engineering construction subdivision organizes
the construction. The maintenance center assists and guides. Before construction, the construction plan
shall be formulated; the safety measures shall be drafted; sufficient personnel, materials and tools shall
be prepared; sufficient construction preparation shall be made.
5.3.8 ()
5.3.8 Treatment requirements for serious injury of long rail (including welding line) of gapless track are
as follows:
(
)
Under the condition of tight time, reinforcement with bump bar and first aid can be adopted, or drilling
on rail and tightening with bar (including bump bar) and bolt can be adopted. The permanent treatment
shall be arranged as per the degree of injury.
5.3.9 ()
5.3.9 Treatment requirements for breaking of long rail (including welding line) of gapless track are as
follows:
1 50mm
50m 5km/h 30mm
1525km/h

1) Emergency treatment: when the break joint of rail is not greater than 50mm, emergency treatment
shall be conducted immediately. Reinforcement with bar or bump bar on break joint, fixation with first
aid, fastening the fastener within 50m range before and after the break joint, and releasing the train with
a speed of 5km/h shall be conducted. If the break joint is less than 30mm, the released train speed
shall be 1525km/h. (If a clamping device without hole is adopted to fix, the train shall be released as
per the release condition of this device). The welding shall be organized after the completion of
operation. Upon unconditional welding, drilling shall be conducted at the end of rail. The bar or bump
bar shall be used. The joint bolt shall be tightened. The running speed shall be improved appropriately.
2 50mm
6m
10.9 50m
2) Temporary treatment: When the rail is severely damaged or the break joint exceeds 50mm, and
welding repair cannot be immediately conducted after emergency treatment, temporary treatment shall
be conducted after the track is blocked. The damage part shall be excised along two sides of break
joint. The 6m rail of the same type shall be inserted between two kerfs. Drilling shall be conducted at
track end. The joint bar shall be used. Grade 10.9 bolt shall be tightened. After the fastener within 50m
before and after the short rail is fastened, the train shall be released as per normal speed.
3 3.8m

3) Upon temporary treatment or emergency treatment, a mark shall be made on the nonworking side of
rail head about 3.8m away from the two sides of break joint. The distance between two marks and
break joint value on nonworking side of rail head shall be accurately measured and recorded.
4

4) Permanent treatment: After temporary treatment or emergency treatment of rail break joint, when the
temperature approaches or is lower than the actual fastening-down temperature of rail, the short rail
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shall be inserted for welding repair.
5 2

5) When thermal welding is adopted, the length of the inserted short rail is equal to the length of
excised rail subtracted by 2 times of reserved welding line. One end shall be welded at first. When the
other end is welded, the rail shall be tensioned, making the distance of two marks on two sides of break
joint equal to original measurement distance subtracted by break joint value. The welding can be
conducted after the above is satisfied. The long rail returns to original state after welding. The original
fastening-down temperature of rail remains unchanged.
5.3.10 0 50
5.3.10 The air temperature shall be not lower than 0 upon welding on track. The rail temperature on
welding line shall be reduced to under 50 when the train is released.
5.4
5.4 Adjusting of rail gaps
5.4.1
C

For checking that whether the size of the entire segment of rail gap can meet the specification,
generally it shall be checked at the time of rail replacement or rail gap adjusting. In daily checking,
according to the rail replacement or the rail temperature at the time of rail gap adjustment, the C value
and subsequent temperature changes of the rail shall be adopted for inspection calculation. Sampling
inspection can be taken when necessary, in sampling location, joint bolt and fasteners on each rail shall
be loosened one by one and make the rail can stretch freely as far as possible, then adopt the average
values of the rail temperature or rail gap.
5.4.2
5.4.2 The rail gap shall be kept uniformly, in case of the following situations appears, it shall be
adjusted.
1
1) The rail previous gap cannot meet the design specification.
2 3mm 3mm
2) In regulating the rail gap, the rail gap and the rail temperature in the limited scope, bastard joint of
3mm or below or the rail gap is larger than the construct rail gap, or the rail gap is uneven seriously.
5.4.3

5.4.3 In adjusting the entire segment rail gap, carry out investigation and calculations in advance and
determine the playing direction and playing momentum and preparing segment working plan, if the rail
apolegamy is improper and the dislocation amount is large, according to the regulation, the rail shall be
adjusted in one strand or two strand according to the length error, the dislocation amount of the joint
shall be adjusted by adding or reducing the size of the rail gap.
5.4.4
5.4.4 Operation requirement of adjusting the rail gap
1
1) Adjust the rail gap without disassembling the joint but loosen the track bolt, when the trains passing
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through, at least fasten four screws (two for each end) for each joint.
2 50mm

2) When disassemble the joint and adjust the rail gap of the whole segment, the interspaces shall not
over 50mm, when the trains passing through, the pulled size shall be distributed to all the joint evenly
and at least fasten four screws (two for each end) for each joint.
3 50mm

