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BRIDGES
Rail and rail joints
• Longitudinal profile of rails.
• Rail cant.
• Rail joints over the bridge-
a) Small bridges having opening < 6.1 m rail joint
should be avoided.
b) For other spans, the preferred position is at 1/3
the span from the ends.
c) Rail joint should be avoided within 3 m from
abutment.
SWR on bridges
• SWR may be continued over girder bridges
with un-ballasted decks up to 13.3 m opening
if symmetrical.
• In case of asymmetrical up to 6.1 m opening.
• If SWR is laid, no fish plated joint should be
located on the girder or within 6 m from
abutment
• 26 m long rolled rails may also be provided.
Precautions for arresting creep.
• Track laid with standard single rails and fish
plated joints be isolated with SWR if laid on
approaches by providing two well anchored
standard rail lengths.
• Track laid with standard single rails and fish
plated joints be isolated with LWR if laid on
approaches by providing 36 m well anchored
SWR on either side.
Provision of guard rails
• Should be provided on all girder bridges.
• Should be provided on Prestressed concrete
girder bridges without deck slab.
• Should be provided on all major and important
ballasted bridges and also on such minor bridges
where derailment may cause serious damages.
• On all flat top, arch and Prestressed concrete
girder bridges with deck slab where guard rail is
not provided the whole width of the bridge
between parapet walls shall be filled with ballast
up to sleeper level.
Design of guard rail
Splaying of guard rail
• In the case of through girder bridges on
double lines, guard rails should be splayed on
either ends.
• Other than through bridges splaying be done
only on the facing direction.
• However the non splayed end should be bent
downwards after it is stopped at the end of
the abutment and wooden block provided.
Trolley refuse
• Bridges with span < 100 m at 100 m.
• Bridges with span > 100 m on each pier.
Hook Bolt
• Hook bolts tie the sleeper with girder flange.
• The lips of the hook bolts will be as per the
design of the girder.
• Hook bolts are of 22 mm dia with square
shank.
Inspection and maintenance of track
on approaches.
• On bridge approaches, sleepers with
arrangement for fixing guard rail should be
provided.
• Full complement of track fittings on
approaches up to 100 m.
• Rail level should be maintained and dip
immediately after abutment should be
avoided.
Continued..
• Rail joint should be avoided within 3 m from
abutment.
• Joggle plating of AT welds if length of water
way is ≥ 100 m and on approaches upto 100m.
Continued..
For important and major bridges:
• In case of CST-9 or wooden on approaches,
PRC / ST with ERC should be provided up to
100 m / up to full breathing length where ever
LWR is provided on approach of bridge.
• 90 cm cess width should be provided up to
100 m on approaches.
Inspection and maintenance of track
on bridges.
• It should be ascertained whether it is central
on the rail bearers and the main girders and in
good line and level.
• The condition of sleepers, spacing and
squareness should be checked.
Continued..
• Rail fastenings should be tight.
• Condition of path way.
• Sand bins should always be filled with dry and
loose sand.
Steel sleepers on bridges
• It refers to both channel sleeper and H-Beam
sleeper.
Introduction
• Track structure on bridges are different from that on
embankment, such as :
Ballasted deck bridge – Rails, fittings and sleeper
are similar to the track structure on approach except
guard rails are provided to prevent over turning of
derailed rolling stock.
Length –
Length of steel channel sleeper depends on the type of
steel girder bridges and its span
Note:
The top flange plate of welded girder has
different width at both ends and at middle
portion of girder. Therefore, Length of sleepers
on A and B location are different.
• Bolt as per specification IS: 3757 – 1985 of Property class 8.8 &
length depending upon the thickness of filler plate component.
Silent feature
• Design is suitable for axle load upto 32.5 t and
curvature upto 1°
• This Drg. is suitable for welded plate girders /
stringers where there is no splice joints.
• Arrangement shown in Drg. for fixing H-Beam is
suitable when there is no rivet on top flange of
girder.
• Length of sleeper varies for DFC, BG, 25 t loading as
shown in this Drg.
• For rail seat assembly and position of holes refer
separate drawing to be issued by Track Directorate
of RDSO.
• Maxm spacing between sleepers shall be 650 mm
centre to centre.
Silent feature
• At rail joints, clear spacing between two
consecutive sleepers shall not be more than
200 mm.
• Surface preparation and sleeper seat painting
to be done while providing H-Beam sleeper.
• Fish plated joint in guard rails to be provided
on each pier to facilitate movement of girder
ends. Welded guard rails should not be
provided.
• If CE of Zonel Rly. considers that guard rail is
stiffer enough to prevent bunching of sleepers
in the event of derailment, he may decide to
dispense of the angles on sleepers.
H-Beam steel sleeper – Seating arrangement for
Riveted / Welded plate girders / Stringers & fixing
Gangway arrangement for (Drg. RDSO / B-1636/5)
• IRS specification for 25 mm thick Nylon cord reinforced
elastomeric pad RDSO / M&C/RP-197/03
• Elastomeric pad is joined to top of girder by Polychloroprene
based self – curing adhesive as Dunlop S-759 of M/s Dunlop
India Ltd. or PLIBOND of M/s Good Year India Ltd. Dentrite PC-
65 of M/s Chandras Chemical Enterprises Pvt. Ltd. or Fevicol
SB-97 of M/s Nabula Chemical Pvt. Ltd. or similar type.
