Rail Handling

Balfour Beatty Group Limited
EASTERN DEDICATED FREIGHT

CORRIDOR PHASE-2
Rev no.: 01
RAIL HANDLING Date: 29/8/2013

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Rail Handling
CORRIDOR PHASE-2
Rev no.: 01

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Table of Contents
1. Introduction .................................................................................................................................... 3
2. DFCC Requirement on Rails ............................................................................................................ 3
3. Available manufacturers ................................................................................................................. 5
4. Options available for Length ........................................................................................................... 5
5. Transportation of Rails .................................................................................................................... 6
I. Transportation by Road .......................................................................................................... 6
II. Transportation by Rail ........................................................................................................... 13

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Rev no.: 01

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1. Introduction

The Dedicated Freight Corridor (DFC) Project:

Ministry of Railways (MOR), Government of India hasplanned to construct Dedicated High Axle
Load Freight Corridor covering about 3363 kms on two corridors, Eastern Corridor from
Ludhiana (Sahnewal) to Dankuni and Western Corridor from Jawaharlal Nehru Port, Mumbai
to Tughlakabad/ Dadri near Delhi along with inter-linking of the two corridors at Dadri.

Dedicated Freight Corridor Corporation of India Ltd (DFCC), a public sector company has been
set up under the Indian Companies Act 1956 for implementation of Dedicated Freight Corridor
Project.

Eastern DFC Route will be approximately 1847 Km long from Dankuni to Ludhiana via
Mughalsarai Allahabad Kanpur Tundla Aligarh and Khurja. Proposed alignment of DFC
has been generally kept parallel to existing Indian Railway line except provision of
detours at locations bypassing the major cities/towns.

Mughalsarai New Bhaupur Section (Double line 402 Kms) Phase 2 of the Eastern Dedicated
Freight Corridor project starts from near Howrah end of existing Mughalsarai station of Indian
Railways (between Mughalsarai-Ganjkhwaja stations) to New Bhaupur station (situated near
the existing Bhaupur station of Indian Railways) via Mirzapur - Allahabad - Fatehpur - Prempur -
Kanpur. Approximate total length in detour is 130 Kms.

This Phase 2 of the total project is divided into 2 contracts i.e. Contract Slice no. 201 and
Contract Slice no. 202. There may be possibilities of awarding both contracts to a single
contractor or separate contractors for individual contracts depending upon the evaluation of
the technical and commercial bids.

2. DFCC Requirement on Rails

The total track length for the Phase 2 i.e from Mughalsarai to New Bhaupur is approx. 830 track
kms.
The total quantity of rail required considering 120MT/km is 830km*120MT/km= 99,600MT
As per DFCCIL (APL-1 from Bhaupur to Khurja Ph 1), specification of the Rails is as follows:

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3. Available manufacturers

The List of available manufacturers for the Grade 880 UIC 60kg are as follows:
Domestic:
Steel Authority of India Limited
Jindal Steel and Power Limited

International
Sr No. Company Name Country
1 Arcelor Mittal Luxemberg, Poland, Germany
2 Nippon Steel Japan
3 Voestalpine Schienen GmbH Austria
4 Tata Corus France

Apart from the above there are various manufacturers from China and Korea that manufacture
rails of 880 Grade.

4. Options available for Length

The rails that are manufactured can be obtained in various lengths.
The standard lengths that have been indicated in IRS T-12 2009 on the length of the rail procured are
as follows:
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Rails of lengths greater than 26m i.e 130m or 260m are also possible. But as of now in india, SAIL
hasnt supplied rails greater than 26m length directly from the manufacturing plant.
So considering that the manufacturer can provide the rails in lengths greater than 26m, the options
that are available with us are:
13m
26m
130m
260m
5. Transportation of Rails

The transportation of rails from the source location to the site can be done in two ways:
I. Transportation by Road
II. Transportation by Rail

I. Transportation by Road
One of the modes of transport of the rails from the source i.e the steel plant to the site location
can be transportation by road.
The vehicle that will be used for the transportation by road shall be Trailers.
The major constraint in transportation of Rails by road has been the length of the Rails.
13m rails (42ft) can be transported easily transported on trailers of 50ft flat bed. This is a
standard trailer and is easily available. These are generally used in transportation of various
other materials other than Rails like Steel rolled sections, steel pipes, steel channels etc.
.
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According to IRC-SP-41, the minimum dimensions for the movement of the vehicle are as
follows:

Figure 1: Minimum turning path for a Trailor according to IRC SP-41

26m rails (85ft) can also be transported on trailers but this will require special type of trailers
with extended beds and has lot of problems during the transit operations.