3) When disassemble the joint and adjust the rail gap of the whole segment, the interspaces shall not
over 50mm, when the trains passing through (speed limited), insert the short rail head (with rail base),
cooperatively use the long hole plywood and pad with a short sleeper, at least fasten four screws for
each joint (two for each end, one for one end and one for a short rail head).
4 150mm
50 7090110130mm
4) When using the short rail head, the largest interspaces shall not over 150mm, the length of the short
head (with rail base) is divided into five kinds of 50, 70, 90, 110 and 130mm.
5.5
5.5 Rail grinding and welding repair work
5.5.1
1m 0.5mm

5.5.1 For the damages of rail corrugation, rail lip, saddle abrasion, welding depression and scale
cracks, profiling grinding machine shall be used for grinding. When using the profiling grinding machine
for grinding operations. Use a 1m straightedge for measuring after grinding, the uneven vector shall
less than 0.5mm. For the rail lip at the joint or the insulated joint rail, and the irregularity, point rail, fixed
type frog, wing rail and rail lip on the non-work edges of the point rail, they shall be polished and
renovated.
5.5.2

5.5.2 The low collapse joint of the rail (including point rail and fog), the crushing, abrasions, chip offfalling, abrasion and manganese steel frog crossing shall be welded; for the segment of long rail with no
gap that the joint generated after inserting short rail, thermite welding shall be adopted for recovering
the jointless track.
5.6
5.6Track oiling

The oiling time of the back turnout slide chair of the main track, the car depot, and the outdoor turnout
in the elevated section shall be added in rainy seasons. The working edge of the fasteners, plywood,
small radius curve and rail of guard rail shall be applied with oil according to the specific circumstances
of the rail wear, clear the tools after each oiling and fill out the Track Oiling Record.
5.7
5.7 Maintenance standard of the rail equipment
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For the detailed equipment standards and maintenance requirements, please see Rules for
Maintenance of Railway Line issued by of Ministry of Railways of the Peoples Republic of China.
6
6 Appendixes
A
Appendix A: Management system of track inspection
B
Appendix B: Notification on clearing the relevant four haves and three-in-one regulation on track
profession
C
Appendix C: Common table

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A
Appendix A: Management system of track inspection

Management system of track inspection

I. The track inspection shall have the following conditions:


1.
1. Familiar with the relevant rules and regulations and tracks;
2.
2. The ability of handling the failures alone;
3. AALRT
3. The inspection personnel (including the replacement personnel) shall pass the AALRT exam and
take appointment with certificate.

II. The track inspection personnel shall carry out the following working system.
1.
1. Shift system

In shifting of duty, the inspection personnel shall handover and make clear the following items:
1)
1) The found problems, the handled situation and the problems that need to be further handed shall be
recorded in the shifting record;
2
2) Signal supplies, tools, materials and other spare parts and so on.
2.
2. Report system
1

1) If any failures that effect the traffic safety and other material circumstances are found, they shall be
promptly reported to the forman or the engineer in charge, for the one can be eliminated, it shall be
eliminated immediately; for the one endangering traffic safety, precautions should be taken immediately
and reported to the control center or maintenance and scheduling center and state the risk degree and
processing time it needed.
2
2) Regularly report the driving safety and personal safety, and the changes of the track equipment to
the forman.

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B
Appendix B: Notification on clearing the relevant four haves and three-inone regulation on track profession

Four haves and three-in-one regulation on track profession

The machine account management of four haves and three-in-one on track is a major component of
technical machine account management on rail and the important component to organize the scientific
and order production of the track shift and improve labor efficiency and track quality, and complete the
monthly and annual tasks and target.

I. Definition of Four haves and three-in-one

Four haves means that the inspection record shall have inspection, analysis, disposal and signature.

Three-in-one means that the construction work notice, daily schedule, the working location, date and
items in the inspection record shall in one.
1

1Inspection: That means the inspection shall be carried out according to the specified date and times
and fill the inspection date and inspection record in the inspection record and indicate the inspection
location and inspection personnel.
1
25 3
3010 6.25m 12.5m

(1) The track shift shall carry out the monthly inspection strictly in accordance with the regulation of the
periodic table of equipment maintenance, inspect the main track and yard track equipment once a
month. The checking date shall not late than 25 th of each month, in special circumstances (such as
holidays or train commissioning) the date can be postponed not more than 3 days, and the inspection
cycle of the track equipment shall not exceed 30 10 days. For the track inspection, carry out the
inspection for each 6.25m curve line or 12.5m straight line (the joint and the welded position must be
inspected), each position of the turnout shall be inspected on the specified position. The main
inspection items are gauge, level, direction, height, twist warp, turnout offset distance, check gage,
guard rail face gage rail (with guard rail) injury or corrosion wear and the states of equipments of
coupling parts, short sleeper, track bed, subgrade, route sign , railroad grade crossing, drainage,
turnouts (including expansion joint), and rail gap and so on.
2