• The solid contents of the adhesive shall be 20 to 22 % and
shelf life min One year.
• Surface of elastromeric pad to be bonded is cleaned by gently
rubbing with fine emery cloth for the purpose of removing any
superficial layers of extraneous matter such as wax.
• Care shall be taken during rubbing that the surface of the
elastomeric pad is not damaged.
• Thin layer of adhesive be applied uniformly both on the surface
of the elastomeric pad and MS Plate to be bonded. After 10 to
15 minutes the two surfaces are joined so that solvent is
evaporated
• Elastomeric pad is placed on the top flange of girder to get the
impression of rivets head to find out their exact location.
• For shop rivet (of 20mm ) 35 mm hole shall be punched in
the elastomeric pad where as for field rivets (of 22mm ) 38
mm hole.
• Holes are filled by ready mix red lead paint (IS:102) after
placing the elastomeric pad in position to avoid accumulation of
water.
• Elastomeric pad shall be joined in position with the MS Plate and
whenever practicable roller pressure shall be applied from one
end so as to avoid air entrapment / gaps.
• To accommodate rivet heads holes are punched by pressure in
elastomeric pad at connection of splices and top lateral bracing
with top flange of plate girder as per requirement.
• Surface of MS plate to which the elastomeric pad is to be
bonded shall be cleaned to make it free from dirt, grease, oil,
rust, mill-scale or any other extraneous matter.
• For riveted / welded plate girder suitable thickness of MS
packing plate to be welded at bottom flange of individual H-
Beam sleeper to maintain the rail level due to thickness of splice
plate & second plate if provided. Elastomeric pad 25 mm thick
should also be provided in case of the stringer.
• Size and shape of Hook bolt shall be as shown in the Drg.
• Position of Hook bolt will vary from span to span. 30 mm hole
for 28 mm Hook bolt in top plate will have to be drilled at site
to suit the span.
• Size of Split pin of Hook bolt is of 4mm as per IS: 549
• Single coil spring washer of Hook bolt as per IS: 3063
• 14 mm hole is provided in H-beam top flange to fix Gangway
plate by bolt with a taper washer, nut & split pin.
• H - BEAM STEEL SLEEPERS
ISHB – 200 is used as H-Beam, suitable for Welded Plate
Girders / Stringers of standard spans. Cross section of
sleeper is 200 mm x 200 mm, Size and Length as per
Drawing No. RDSO / B-1636 / 8.
For riveted plate girders
same type of H-Beam
with same fixing
arrangement is used.
Length of H - Beam
sleeper varies as per
the type of girder
bridges. Drg. No.
RDSO/ B-1636/ 5.
• H-Beam steel sleeper consists of:
a) Stiffener plates –
These are welded on both sides with top flange
of H-Beam in full length and with web portion of
the H-Beam upto a depth of 168 mm.
These plate shall be having a tapered cut beyond
168 mm depth and shall tight fit with the bottom
flange without welding as shown in the Drawing
No. RDSO / B-1636 / 8 which is suitable for
welded plate girders / stringers where there is no
splice joint.
b) Rail fastening assembly –
Position of holes on top flange of H-Beam for Rail
Fastening Assembly shall be given by Track
Directorate of RDSO through a separate drawing.
c) Packing plates for fixing Guard Rails –
Two Nos. Packing plates are welded to the top
flange of H-Beam as shown in the drawing for
fixing Guard Rails for which 27 mm Dia. holes are
drilled through in welded packing plates & H-Beam.
Guard Rail Assembly will be as per Drg. No. RDSO
/ T-5155 to 5164.
d) Gangway Plate –
Two Nos. holes per sleeper are placed diagonally
for 12mm dia bolt for fixing Gangway Plate of size
6 x 740 mm are provided on top flange of H-Beam.
The bolt and nut assembly for fixing gangway
includes split pin and Taper washer to suit to H -
Beam top flange from bottom side.
Fixing of Gangway Plate
Track fittings for H-Beam sleepers –
The rail free fastening is a simple arrangement in which -
the toe load of ERC is not transferred to the rail.
rails longitudinal movement due to thermal forces is
permitted.
rail is secured in its position retaining desired line and level.
RDSO Report No.CT-32 (Rev.1) detailed about
Zero Toe Load Fastener (ZTLF) for which
prototype to be developed and to be verified for
the usability of the design in first phase.
Field Trail of new design of Rail Free Fastening
system is required for validation before adoption
for regular use. The prototype should be fixed
on H – Beam sleepers and offered for inspection
to RDSO.
• Field trial scheme for rail free fastening system
(RFFS) on H-beam sleepers –
Once prototype is approved, the RFFS should be got
developed by the firm and got them inspected by the
consignee, with first 20% quantity by Track Directorate of
RDSO, as per contract conditions.
Performance of fittings shall be checked in actual field
conditions through trial. Limited field trial shall be
conducted initially for one year to cover changing
weather conditions.
Field trials shall be carried out under the direct
supervision of the AEN of the section.
Trains shall be permitted to run at restricted speed
initially and speed may be raised subsequently.
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III 87 m
II 110 m
I 146 m
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