S ynopsis-Indian Railways with approximately 63000 kms track is one of the biggest

railways of the world railway system. Track maintenance in the railway has undergone a sea
change during the past 30 years due to continuous developments in various track components
viz sleepers, fastenings and long welded rails. The track structure has become sturdier and it
has become less amenable for manual maintenance. Therefore mechanized maintenance of
track has become unavoidable and gradually track maintenance has started to be done in a
big way by machines. Being fit for modern heavy track structure and giving quality out put far
superior than what one can achieve manually, a blue print for 100% mechanization of track
maintenance is being presented here.
Similarly at present track relaying is being done manually as well as by machines. But
the quality and progress of machines has outplayed what we achieve manually. Therefore a
blue print of hundred percent mechanization of track relaying is also being presented.
!
! !
M aintenance activity involved
1-Through packing/Tamping
2.Slack attention to
a-attention to bad spot generally on approaches of bridges , level crossing and at turnouts.
b-packing of glued joints ,welded joints.
c-attention of switch expansion joints (SEJ).
d-minor rectification of alignment.
3-Casual renewal of track components.
4-Systematic overhauling .
5-Ballast profiling.
6-Emergency repairs viz.rectification of rail /weld fractures etc.
7-Destressing of LWR tracks.
8-Transportion,loading and unloading of P.Way material.
9- Ultrasonic testing of rails.
10-Lubrication of elastic rail clips.
11-Patrolling
a-hot weather patrolling.
b- monsoon patrolling.
c- Cold weather patrolling
d-Security patrolling
e-Keyman daily patrol
12-manning caution and speed restriction boards.
13-Tree cutting for improved visibility.
14-Lubrication of rails and joints
15-Resurfacing of switches and crossings
16-Pre monsoon attention to drains /waterways
Page 1 of 15

17-Pulling back of creep and gap adjustment

18-Attention to level crossings
19-Periodic deep screening
20-Rail welding
21-Rail cutting /drilling and chamfering
22- M inor cess repairs
" #$
%
The track should be maintained either by conventional system of track maintenance or by
three tier system of track maintenance.
In both the systems, track requires to be overhauled periodically with the object of
restoring it to best possible condition, consistent with its maintainability. Periodicity of
overhauling depends on several factors, such as type of track structure, its age, volume of
traffic, rate of track deterioration, maximum permissible speed, system of traction, condition
of formation etc.

Annual programme for regular track maintenance

Period
Work
1 Post monsoon attention for about six
Attention to run down stretches, one round of
months
through packing
2 Pre monsoon attention for about two
Clearing of drains etc
months
3 Attention during monsoon for about
Attention to track as required
four months

(A) Conventional s ystem of track maintenance- in this track is maintained manually

(B) Three tier system of track maintenance: (1) 3- tier system of track maintenance shall be adopted on sections nominated for
mechanized maintenance. This shall consist of the following 3 tiers of maintenance(i)
On track machines
(ii)
M obile maintenance units
(iii)
Sectional gangs
(2) Large track machines for track maintenance include tie-tamping machines for plain
track and points and crossings, shoulder ballast cleaning machines, ballast-cleaning machines,
ballast regulating machines and dynamic track stabilizers.
These machines shall be used as per the various instructions issued in Indian Railways Track
M achines M anual.
These machines shall be deployed to carry out the following jobs.
(a) Systematic tamping of plain track as well as points and crossings
(b) Intermediate tamping of plain track as well as points and crossings
(c) Shoulder ballast cleaning
(d) Ballast profiling / redistribution
Page 2 of 15