36510
10mm
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(2) The track shift shall carry out the inspection to the curve versine once a year, including the main
track curve and the joint curve behind the turnout. In principle, the curve inspection shall be completed
in the fourth quarter, for the shift that has many curves, the inspection shall be arranged reasonably
within the quarter, but the inspection period of the curve must be within 365 10 days. In addition, the
track shift shall observe the wear of rail on curves in each quarter (the observation shall be relative
fixed and a mark shall be made), the curve that the side wearing of the upper strand up to 10mm shall
be reported to the sub-department for record.
2
2. Having analysis: conduct overrun position analysis in accordance with the tolerance management
value of static geometric dimension of track specified in this specification.
1

8mm8mm 18m
(1) Where the inspection result exceeds the tolerance value of regular maintenance yet under the
deviation value of urgent repair, a transverse line shall be marked under the overrun position of
gauge, level and offset in red pen, a transverse line shall be marked below the two points of
overrun position of twist of track in red pen, and a shall be marked below transverse line in red pen,
marking peak value, eg. twist of track is 8mm, mark 8mm, the range within 18m shall be analyzed
while analyzing twist of track.
29148

10mm10mm
(2) Where the management deviation value of urgent repair is exceeded, a transverse line shall
be marked under gauge, level, 91, 48 and offset overrun position in red pen, marking below
transverse line, a transverse line shall be marked below the two points of overrun position of
twist of track, marking below transverse line and indicating specific peak value, eg. twist of track is
10mm, mark 10mm.
3
1 2
(3) The overrun items and quantity on this page shall be written on logging field alignment, high-low,
bad alignment and high-low positions shall be indicated with rail number. Eg.: expired maintenance: 1
position at gauge; 2 positions at twist of track.
3
3. Having disposal: bad positions found in inspection shall be disposed within the required time.
1 48 7

(1) Where overrun position is under the following conditions, main track and auxiliary track (including
testing track) shall be arranged with treatment within 48 hours, yard track shall be arranged with
treatment within 7 days: level 3 and 4 overrun positions of track inspection car; positions exceeding the
management deviation value of urgent repair found in monthly inspection and serious lurching positions
found in leadership train crew-adding inspection. But positions found in each shifts inspection that
endanger traffic safety must be disposed immediately.
2

(2) Where overrun position is under the following conditions, it shall be disposed prior to the next track
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inspection cycle: the position that exceeds the tolerance value of regular maintenance yet under the
tolerance value of urgent repair; level 2 overrun positions found by track inspection car and other
general lurching positions found by other manual train crew-adding.
3
3 3 1 5 +13 5 1 8 3
(3) Upon completion of all overrun position treatment, repair date, items, quantity and quality return
inspection shall be recorded in urgent repair content field of inspection log book. Eg.: repaired on
March 3, 1 position at gauge, 5 pcs in quantity, return inspection +1; repaired on March 5, 1 position at
twist of track, 8 pcs in quantity, 3 return inspections.
4

(4) Urgent repair workload shall be separately listed in daily plan, indicating items and quantity. Urgent
repair workload shall be satisfied first while preparing daily operational plan.
4
4. Having signature: namely with the signatures of inspector and shift leader after renovation of overrun
position.
5

5. Three-in-one: refer to the renovation content of overrun position recorded on construction


notification and daily plan (including operation location, date, item and quantity) conform to that on the
inspection log book, overrun position must not be eliminated in a fake way.

II. Relevant filling rules of track, turnout and curve versine on inspection log book
1
1. All inspection log books must indicate inspector and inspection date first, monthly inspection must be
accomplished by two people, separate operation is not allowed.
2ZHHYYH
HZ
2. Track inspection log books must indicate curve radius, superelevation and positions of curve straightspiral point (ZH), point of spiral to curve (HY), point of curve to spiral (YH), point of spiral to tangent
(HZ), in case track gauge requires adjusting inspection at the junction of curve and straight line, an
adjustment word shall be marked on the record.
39148

3. In alignment, high-low field, the over-limit gauge, level, twist of track, alignment, high-low, offset,
91, 48 shall analyze an expired maintenance and over-urgent repair standard in accordance with the
tolerance management value of static geometric dimension of track specified in this specification,
marking items and quantity respectively. Various equipment damages found in inspections shall also be
recorded in this field.
4
1mm
+1
4. Items, quantity, return inspection quality, date, shift leader signature in treating overrun position shall
be marked in the field of urgent repair content, pay attention to that in filling return inspection quality,
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data must represent the maximum deviation value on site. Eg. the maximum deviation value of site
gauge is 1mm after operation, then write gauge return inspection+1. Various equipment damages found
in inspections shall also be recorded in this field.
5 18m

5. Inspection log book of turnout must analyze twist of track within the range of 18m (including front and
back track of turnout or adjacent turnout), and pay attention to the inspection and analysis of twist of
track in back track of frog. Inspections of offset shall all start from the heel of switch rail, and fill in the
deviation value among planned offset and site offset and planned offset.
6

6. Inspection log book of curve versine, start and terminal point mileage of each curve, various
elements (curve radius, curve length, superelevation, widening, planned versine, easement curve
length) shall be clearly filled.
7 1 1 3
7. The filling regulations of inspection log book of track, turnout and curve versine are as per attached
table 1 and 3.
8.
8. Inspections of other items shall be filled as per the specified cycle and format.