Rail lifting and handling:

As per DFCCIL (APL-1) document, following specification on the handling of rails has been
indicated:
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The high carbon and alloy steel used in the manufacture of rails renders the rails very
sensitive to shock or impact loading, bruising, notching or marking on the surface, and the
point or line loading.
This is especially true in handling the longer rails being produced in the rail mills welding
plants. The staff handling such rails are required to:

o Use strings made of flat link chains or holders of specific material.
The attachments can be classified into two types:
Single rail lifting
Multi rail lifting
There are various suppliers of these lifting attachments such as:
Geismar
Engcon
Camlock etc.

Single rail Lifting:

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Multi rail Lifting

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o Use of magnetic devices is preferable.
o Use multipoint slinging for lifting of rails. As per the Flash Butt Welding manual by
RDSO the recommended lifting points are as follows:

o Stack the rails on firm, level and well drained ground.

o Stack subsequent layers on the uniformly placed spacers
o Place rails of shorter length in upper layers
o Handle rail gently without sudden impact.
o Use protective clothing, gloves and helmet of distinctive colour

Location of Unloading:
Unloading of the rails can be done at two locations:

At the depot location
At intermediate locations such as level crossing, junction stations, crossing stations etc.
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At the depot location:

Unloading the rails at the depot location shall involve extra expenditure on transporting the
rails again from the depot to the site location and hence this option can be avoided.

At intermediate locations such as level crossing, junction stations, crossing stations etc.:
One of the best locations for unloading the rails shall be the intermediate level crossing,
junction stations, crossing stations locations where there will be enough space to unload the
rails and stack them in layers.

The unloaded rails stacked on the cess of the formations at these locations shall be lifted
and placed on the formation using a using a 360deg excavator with a special lifting
attachment as mentioned above.

After the rails are placed on the formation, the rails are then welded using a mobile flash
butt welding plant.

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After the rails are welded, these are then dragged on rollers using a tractor or vehicle of
similar power, all along the alignment.

Welding is done in lengths of 500m as lengths more than 500m will be difficult to drag.

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II. Transportation by Rail
The most economical way for the transportation of rails from the steel plant / the rail manufacturing
unit to the site location shall be by rail.
The scope of transportation of rails by Indian Railway route shall be in the scope of the
manufacturer/supplier.
The rails can be obtained by Indian Railway network from the following domestic vendors:
Steel Authority of India Limited
Jindal Steel And Power Limited
Rails of all lengths can be obtained on Railway Rakes i.e. 13m, 26m, 130m and 260m.
The rails of 13m lengths can be transported easily using the standard flat wagons i.e. BFR or the
BRNA wagons.
As per the discussion held with Mr. Bajaj of Jindal Steel and Power Limited, the rails of length greater
than 13m needs to be transported using special flat wagons known as the BLL flat wagons.
For the carriage of 260m long panels, JSPL has submitted the request for allotment of wagons to
Indian Railways.
In these flat wagons, at the coupler location there are these flat plates which have the roller
attachment on which the rails will be mounted.
As per the information obtained from JSPL, one rake of BLL wagons i.e. 40 no.s of wagons can carry
260m rail panels for quantity equivalent to 17kms of Track length.

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Handling of rails of 260m while unloading of rail panels:
The loading arrangement of the rails for the 260m long rails shall be under the scope of the
manufacturer/supplier.
The unloading of the rails however will be under our scope and the necessary arrangement
for the unloading process shall be arranged at the unloading point.

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The high carbon and alloy steel used in the manufacture of rails renders the rails very
sensitive to shock or impact loading, bruising, notching or marking on the surface, and the
point or line loading.
This is especially true in handling the longer rails being produced in the rail mills welding
plants. The staff handling such rails are required to:

o Use strings made of flat link chains or holders of specific material.
Multi rail lifting

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There are various suppliers of these lifting attachments such as:
Geismar
Engcon
Camlock etc.

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o Use multipoint slinging for lifting of rails. As per the Flash Butt Welding manual by
RDSO the recommended lifting points are as follows:

Rail Handling

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Balfour Beatty Group Limited

EASTERN DEDICATED FREIGHT

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