(e) Track stabilization

(f) Periodical deep screening
(3) Mobile Maintenance Units(a) The mobile maintenance units (MMU) shall consist of two groups(i)
MMU-I one for each PWIs section
(ii)
MMU-II one for each sub division
(b) The functions of MMU shall be as below:
MMU-I (Rail cum road vehicle based)
One with each PWI in charge with a jurisdiction of 40-50 kms double line or 90-100kms
single line:
(i)
Need based spot tamping
(ii)
In situ rail welding
(iii)
Casual renewals and repairs except planned renewals
(iv)
Over hauling of level crossings
(v)
Replacement of glued joints
(vi)
Rail cutting /drilling and chamfering
(vii) Permanent repairs to factures
(viii) Creep or gap adjustments involving machines
(ix)
Distressing of LWR/CWR
(x)
Loading/ unloading of materials
(xi)
Any other functions assigned
MMU-II(Road vehicle based) one with each sub division
(i)
Reconditioning of Turnouts
(ii)
M inor repairs to the equipments of MMU
(c) The MM U shall be equipped with the following equipments. These equipments shall
be used according to the working instructions, as and when issued.
List of Equipments for MMU-I
(A) Communication equipment
1-walkie talkie
4 sets
2-portables field telephones 4 sets
(B) Rail cutting / drilling equipment
3- disc cutter
1
4- rail cutting machine
1
5- rail drilling machine
1
6-chamfering kit
1
(C) Rail welding equipment
7. Rail welding equipment
2 sets
8. Weld trimmer
1 set
9. Rail profile grinder for welded joints 1 set
(D) Spot tamping with lifting lining
10-Off track hand held tamper with generators 1 set
11-Lifting jack-hyrahlic/mechanical
4 sets
12-Lifting-cum-slewing device
2 sets
(E) Destressing Equipment
13-Rail tensors-hydraulic/mechanical
2 sets
Page 3 of 15

crossings

14-Rollers,wooden mallets 1complete set for distressing 3 km LWR

(F)Inspection gadgets
15-Inspection kit 1 No.
16-Gauge- cum- level 1 No
17-Rail thermometer 1 No
18-Vernier calipers 1 No
19-M icrometer 1 No
(G)M aterial handling equipment
20-Rail dolly 6 no.
21-M ono rail wheel borrow 2 no.
(H)Safety and protection equipments
22-Warning system
23-Red banner flag
24-Red hand signal flag
25-Green hand signals flag
26-Detonators
(I)Gas cutting equipments with accessories 1set
List of Equipments for MMU-II :
(A)Points and crossing reconditioning equipment
1-Welding generator 1set
2-Arc welding equipment 1set
3-Hand held rail grinder 2sets
(B)For minor repairs to equipments
4-Spanner of sizes 2sets
5-Turfer 2
6-Files of sorts 2sets
7-Bench drill 2
8-Vice bench 2
9-Bench grinder 2
(4) Section Gangs :
The sectional gangs under 3-tier system of track maintenance performs
the following functions:
(a) Patrolling of track
(i)Keyman daily patrol
(ii)Hot/cold weather patrolling
(iii)M ansoon patrolling
(b) Waching vulnerable locations
(c) Attention of emergencies viz. temporary repairs of fractures
(d) Need based attention to bridges,turnouts, SEJs and approaches of level

and other fittings

Page 4 of 15

(e) Greasing of ERCs,lubrication of joints ,casual changing of rubber pads

(f) M inor cess repairs
(g)Cleaning of drains and boxing of ballast
(h)Attention to loops

(i)Creep and gap adjustment not not involving use of machines

(j)Cleaning of crib ballast for effective cross drainage
(k)Pre and post tamping attention
(l)Assistance to MMU&OMU as required
(m)Any other functions assigned
&
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#$
%
:
Track relaying activities involves following activities:
1.Plain track relaying viz.CTR, TRR and TSR
2.Turnout relaying
At present both these activities are performed both manually and by

machines.
'