III. Ledger requirements regarding Four haves and three-in-one


1.

1. Day operational plan book of each shift shall fill in the operation assignments, operation items, serial
number (code) of daily operational plan, construction order number, starting and ending time of
operation and actual operation time of shift staff on that day.
2.
2. The production month of shift per month equals to natural month.
3.

3. Each shift shall make a statistical summary of the report, approval and implementation of the
operational plan of the month at the end of month, and store together with four haves and three-in-one
in case of inspection.

IV. Inspection and analysis standard


1.
1. See the tolerance management values of static geometric dimension of track in the following table:
1.1 V80/h
1.1 The regulations of the tolerance management values of static geometric dimension of track (V80
/h) are as per the following table.
4
Table 4 The tolerance management values of static geometric dimension of track
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Acceptance of
operation ()

Twist of
track
(twisted)

Items

Main track
and
auxiliary
track

Gauge

Regular maintenance
()

Yard
track

Main track
and
auxiliary
track

+6
-2

+6
-2

Level

High-low

Direction

Urgent repair ()

Yard
track

Main track
and
auxiliary
track

Yard
track

+7
-4

+9
-4

+9
-4

+10
-4

10

11

10

11

10

11

Easement curve

Straight line and


circular curve

10

1456
10m
6.25m 18m
Note: gauge deviation does not include the widening value of gauge set by rules, but the maximum
gauge (including widening value and deviation) shall not exceed 1456; alignment deviation and highlow deviation are the maximum vector value measured by 10mstring; twist of track deviation does not
include the torsion caused by curve superelevation downslope, the girth in inspecting twist of track is
6.25m long, but there is no twist of track that exceeds the ones listed in table within the range of
extended 18m; testing track is handled as main track.
1.2 V80/h
1.2 The tolerance management values of static geometric dimension of turnout (V80 /h) are as per
the following table.
5
Table 5 The tolerance management values of static geometric dimension of turnout

Items

Acceptance of
operation ()

Main track
and
auxiliary
track

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Yard
track

Regular maintenance
()

Main
track and
auxiliary
track

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Main track
and
auxiliary
track

Urgent repair ()

Yard track

Main
track
and
auxiliary

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track

Gauge

+3
-2

+3
-2

+5
-3

+5
-3

+6
-3

+6
-3

Level

10

High-low

10

Straight line

10

Offset

10

Direction

Twist of track
(twisted)

1mm
Note: Gauge at the tip of switch rail, acceptance standard of operation is 1mm.

Offset deviation is the difference between site offset and calculated offset.
0 2mm 3mm
Limiting value of lead curve lower strand being higher than the upper strand: acceptance of operation
is 0, regular maintenance is 2mm, urgent repair is 3mm.

No twist of track that exceeds the ones listed in table.

Testing track is handled as main track.
2.
2. According to Track Maintenance Instruction, curve versine operation tolerance management values
and frequent maintenance tolerance management values are as shown in the following table:
6
Table 6 Curve Versine Operation Acceptance Tolerance

m
Curve radius
(m)

Easement curve
versine and calculated
versine difference
(mm)

Circular curve versine


continuous difference (mm)

Circular curve versine


maximum and minimum
differences (mm)

R250

12

18

250R350

10

15

350R450

12

R450

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7
Table 7 Curve Versine Frequent Maintenance Tolerance

Easement curve versine


and calculated versine
difference (mm)

Circular curve versine


continuous difference
(mm)

Main track
and
auxiliary
track

Yard track

Main track
and
auxiliary
track

R250

250R350

350R450

m
Curve radius
(m)

Circular curve versine


maximum and minimum
differences (mm)

Yard track

Main track
and
auxiliary
track

Yard track

14

16

21

24

12

14

18

21

10

12

15

18

450R800

10

12

15

R800

12

Note: For curves without easement curve, the versine of two points each at both ends of the curve shall
be analyzed and processed in the light of easement curve standard.
1.3
1.3 Rail defect according to the degree is divided into light defect, heavy defect and breakage.
1
1) Standard for light and heavy defects of rail
8 9 10()

See Tables 8, 9 and 10 for the standard for light and heavy defects of rail. When the flaw detector, track
(inspection) foreman think that the rail has a defect, it may also be judged as a light or heavy defect.
2
2) Rail breakage standard

Rail breakage refers to one of the following cases:

Total section of the rail breaks;

The crack runs through the whole railhead section;

The crack runs through the whole rail base section;


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80kmh 50mm 10mm
A chip off-falling with the length not greater than 50mm and depth not greater than 10mm is on the top
of the rail in the zone with the allowable speed not greater than 80km/h.
8
Table 8 Standard for light and heavy defects of rail

