Inspection and Maintenance

of
Points & Crossings

By

Anurag Rastogi
Prof Track Machine/IRICEN
 Objectives
• At the end of the session, we may be able to →
 List out Inspection schedules of various officials
 Explain how & what to check and how to
maintain Points and Crossing under -
 Switch Portion
Lead portion
Crossing Portion
Turn-in curve portion
 Inspections
In-charge SE/P.Way and sectional JE/P.Way
• All Points and Crossings on Passenger
and Running lines -
 Once in 3 months by rotation (Table 1B)
• All Points and Crossings on Other lines
and Yard lines -
 Once in 6 months by rotation (Table
1B)
 For Points and Crossings on PSC Sleepers
 Detailed inspection Once a year(cs135)as per
Annexure 4/3
 Intermediate inspections as per Annexure
 Inspections contd..

• Additional items in Annexure 4/3 over 4/3A –

Condition & Measurement of Stock rails
Gap bet Leading stretcher bar and foot of
S/rail
Condition of gapless joint
Measurement of Turn-in curve
 Inspections contd…

• AEN to inspect all Points and Crossings

thoroughly on Passenger running lines once in a
year; and
10% of Points & Crossings on other lines every
year (Table 1A)
• DEN to inspect certain number of points
(Discretion) in running lines and those
recommended for renewal (Para 429)
Note - Results of Inspections to be recorded as per
pro-forma in Annexure 4/3, 4/3A or 4/4, 4/4A/B (for
diamond crossing, with/w/out slips) & entered in
TMS.
 Joint Inspection with S&T Branch
• Joint Inspections (SE/P. Way and SE/Signal)
 All interlocked points to be inspected jointly once in a
quarter alternatively by SSE/P Way In-charge &
sectional SE/P Way.
 Mainly Switch portion is inspected
 Results and compliance reviewed at Divisional level
• Maintenance Requirements from Signalling
Considerations
 Switch should be reasonably ‘free’ to pull
 Proper housing of tongue rail; (?) 3/4 sleepers
 Burr on stock rail to be removed
 Switch should not be out of square
 Minimum gap between stretcher bar and bottom of rail
(1.5 mm to 3 mm/5 mm)
17:46
STATION
POINT NO TYPE

SECTION OF RAIL ANGLE OF CROSSING

TYPE OF SLEEPER
TYPE OF SWITCH (Curved/Thick ON CURVED/STRAIGHT
webbed)

INITIAL OPENING LH
RH
SL NO INSPECTION DETAILS QUARTER-1
OBSERVATION DATE OF
ATTENTION
1 Condition of Tounge/Switch rail (OK/Requires replacement)
a. Whether chipped or cracked over 200 mm length
within 1000mm from ATS
b. Whether twisted or bent (causing gap of 5 mm or
more at toe)

2 Condition of stock rail

(OK/Requires replacement)
LH STOCK RAIL

RH STOCK RAIL
3 Condition of wooden sleeper in point area if available

Condition of packing of point layout (Packing to be checked

under train movement)

17:46 04-02-2021 0930-1130 21604 (REFRESHER PWAY) 7

17:46
4 Housing of switch rail with stock rail (No. of sleepers)(for 1:81/2 3 sleepers and 1:12 4
sleepers)
5 Condition and adequacy of fittings upto the heel of switch (stud bolts, slide chair, plate
screw)
6 Whether tongue rails are out of square. More than 15 mm out of square to be corrected
(Except in curves)
7 Whether any BURR on stock/tongue rail obstructing the housing of switch etc?

8 Minimum opening of switch at TOE 115 mm (Normal Switch) 160 (Thick Webbed switch)

9 Condition of leading stretcher bar.

The clearance between leading stretcher bar & bottom of rail shall be at least 1.5mm but
not to exceed 3.0mm.

10 Condition of stretcher bar

11 Gauge at the TOE of switch
12 Condition of sleepers on which point machine is installed

13 Condition of drainage

14.I Condition of point machine

a) Whether point machine free from any obstruction (dust, rust or
any foreign
materials and corrosion)?
Painting required or not?
b) Make and age of motor:
(7 years for suburban/ 12 years for A & B routes/
15 years for D & D Spl routes

c) Whether point machine is provided with suitable gaskets and wire

entrances sealed to make them water tight and dust proof.
[All the extra opening shall be closed as far as possible]

d) Whether motor armature is clear and free from carbon deposits?