:
Track machines in Indian Railways can be divided in to two

groups
(A)Large track machines: following machines come under this category

(i) Plain track tamping machines

(b) 06-16 universal tamping machine (UT)
(c) 08-16 unomatic
(d) 08-32 duomatic
(e) 09-32 continuous action tamping machine
(f) 09-3x tamping express
(ii) Points and crossings tamping machines
(a) 08-275 Unimat
(b) 08-275-3s Unimat
(iii) M ulti Purpose Tamper (M PT)
(iv) Dynamic Track Stablizer (DTS)
(v) Ballast Cleaning M achine
(a) RM -80 for plain track
(b) RM -76 for points and crossings
(vi) Shoulder Ballast Cleaning M achines
(a) FRM -80 Plasser make
(b) KSC-600 Kershaw M ake
(vii) Plassers Quick Relaying System (PQRS)
(viii) Track Relying Train (TRT)
(ix)
Points and Crossings Changing M achine T-28
(x)
Sleeper exchanger and crane
(xi)
M obile Flash Butt Welding Plant K-355 APT
(xii) Rail Grinding M achine (Loram)
(B) Small Track Machines : list of the m/c which come under this category are
as under
Page 5 of 15

Sl no
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Type of machine
Abrasive rail cutter
Abrasive rail cutting wheel
Rail cutting machine (saw type)
Rail drilling machine
Hydraulic rail tenser
Hydraulic rail bender
Hydraulic rail joint straightner
Rail creep adjuster
Hydraulic sleeper spacer
Concrete sleeper breaker with angle grinder
Concrete sleeper drilling machine
Portable DC welding generator
Double action weld trimmer for AT welding
Rail profile weld grinder
Heavy duty hydraulic extractor for jammed ERC
Toe load measuring device (mechanical)
Electronic Toe load measuring device
M echanical track jack
Hydraulic track jack
Portable track lifting & slewing device (TRALIS)
Self propelled light weight trolley
Powered material trolley
Light weight rail cum road trolley
Jib crane attachable to BFR-BRH for handling concrete
sleeper
Attachment for rail dolly for PRC sleeper
Powered rail hauling system
Hand held off track tamper
Portable ballast cleaner (semi mechanized)
Portable shoulder ballast compactor

(
(A)Large Track Machines
annexure I:

(B)Small Track Machines :Data of small track machines is not available on date.
However large numbers are used in the system.

Page 6 of 15

,
The total route kilomerters of IR is approx. 63500 ,of which
approx.45700 is B.G.,approx.14300 is M .G.and balance is N.G.As per Uni
Gauge Policy 1992 rest of M .G.and N.G.routes will be gradually converted
into B.G.Due to this reason only complete mechanization in existing B.G.is
considered.In this also mechanization is planned in 2 phases :
PHASE 1:All A,B and C routes
PHASE 2:Remaining routes
In mechanization of maintenance existing 3-tier system will be
adopted.MMU-I and MMU-II to be adopted in all divisions in IR which is
presently used in only two divisions viz. Kota and ALD.The inherent problem
in existing RCRV to be rectified by design/adopting superior vehicle.Small
track machines to be provided to all sub divisions as per yardstick of
IRSTMM.For this creation of posts of requisite skill staff to be done and to be
recuited.The details of requirement of large track machines for complete
mechanization ii given below:
6.1.PHASE 1
6.1.1.Complete Mechanization Plan For Track Maintenance of Group A, B and C
Routes of IR
Total Track km of Group A route on IR
:
13937 km
Total Track km of Group B route on IR
:
15751 km
Total Track km of Group C route on IR
:
1541 km
Total Track Km
:
31229 km
Total Turnout on running line of Group A route on IR
:
12670 Nos
Total Turnout on running line of Group B route on IR
:
13737 Nos
Total Turnout on running line of Group C route on IR
:
1191 Nos
Total Turnout on running lines
:
27598 Nos
A) Plain Track Tamping
Taking a tamping cycle of 18 months (approximately), tamping requirement
every year will be 20819 km.
Taking block availability of about 2.5 hours per day, working of machine for
about 24 days in a month and Taking block availability of about 2.5 hours per
day, working of machine for about 24 days in a month and progress of about
900 m per gross block hour, each high output tamper would do about 650 km
every year.
Total 35 high output tampers alongwith equal number of DTSs are required
for this work .