Defect items

Defect degree


Remarks


Light defect


Heavy defect

max80kmh

max80kmh

Head abrasion

See
rail
head
abrasion standard

See rail head abrasion


standard

Peeling or chip
falling at the rail
end or top

15mm
4mm
Length of more than
15mm and depth of
more than 4mm

30mm
8 mm
Length of more than
30mm and depth of
more than 8mm

Rail
surface
scratch

1mm
Depth of more than
1mm

2mm
Depth of more
2mm

than

3.5mm
More than 3.5mm

1m

Measure the vector at the


lowest place with a 1m straight
ruler, including the rail end and
top crush and abrasion

Rail surface crack

Yes

()
(

)
Including bolt hole crack,
horizontal crack at railhead
lower jaw (rust), horizontal
crack at rail web, longitudinal
crack of railhead, rail base
crack (excluding scale cracks
on the rail top surface or near
surface caused by wheel-rail
contact fatigue)

Rail internal crack

Yes

()

Low rail joint

3mm
More than 3mm

Wave abrasion

0.5mm
Trough of more than
0.5mm

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Including core flaw (black,
white core), longitudinal crack
of rail, etc.

Railhead expansion, rail web


warp or bumps which are
determined as a hidden
internal crack

Rail deformation

Yes

Rail corrosion

5 mm
8 mm
After rust removal, rail
base thickness is less
than 5mm or rail web
thickness is less than
8mm
9
Table 9 Railhead Abrasion Light Defect Standard


(kg
m)
Rail

50

(mm)
Total abrasion

(mm)
Vertical abrasion

(mm)
Side abrasion

max80km/h

Main track
and testing
track

Other
tacks

max80km/h

Main track
and testing
track

Other
tacks

max80km/h

Main track
and testing
track

Other
tacks

12

14

12

14

=+12
Note: Total abrasion= Vertical abrasion +12 Side abrasion
13 ()
Vertical abrasion is measured at the place 13 of railhead width (from the standard working edge).
() 16mm
Side abrasion is measured at the place 16mm below rail tread (according to the standard surface).
10
Table 10 Railhead Abrasion Heavy Defect Standard


(kg/m)
Rail

50
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(mm)
Vertical abrasion

(mm)
Side abrasion

max80km/h

Main track and yard track

max80km/h

Main track and yard track

10

17

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1.4
1.4 Union piece defect
1
1. Rail fastening shall be repaired or replaced if the defect reaches the following standard:
a)
a) Screw spike is broken or floated; nut or screw thread is damaged or severely rusty.
b)
b) Gasket is damaged or has poor function.
c)()
c) Elastic strip and pinch plate (clip) are damaged or can not maintain the proper crimping pressure.
d) 2mm
d) Pinch plate, gauge apron are severely worn; the open joint between pinch plate and gauge apron is
more than 2mm.
e)
e) Apron block, iron block are damaged or have poor functions.
2
2. Fishplate shall be repaired or replaced if the defect reaches the following standard:
a)
a) Breakage.
b) 15mm
b) Crack appeared in the range of two bolt holes in the middle: cracks on the main track, testing track;
fishplate at other station tracks is more than 15mm.
c)
c) Cracks at other parts are developed to the bolt hole.
3
3. Fish bolt and gasket shall be repaired or replaced if the defect reaches the following standard:
1) 3mm
1) Bolt breaking, serious rust, screw thread damage or rod diameter abrasion exceeding 3mm unable to
maintain the required torque.
2)
2) Gasket breaking or lack of elasticity.
1.5
1.5 Rain strengthening equipment flaw

Rain strengthening equipment includes tie rod, guardrail. Rain strengthening equipment shall be
repaired or replaced if the defect reaches the following standard:
1
1. Tie rod breaking or screw thread damage, nut, gasket, steel pallet damage or poor function.
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2
2. Guardrail damage or poor function.

V. Turnout flaw
1
1. Various parts of the turnout shall be complete with good functions, which shall be supplemented
timely in case of absence. They shall be repaired or replaced if having one of the following flaws or
defects:

Bolts, connecting rods, jacking block and spacer block damage, deformation or poor function.
3mm
Slide chair damage, deformation or sliding plate abrasion of more than 3mm.

Guardrail support breaking.

Damage or failure of rubber mat or cutting resistant washer below sleeper and sleeper base plate.
2mm
5mm
Clip, pin, apron damage. Open joint between clip and slide chair shoulder and open joint at front and
back of the apron is greater than 2mm. The distance from inner side of pin cap to slide chair edge is
greater than 5mm.

Other parts damage, deformation or poor function.


2
2. Switch rail shall be repaired or replaced if having one of the following flaws or defects:
1mm
Point of switch is not closely attached to the stock rail, with the gap of more than 1mm.

Switch rail lateral bending results in non-compliance of the track gauge.


50mm 2mm
At the section with switch rail top surface width of 50mm and above, switch rail top surface is lower than
the stock rail top surface, movable point frogs top surface is 2mm or above lower than the wing rail top
surface.
50mm 2mm
At the section with switch rail top surface width of 50mm and below, switch rail top surface is higher
than the stock rail top surface, movable point frogs top surface is 2mm or above higher than the wing
rail top surface.

