BANGALORE METRO RAIL PROJECT

(BMRCL)

TRACK PLINTH INSTALLATION
Contents
Method of Track Plinth Installation
Technical Information
Project Information
Method of Turnout Installation
Project Information
Airport
Project : Bangalore Metro Rail Project (Phase 1 ) - Track works

Owner : BMRC (Bangalore Metro Rail Corp. Limited)
Consultant : RITES-OCCL-PBI-SYSTRA

Contract Value : Rs. 3,318 Million Rupees (Original Contract)

Duration : 22 September 2009 - 15 October 2012 = 160 weeks
(Reach 1 : 22 September 2009 December 2010)

Scope of works : Supply, installation and test of railway tracks and 3
rd
rail
(BMRCL supplies rails &turnouts and 3
rd
rail components)
Airport
Supply of track Fastenings, Ballast, PSC sleepers, Buffer stops etc.
Setting-out final alignment
Welding by flash butt/ thermit
Laying of ballastless track on Mainlines and in selected areas of
depots
Laying and tamping of ballasted track on mainline at Baiyappanahalli
terminal beyond passenger platform and in maintenance depots
Install third rail system
(under supervision/supply of all items including tools by Power Supply
Contractor)
Testing and Commissioning


Contractors Scope of Works
Airport
Technical Information
(Mainline, Elevated)
Descriptions Details
Gauge Standard Guage (1435 mm)
Trackform Ballastless Track : Track Plinth
Rail Type UIC-60 (60 kg/m) Head Hardened Rail
Radius of Curve Horizontal : Minimum 117.9 m
Vertical : Minimum 1500 m
Cant/Cant Def. Maximum Cant : 125 mm
Maximum Cant Deficiency : 100 mm
Rail Inclination 1:20 (towards the center line of track)
Fastening System Vossloh Fastening system 336
Turnouts 1:7, 140 m Radius with canted rails, Thick web
switches and CMS crossings with welded legs
1:9, 300 m Radius with canted rails, Thick web
switches and CMS crossings with welded legs
Construction
Methodology
Top down Construction
Airport
Full Assembly of Fastening System
(VOSSLOH System 336)
Airport
Airport
Track Plinth
(Mainline, Elevated)
Straight Track
Airport
Track Plinth
(Mainline, Elevated)
Curved Track, cant 125
Airport
Method of Track Plinth Installation
Survey Works
Marking Track Plinth Location, LWR Distribution & Supporting
Initial Adjusting of Rail & Fastening Placement using dummy plate
with holes for avoiding voids
Rebar Placing & Placement of Stray Current Arrangement
Final Check Approval for Concreting
Replace Fastenings and LWR , Welding and De-stressing
Shuttering & Final Adjustment of Rails & Fastenings Placement
Concreting, Demouldling, Curing
Removal of Rails & Baseplates/Dummy plate, Finishing the
Concrete Surface under Baseplate
* Alumino -Thermic Welding
Track Plinth Installation
Survey Works
Traverse & Control Points working
Transfer Coordinate to Viaduct
Checking for Centerline of Viaduct
Track Plinth Installation
Survey Works
Marking Centerline of Track
Center line of Track & Track Plinth
Edge are marked on viaduct surface
Track Plinth Installation
Rail Distribution to Working Area
Distribution of Rails from Stocking Area
Rails reaching to Working Area
Rails Supported by Wooden
Track Plinth Installation
Support Rails and Initial Adjustment
Supporting Rails by Rail Gauge Holding Bar Initial Adjustment for Line & Level
Track Plinth Installation
Fastening Placement & Rebars Fixing
Fastening Placement
(Designed Locations)
Rebars Fixing
Track Plinth Installation
Rebar Fixing
Ensuring Continuity of Provision for Stray Current Protection
Track Plinth Installation
Shuttering
Shuttering
Ensuring on Concrete Covering
Track Plinth Installation
Final Setting
Final Checking of Line & Level Final Checking of Track Gauge (1435mm)
(Checking for cant at curved area)
Track Plinth Installation
Final Setting
Final Checking of Rail Inclination
(1:20)
Adjusting for Rail Inclination
Track Plinth Installation
Cleaning & Cover Fastenings
Cleaning
Wraping Fastening System & Final Check
Before Concreting
Track Plinth Installation
Concreting & Finishing
Preparing Concrete Pump & Installing Pipe for Concreting
Track Plinth Installation
Concreting & Finishing
Concreting & Vibrating
Surface Finishing
Track Plinth Installation
Demoulding & Concrete Curing
Demoulding after 24 hours & Concrete Curing
Track Plinth Installation
Finishing of Track Plinth Casting
Remove Rails and Dummy Plate Underneath Base Plate
Method of Turnout Installation
(Ballastless Track, Mainline)
1. Survey works
2. Mark the center of straight track, Turnout track, and end point of Turnout
3. Pre-assemble half-switch assemblies, crossing assembly and half check rail
assemblies.
4. Lay down the rail assemblies as under
The straight half-switch is laid first.
Check the position of the plates according to marks on the foot of the stock
rails.
Ensure straightness
Lay the curved half-switch and ensure squaring of the half switches at the
end of the stock rails
Lay the crossing and ensure the correct distance between switch toe and
point of crossing. Adjust the crossing, moving it forward or backward
Lay the two external rails of the intermediate part as well as the closure
rails to correct orientation
5. Adjustment of the Switches
Adjust the straightness and alignment of the overall Turnout with a string.
Check the Track gauge in main track at every base plate and adjust the
gauge by moving the curved half-switch
Check the Track gauge in the diverging Track at each base plate and
adjust the gauge by moving the curved half switch
Put clamp to fix the stock rail and switch rail together.



Method of Turnout Installation
(Ballastless Track, Mainline)
6. Adjustment of the intermediate part and crossing.
Check the gauge at every base plate and adjust by moving the crossing
Put in straight closure rails as required and check gauge at every base
plate
Put in place the curved closure rail and check versine at quarter points.
Check the gauge at every base plate.
Check the Track gauge in the diverging track and adjust by moving the
external curved rails.
7.Ensure that all fittings are in position.
8. Installation of reinforcement rebar work and Tube slip pipe for Signaling work
9. Installation of shuttering work and included block out for point machine
10. Final adjust top of rail to meet design parameter vertical alignment,
Horizontal alignment, Gauge
11.Cleaning work, plastic warp fastening, and Concreting after 24 hr. De-mold
and curing
12. Grouting by chemical non-shrink underneath base plate
13. Welding



Method of Turnout Installation
Tool for Supporting and Adjusting
Typical installation of track gauge holding rail bar
Method of Turnout Installation
Tool for Supporting and Adjusting
Supporting System
Turnout Installation

Provided Gap between Track Slab
Block out for Point Machine
Turnout Installation

Gap underneath Fastening System
Shall be Grouted by Non-Shrink Grout
Installed Crossover
Turnout Installation

Non-Shrink Grout under Pad