Page 7 of 15

B) Turnout Tamping
Taking a tamping cycle of 12 months (approximately), tamping requirement
every year will be 27598 Nos.
Taking block availability of about 3 hours per day, working of machine for
about 24 days in a month and progress of about 1 turnout per gross block
hour, each turnout tamper would do about 850 turnouts every year.
Total 35 high output tampers are required for this work .
C) Deep Screening
Taking a Deep Screening cycle of 10 years, screening requirement every year
will be 3123 km.
Taking block availability of about 2.5 hours per day, working of Ballast
cleaning machine for about 24 days in a month (for 8 months in a year) and
progress of about 120 meter per gross block hour, each BCM would do about
60 km every year.
Total 57 BCMs alongwith equal number of BRMs,WSTand DTSs are required
for this work .
D) Shoulder Screening
Taking a Shoulder Screening cycle of 10 years, screening requirement every
year will be 3123 km.
Taking block availability of about 2.5 hours per day, working of Shoulder
Ballast cleaning machine for about 24 days in a month (for 8 months in a year)
and progress of about 250 meter per gross block hour, each BCM would do
about 120 km every year.
Total 29 SBCMs are required for this work.
NOTE: In calculating machine requirement 10% extra machines have been taken
for taking care their failures during service and for its schedule maintenance
From above total requirement of machines for periodic maintenance activities is
as under:
S.No.
Name of Machine
Total Req.
1
High output tamper(CSM,O9-3X)
35
2
UNI
35
3
BCM
57
4
SBCM
29
5
DTS
92
6
BRM
57
7
WST
57

Page 8 of 15

6.1.2. Complete Mechanization Plan For Track Relaying of A,B and C Routes of
IR
A)Plain Track Relaying:
Assuming that 7.5% of track to relaid every year .Total laying potential for a
year comes 2342 km. .
Total number of TRT and PQRS available on IR are 8 and 40 sets
respectively.Taking progress of TRT and PQRS as 12km per month and 5 km
per month per set respectively.Total relaying to done by these machines in a
year is 3197 km. Therefore no additional machine required.
In addition to these machines equal numbers of WSTs ,DTSs and BRMs are
required for tamping and ballast profiling.
B)Turnout Relaying
Assuming that 7.5% of turnouts to relaid every year .Total laying potential for
a year comes 2070..
Taking progress of relaying a T-28 as 12 turnouts in month.Total number of T28 required are 16 nos..
NOTE: In calculating machine requirement 10% extra machines have been taken
for taking care their failures during service and for its schedule maintenance
From above total requirement of machines for relaying as under:
S.No.
Name of Machine Total Req.
1
TRT
8
2
PQRS
40 sets
3
T-28
16
4
DTS
48
5
BRM
48
6
WST
48
In above table it is assumed that Unimats used in maintenance will be utilized in
tamping of turnouts laid by T-28.
Therefore total nos. of large track machines required for complete mechanization
of maintenance and relaying is as under:
S.No.
1
2
3
4
5
6
Page 9 of 15

Name of machine

Total
req.
High output tamper(09- 35
3X,CSM)
WST
105
UNI
35
BCM
57
SBCM
29
TRT
8

Available
IR
63
71
63
65
29
8

in Balance to
provided
34
-

be

7
PQRS
40 set
40 set
8
T-28
16
25
9
BRM
105
39
66
10
DTS
140
65
75
In above analysis it is assumed that when BCMs is not working for 4 months , its
follow machines can be utilized by open line for attention after track recording and
ballast profiling.These machines can also be given to construction organization for
that period.
6.1.3.Additional Staff requirement:
This is given below:
Staff for field operation:
S.No. Name of machine
Astt.
Charg
Forem eman
an
cum
cum
operat
senior or
operat
or
1
WST
34
34
2
BRM
66
66
3
DTS
75
75