Switch rail working face is damaged, and the wheel flange may possibly climbs to the switch rail if it is
developed continuously.
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Two switch rails of internally blocked turnout are separated from each other; two switch rails of transfer
drive externally blocked turnout are separated from connecting device or externally blocked devices fail.

Other flaws reaching the rail light defect standard.


3
3. The stock rail shall be repaired or replaced if having one of the following flaws or defects:

The buckling point position or buckling size of curved stock rail does not meet the requirements,
resulting in noncompliance of track gauge.
50kgm 6mm 8mm 10mm
Stock rail 50kgm vertical abrasion is more than 6mm at the main track and 8mm at the testing track,
10mm at other station tracks.

Other flaws reaching the rail light defect standard.


4()
4. Solid manganese steel frog heavy defect standard (Solid manganese steel whole cast wing rail, frog
block of movable point frog):
1 40mm ()50kgm 6mm
8mm 10mm
1) At the section with frog width of 40mm, frog vertical abrasion (excluding heightened part of the wing
rail), 50kg/m is more than 6mm at the main track and 8mm at the testing track, 10mm at other station
tracks.
2() 11
2) Vertical crack length (including crack at the rail surface) is more than the limits listed in Table 11.
11
Table 11 Vertical Cracks


Items

mm)
Frog

(mm)
Frog wing

050
Width 050

50
Width 50

Length of one crack

50

50

40

Length of two cracks

60

80

60

3
3) Longitudinal level crack length is more than the limits listed.
4 30mm
4) Frog foot, frog root railhead and low jaw cracks are more than 30mm.
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5 120mm 120mm
40mm
5) Frog foot, frog root pouring section change part is inclined or horizontal crack is more than 120mm,
or vertical height is more than 40mm even through not more than 120mm.
6
6) Baseplate crack is extended to the rail web internally, and exceeds the connecting point of rail web
and arc.
7
7) Bolt hole crack is extended to the rail end, railhead lower jaw or rail base; two neighboring holt holes
are penetrated.
8 30mm 6mm
8) Frog, frog wing surface is peeling or falling chip with the length of more than 30mm or depth of more
than 6mm.
9()
9) Rail detector or track (inspection) foreman thinks that there are other flaws affecting the running
safety.
12
Table 12 Longitudinal level crack

Items

(mm)
Frog (mm)

(mm)
Frog wing
(mm)

(mm)
Flangeway (mm)

Length of crack at one side

100

80

200

(
)
Crack at one side is developed to the rail
surface (including length of crack at the
rail surface)

60

60

()
Crack coalescence at both sides (means
coalescence length)

50

Length of cracks at both sides at relative


part

A
Maintenance Regulations of Line
Facilities (Version A)

100

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C
Appendix C: Common tables

Common tables
C1
Appendix C1: Tally book of track oiling
C2
Appendix C2: Tally book of track inspection
C3
Appendix C3: Tally book of track inspection
C4
Appendix C4: Tally book of turnout inspection
C5
Appendix C5: Tally book of diamond turnout inspection
C6:
Appendix C6: Tally book of curve versine inspection
C7
Appendix C7: Tally book of routine maintenance and inspection for anti-drop guardrail
C8
Appendix C8: Statistical report on rail equipment state
C9
Appendix C9: Monthly report on damaged rail
C10
Appendix 10: Tally book of bumper inspection
C11
Appendix C11: Signature book of track inspection

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C1
Appendix C1: Tally book of track oiling

Tally book of track oiling


E/AALRT 0030-01-B1

Team:

Date:

S/N

Item
(slide plate,
small radius
curve, switch
rail, guard rail,
turnout, curve
of turnout, rail
and others )

Position and location

Workload

Operator

Remark

Recorder:
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Facilities (Version A)

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C2
Appendix C2: Tally book of track inspection

Tally book of track inspection


E/AALRT 0030-02-B2

Table-filling unit:

Inspection and section (Start-stop position or serial number of track)

Inspection Date:

S/N

Weather:

Item

Main inspection content

Rail

Inspection whether marked damage is aggravated


and determine the rail according to damage
standards.

Inspection
of clamp
plate and
bolt

Inspect the clamp plate (including emergency


restore device) deformation, flaw, breaking and rail
gap according to the standard; inspect whether track
bolt, fastening bolt and gasket are loose and
damaged.

Turnout

Inspect crack falling, matching and empty sling of


switch rail; inspect frog and guard rail; inspect
connecting parts.

Subgrade
and ballast
bed

Inspect sinking, subsidence and collapse of


subgrade and ballast bed; inspect immersion and
submergence of subgrade and ponding of ballast
bed; inspect whether drain is silted up.

Clearance
limit
obstacles

Remove clearance limit obstacles and do small


repair in inspection.

Inspect whether ballast bed and concrete short

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Maintenance Regulations of Line
Facilities (Version A)

E/AALRT 0072-2015

Result
s

Remark

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Ballast
bed and
short
concrete
tie

sleepers are cracking or out of shape seriously.

