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W./No.2017 /Track-l(P)/9 (2) Vol Ill ~-thfi /Date: 10.10.2025
General Manager,
All Zonal Railways.
Sub: Frequency of USFD testing on CC+8+2t (22.9t) routes.
Ref: (l) Board letter no. 2019 /CE-II/TSC/88/Puri dated 28.08.2020.(Copy
enclosed).
(ll) Board letter no. 2016/CE-II/TS/2/CC+8+2t dated 13.11.2024.
1. The track structure for operation of CC+8+2t loaded trains with varying
speeds was issued vide letter under reference (i). It was highlighted that for
operation of CC+8+2t axle load wagons on 52 kg rail, certain actions which
inter alia include installation of WILD, detachment of defective wagons,
readjustment or detachment of overloaded wagons, carrying out USFD
testing at higher frequency, replacement of 52 kg rails on priority etc. were
stipulated.
2. Similarly, operation of CC+8+2t axle load primarily on 60kg rails but having
very small stretch of 52kg track on new routes was also permitted with
similar stipulations.
3. It has, however, been observed that the defect generation rate in 52 kg, 90
UTS rails has increased· considerably on routes carrying higher axle loads
(CC+8+2t). Accordingly, frequency of USFD testing of rails for all CC+8+2t
routes on 52 kg rails, irrespective of-temperature zone, was enhanced vide
letter under reference (ii).
4. Zonal Railways are therefore advised to ensure compliance ·with· _the
stipulations mentioned in the letter dated 28.08.2020. Expeditious action
shall be taken to replace 52 kg rails with 60 kg rails on these routes.
5. Further, as an interim measure, USFD testing of AT welds that have
exceeded 50% of their service life on all CC+8+2t routes on 52 kg rails shall
be carried out by hand probing at a frequency as indicated below, in addition
to the provisions given in para 8.15.2 of the Manual for Ultrasonic Testing
of Rails and Welds (Revis~d - 2022):
Routes GMT of Testing frequency once in (for AT welds that
section have exceeded 50% of their service life)
CC+8+2 routes <10 2 Years
on 52 Kg ~10 1 Year
6. Zonal Railways are advised to take necessary action on the above directions
and. liquidate the arrears of testing, so as no AT welds meeting the above
criteria remains •untested for more . than 1 / 2 years as per frequency
prescribed in the above ·table.
This is issued with the approval of AM/ CE.
\D1\~t~
(Alok Kumar)
Executive Director/Tr (PIIP)
Railway Board
Copy to: PED/Infra-I/ROSO for information and necessary action.