Highl
y
skille
d

Skille
d
fitter

Khala Total
si/Kh
alasi
helper

68
66
75

34
66
75

102
198
150

Staff for field supervision, technical and general services:

S.No.
1
2
3
4
5

Category
Assistant engineer
Foreman
Highly skilled fitter
Sr.clerk-cum-material chaser
Semi-skilled
Total

Nos.
41
41
81
41
122
326

Staff for repair and maintenance:

S.NO.
1
2
Page 10 of 15

Category
Nos.
Assistant engineer (track machines) 20
Shop
superintendent
(track 20
machines)

272
462
450

3
4
5
6
7
8
9
10
11
12
13

Asst. Shop superintendent (track

machines)
Asst. foreman (track machines)
Charge man (track machines)
Track machine maintainer (HSKI/HSK-II/skilled)
Head clerk
Senior clerk
Draftsman
Clerk-cum- typist
DSK
Store man/material chaser
Track machine khalasi (unskilled)
Total

20
41
20
243
20
20
20
41
20
61
284
830

6.2.PHASE 2
6.2.1.Complete Mechanization Plan For Track Maintenance of Remaining
B.G.Routes of IR
Total Track Km
:
32304 km
Total Turnout on running lines
:
28548 Nos
A) Plain Track Tamping
Taking a tamping cycle of 18 months (approximately), tamping requirement
every year will be 21536 km.
Taking block availability of about 2.5 hours per day, working of machine for
about 24 days in a month and progress of about 900 m per gross block hour,
each high output tamper would do about 650 km every year.
Total 36 high output tampers alongwith equal number of DTSs are required
for this work .
B) Turnout Tamping
Taking a tamping cycle of 12 months (approximately), tamping requirement
every year will be 28548 Nos.
Taking block availability of about 3 hours per day, working of machine for
about 24 days in a month and progress of about 1 turnout per gross block
hour, each turnout tamper would do about 850 turnouts every year.
Total 37 high output tampers are required for this work.
C) Deep Screening
Taking a Deep Screening cycle of 10 years, screening requirement every year
will be 3230 km.
Taking block availability of about 2.5 hours per day, working of Ballast
cleaning machine for about 24 days in a month (for 8 months in a year) and
Page 11 of 15

progress of about 120 meter per gross block hour, each BCM would do about
60 km every year.
Total 57 BCMs alongwith equal number of WSTs, DTSs and BRMs are
required for this work.
D) Shoulder Screening
Taking a Shoulder Screening cycle of 10 years, screening requirement every
year will be 3230 km.
Taking block availability of about 2.5 hours per day, working of Shoulder
Ballast cleaning machine for about 24 days in a month (for 8 months in a year)
and progress of about 250 meter per gross block hour, each BCM would do
about 120 km every year.
Total 29 SBCMs are required for this work.
NOTE: In calculating machine requirement 10% extra machines have been taken
for taking care their failures during service and for its schedule maintenance
From above total requirement of machines for periodic maintenance activities is
as under:
S.No.
Name of Machine
Total Req.
1
High output tamper(CSM,O9-3X)
36
2
UNI
37
3
BCM
57
4
SBCM
29
5
DTS
93
6
BRM
57
7
WST
57
6.2.2Complete Mechanization
B.G.Routes of IR

Plan

For

Track

Relaying

of

Remaining

Total Track Km
:
32304 km
Total Turnout on running lines
:
28548 Nos
A)Plain Track Relaying:
Assuming that 7.5% of track to relaid every year .Total laying potential for a
year comes 2423 km. .
Taking progress of PQRS set as 5km per month .Total relaying to done by this
machine in a year is 60km. Therefore 44 number of PQRS sets needed .
In addition to these machines equal numbers of WSTs ,DTSs and BRMs are
required for tamping and ballast profiling.
B)Turnout Relaying
. Assuming that 7.5% of turnouts to relaid every year .Total laying potential
for a year comes 2141.
Page 12 of 15