Track sign

Inspect whether the track signs is firm

Bumper
inspection

Clean barriers within the scope of various bumpers;


tighten the loose bolts timely as required.


Inspected by: (signature)

A
Maintenance Regulations of Line
Facilities (Version A)

Date:

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C3
Appendix C3: Tally book of track inspection

Tally book of track inspection


E/AALRT 0030-03-B2
ADISS ABABA EW & NS (LINE PHASE 1) LRT PRJECT
NS LINE TRACK CHECKING RECORD
NS left

design
s.el

site
s.el

level

profile

gauge

A
Maintenance Regulations of Line Facilities (Version A)

remark

NS right

design
s.el

site
s.el

level

E/AALRT 0072-2015

profile

gauge

remark

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C4
Appendix C4: Tally book of turnout inspection

Tally book of turnout inspection


E/AALRT 0030-04-B2
:

Name of track: Name of station:

Serial number of turnout:

Switching portion

9
0

9
2

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4
9

Bent

Guard
rail face
gage

Straight

Bent

Straight

Bent

E/AALRT 0072-2015

Guard
rail
check
gauge

Back
frog

Straight

Bent

Central
frog

Straight

Bent

Straight

Front
frog

Back

Central

A
Maintenance Regulations of Line Facilities (Version A)

Front

Back

Central

Front

Frog portion

Curve of
turnout

Straight line

Bent

Curve of turnout portion

End of
switch
rail

Straight

Central switch rail

Gau
ge

Point of switch rail

Insp
ectio
n
items

End offront slope

Insp
ectio
n
date

Type:

4
7

AALRT
AALRT Enterprise Standards

Level

-1

-4

Offse
t

Note

1 1 10mm
Expired maintenance: 1 position at gauge; 2 positions at offset;
1 1 1
Expired urgent repair: 1 position at back guard rail, 1 position at check gauge and 1 position at twist of track
1 1 1 1 1 15 10
-1 92 47 9 9
Urgent content: eliminate expired urgent repair: 1 position at back guard rail, 1 position at check gauge and 1 position at twist of track;
eliminate expired maintenance: 1 position at gauge; 2 positions at offset; in total, 15 pcs for gaging of track, 10 pcs for pad level
return inspection: gauge-1, check gauge 92, back guard rail 47 without twist of track
Team leader: Wang Wu September 9

Gau
ge

Level

Offse
t

Note

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C5
Appendix C5: Tally book of diamond turnout inspection

Tally book of diamond turnout inspection


E/AALRT 0030-05-B1

Name of track: Name of station:

Serial number of turnout:

Type:

Former acute angle frog

Ga
uge

Lev
el

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Back-end frog

Center frog

Front-end frog

Back-end frog

Center frog

Guard rail face gage

Guard rail check

Guard rail face gage

Guard rail face gage

Back half

Back acute angle frog


Guard rail check gauge

Front half
Guard rail check

Obtuse angle frog

Center frog

Front-end frog

Atr
ack

Guard rail face gage


Item

Guard rail check gauge

Front-end frog

Part

Center frog

Back-end frog

Inspe
ction
date

Obtuse angle frog

AALRT
AALRT Enterprise Standards

B
tra
ck

Ga
uge

Lev
el

Others and
date
of
temporary
repair

A
tra
ck

B
tra
ck

Ga
uge

Lev
el

Ga
uge

Lev
el

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Others and
date
of
temporary
repair

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C6:
Appendix C6: Tally book of curve versine inspection

Tally book of curve versine inspection


E/AALRT 0030-06-B1

km+

The location of curve

km+
km+

Versine
calculati
on

km+

Length of transition curve

No. of
gaugi
ng
point

m
Radius of curve

m Overall length of curve

Date

Site
versi
ne

Versi
ne
after
lining

m Location of Straight-spiral point: No. gauging point + m


+

m Spiral-straight point: No. gauging point +

Date

Site
versi
ne

Versi
ne
after
lining

A
Maintenance Regulations of Line Facilities (Version A)

Date

Site
versi
ne

Versi
ne
after
lining

Date

Site
versi
ne

E/AALRT 0072-2015

Versi
ne
after
lining

Date

Site
versi
ne

Date

Versi
ne
after
lining

Site
versi
ne

Versi
ne
after
lining

46 57
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Not
e

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AALRT Enterprise Standards

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C7
Appendix C7: Tally book of routine maintenance and inspection for anti-drop guardrail

Tally book of routine maintenance and inspection for anti-drop guardrail


E/AALRT 0030-07-B1

Date of construction:

S/N

Date of
inspection

Weather:

Detection
area(mileage)

Whether
the
groove
width
K of
guardrail
rim is
normal

2mm
1mm
If
transverse
guardrail
ends
unevenness
in line or
surface is
more than
2mm or
1mm

A
Maintenance Regulations of Line Facilities (Version A)