Taking progress of relaying a T-28 as 12 turnouts in month.Total number of T28 required are 17 nos..
NOTE: In calculating machine requirement 10% extra machines have been taken
for taking care their failures during service and for its schedule maintenance
From above total requirement of machines for relaying as under:
S.No.
Name of Machine Total Req.
1
PQRS
44 sets
2
T-28
17
3
DTS
44
4
BRM
44
5
WST
44
In above table it is assumed that Unimats used in maintenance will be utilized in
tamping of turnouts laid by T-28.
Therefore total nos. of large track machines required for complete mechanization
of maintenance and relaying is as under:
S.No.

Name of machine

Total
req.

High
output
tamper(093X,CSM)
WST
UNI
BCM
SBCM
PQRS
T-28
BRM
DTS

36

Available in IR after A,B&C Balance to be

routes
complete provided
mechanisation
28
8

101
37
57
29
44 set
17
101
137

28
8
14 set
9
-

2
3
4
5
6
7
8
9

101
9
49
29
30set
8
101
137

In above analysis it is assumed that when BCMs is not working for 4 months , its
follow machines can be utilized by open line for attention after track recording
and ballast profiling.These machines can also be given to construction organization
for that period.
6.2.3. Additional Staff requirement:
This is given below:

Page 13 of 15

S.No.

1
2
3
4
5
6
7
8
9

Staff for field operation:

Name of machine
Astt.
Charg
Forem eman
an
cum
cum
operat
senior or
operat
or
CSM,09-3X
8
8
WST
101
101
UNI
9
9
BCM
49
98
SBCM
29
58
PQRS sets
60
T-28
16
8
BRM
101
101
DTS
137
137

Highl
y
skille
d

Skille
d
fitter

Khala Total
si/Kh
alasi
helper

16
202
9
98
58
16
101
137

8
101
9
49
29
60
8
101
137

24
303
18
196
116
60
24
303
274

Staff for field supervision, technical and general services:

S.No.
1
2
3
4
5

Category
Assistant engineer
Foreman
Highly skilled fitter
Sr.clerk-cum-material chaser
Semi-skilled
Total

Nos.
123
123
245
123
368
982

Staff for repair and maintenance:

S.NO.
1
2
3
4
5
Page 14 of 15

Category
Assistant engineer (track machines)
Shop
superintendent
(track
machines)
Asst. Shop superintendent (track
machines)
Asst. foreman (track machines)
Charge man (track machines)

Nos.
61
61
61
123
61

64
808
54
490
290
180
72
707
822

6
7
8
9
10
11
12
13

Track machine maintainer (HSKI/HSK-II/skilled)

Head clerk
Senior clerk
Draftsman
Clerk-cum- typist
DSK
Store man/material chaser
Track machine khalasi (unskilled)
Total

736
61
61
61
123
61
184
859
2513

At present there are sufficient number of machines available on IR to switch

over to complete mechanisation of track maintenance and relaying on Group
A, B and C routes. But for better quality shortfall of WSTs, BRMs and DTSs to
be made good.
For remaining B.G. routes complete mechanization will take some time .The
track machines are sanctioned through various RSP and it has been planned to
achieve full mechanisation by 2012 as per IRMP (2005-2010). Therefore it is
expected that by 2012 these will also completely mechanised.
There is already shortage of staff for existing track machines in some zonal
rlys and due to additional staff required for new track machines this problem
only aggravate. Therefore planning of creation of posts and their recruitment
need to hasten.
Zonal railways have tendency to carry out works, specially screening,
relaying of turnouts etc manually at the cost of quality of the output. We may
have to impress upon the zonal railways to work sincerely and honestly
towards achieving complete mechanisation of track maintenance.

Page 15 of 15