If working
surfaces
of the
guardrail
is scraped

Insulation
buffer
washer is
damaged

E/AALRT 0072-2015

If
transverse
spacing
cushion
block is
damaged

If
fastening
bolt fails
or rusts

Handling
information

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Remark

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C8
Appendix C8: Statistical report on rail equipment state

Statistical report on rail equipment state


E/AALRT 0030-8-B1

Year
km
Of which, signal is
disqualified

km
Quantity evaluation (Km)

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Total

Existing serious damage on the


gapless track

One year new emergence

Existing attrition

E/AALRT 0072-2015

One year new mergence

Concrete sleeper

Ballast bed

Seriously
damaged
rail

Seriously damaged welding head

Lightly
damaged
rail

Go slow

Seriously damaged welding head

A
Maintenance Regulations of Line Facilities (Version A)

Damaged rail

Tie

Ballast bed

Qualified rate

Disqualification

Good

Excellent

Inspection number km

Name of track

Bad results (grade)

AALRT
AALRT Enterprise Standards

Note: Qualified rate is the percent of excellent number and qualified number accounting for evaluation number

Reporter:

Date

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C9
Appendix C9: Monthly report on damaged rail

Monthly report on damaged rail


E/AALRT 0030-9-B1

Date

Inspectio
n
number

Accumulative existing number

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Manganese steel

Lightly
damaged
frog

Assembly

Seriously damaged rail

Lightly Damaged rail

Damaged clamp plate

Total

E/AALRT 0072-2015

Manganese steel

Assembly

Total

Manganese steel

Assembly

Damaged switch rail

Broken rail

A
Maintenance Regulations of Line Facilities (Version A)

Total

Others

Welding head

Attrition

Cracked hole

Fissure

Lightly damaged rail

Turnout group

Seriously
damaged frog

Seriously damaged Welding head

Lightly damaged
frog

Seriously damaged rail

Track road km

Category of main Station track

Name of track

Found number in this month (piece, group and block )

AALRT
AALRT Enterprise Standards

Note: In addition to the required inspection month, this table shall be filled in monthly.

This table include damage detectors and other found damaged rail

Reporter:

Organization:

It is 1 position piece between original two welding heads of gapless track; seriously damaged rail refers to

Date

the 1 position is reinforced by clamp plate on the gapless track in the frame Accumulative existing number

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10
Appendix 10: Tally book of bumper inspection

Tally book of bumper inspection


E/AALRT 0030-10-B1

Team:

Date:

S
/
N

Posi
tion
and
locat
ion

Bum
per
type

Whe
ther
there
is
forei
gn
body
withi
n the
rang
e of
bum
per
slidin
g

Whe
ther
there
is oil
pollu
tion
at
the
railh
ead

E/AALRT 0030-10-B1

Whethe
r there
is
displace
ment
and
deforma
tion

A
Maintenance Regulations of Line Facilities (Version A)

Whe
ther
parts
are
lost

150
300

350N
.m
Whet
her
faste
ners
are
loose
, and
faste
ners
shall

Initial
tighte
ning
condit
ions
after
bolts
are
loose

Rust
prote
ction
of
bolts
oiling

E/AALRT 0072-2015

If
hydr
aulic
oil
leaks

Chec
k
hydr
aulic
oil
stock

Whet
her
faste
ning
bolts
are
filled
with
little
lubric
ant

Whet
her
supe
r
eleva
tion
spike
s
and
sleep
er
bolts
are
hand
led
well

Chec
ked
by

54 57
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Rem
ark

AALRT
AALRT Enterprise Standards
be
tighte
ned
timel
y.
The
torqu
e is
150,
300

350N
.m

Recorder:

Reviewed by:

1/ 2
Note: 1. This table is made for all styles of bumper and filled in according to content of bumper inspection; for the content which are not involved, please fill
/ in the table.
2. For the content about survey data, specific data results shall be filled in this table.

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C11
Appendix C11: Signature book of track inspection

Signature book of track inspection

Job No.

Name

A
Maintenance Regulations of Line
Facilities (Version A)

Date

Arrival time

E/AALRT 0072-2015

E/AALRT 0030-13-B1
E/AALRT 0030-13-B1

Remark

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D
Appendix D: Wording instruction in this specification

Wording instruction in this specification



When the clauses in this specification are implemented, wording for strictness degree is described as
follows in order to make differential treatment during the implementation.
1
1. The words mean strictness and to have to do it:

Positive words use must; opposite words adopt strictly prohibit


2
2. The words mean strictness and shall do it in normal conditions:

Positive words use should;

Opposite words adopt should not or cannot


3
3. The words mean to allow for some choices and if permitted, shall do it firstly:

Positive words use advisable;

Opposite words adopt inadvisable;

The words mean to allow for some choices and if permitted, can do it; words use can.

Main line, auxiliary


line and platform
No. and definition

SN

Standard name

Prepared by

Gong Chengguang

2015.08.30
Date: August
30, 2015

Revision

/
Preparation/Revision

/
Prepared/Revised
by

Issued on

Standard history tracking

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Facilities (Version A)

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