17:46 04-02-2021 0930-1130 21604 (REFRESHER PWAY) 8

17:46 e) Whether point motor insulation and switch bracket insulation is proper?

14.II Operation of point machine

a)
Whether any unusual noise observed while operating?

b) Stroke of the point machine

143mm for IRS /Siemens
220mm for IRS clamp type

c) Whether operating current is proper?

1.2 – 1.5 A for IRS/Siemens
4.3A for IRS clamp type

d) Obstruction test by 5mm piece @150mm from ATS

i. Point lock plunger shall not be locked
ii. Point detector contacts should not assume the position indicating
point closure
iii. Friction clutch should slip

e) Slipping current
Upper limit shall not be more than 1.5 to 2 times of normal working current
&
Lower limit 0.5 A less than normal working current. (Any difference
between normal
operating current and operating current under obstruction is less than 0.5
A,
machine to be replaced)

15 Functioning of locking arrangement

16 Condition of rodding including ground connections

a) Whether any play is experienced in pull rod while operating?
Whether any hill mark is available?

b) Whether driving rod is having clearance from rail bottom of 25mm to 40mm
or not.

17:46 04-02-2021 0930-1130 21604 (REFRESHER PWAY) 9

17:46
c) Whether rod renewal required due to excess corrosion or not
d) Whether fitting of rod arrangements are intact or not
e) Lead wires having twist or bent and free from rail, sleeper and ballast etc.

17 Condition of insulation joints at track circuited points

a) (Glued joint/block joints)
b) Condition of insulation joints at Gauge tie plate, stretcher bar etc
18 Full complements of bolts and nuts at connections at stretcher bar/
extension pieces
19 Condition of lubrication of points
20 Condition of lubrication of slide chairs
21 General
Whether sleepers are properly positioned with rodding cross run cross the
track
Any other item/deficiency
Signature of SSE/SE/JE (PWAY) with date
Signature of SSE/SE/JE (Signal) with date

17:46 04-02-2021 0930-1130 21604 (REFRESHER PWAY) 10

 Inspections involving S & T
Cleaning and Lubrication of Points:
 At all interlocked and partially interlocked
stations:
Signal staff shall be responsible for the
periodical cleaning and lubrication of those
slide chairs in which interlocking and
signalling gears are connected. (generally
upto third sleeper from toe of switch) in all
points interlocked with signals or provided
with locks.
PWI shall be responsible for cleaning and
lubrication of remaining all slide chairs.
 Inspections involving S & T contd..
• Hand Operated Points:
 PWI shall be responsible for cleaning and lubrication of
all slide chairs.
 Stretcher bar connected to the pull rod should jointly
be maintained by PWI and SI. Other stretcher bar by
PWI
 Insulated stretcher bar to be jointly maintained with
SI.
 SI will be responsible for keeping interlocking parts and
apparatus in working order.
 If slewing of point is likely to disturb adjustment, it
should be done in presence of SI.
Turnout Components & Features

Overall Length
 Inspection & Maintenance of Points &
Crossing (Para 429 of IRPWM)
• General –
 No 1 in 20 cant → Approach sleepers for running out/in of
cant
 No junction fish plates at SRJ & HOC, min. one rail on either
side
 Welding of SRJ & lead rail joints
 Spherical washer in switch portion ( to cover up for skew
rail) on LHS side only as holes are made accordingly
 Sleeper spacing as per Fan shaped layout in PSC T/Os
(Annex 4/2) – cumulative spacing
 Track geometry at T/Os should not be inferior to
approach track
Effect of absence of Spherical Washers
 Inspection of Points & Crossing
(General) contd..
 Clearances at toe of switch (115/160), JOH, heel
of switch, check rail & wing rail (built-up
crossing) to be maintained within tolerance as
per SOD
 Chairs & Fastenings must be properly secured
i/c single coil spring washer for plate screws
 Packing under switch & crossing should not be
loose.
 Cess to be low enough to permit efficient
drainage & adequate ballast cushion.
 Elastic fastenings to be examined & replaced in
case of creep
 A. Maintenance of Switches
• New Tongue rail selection for T/O
 Curvature of T/rail & Stock rail to be checked
before laying
 Precurved T/rails for T/Os taking off from
curve
 Planing of T/rail & location is given in Annex
4/5
 A. Maintenance of Switches contd..
• Badly worn and damaged tongue rails should be
replaced
• A Tongue Rail is classified as worn/damaged when:
 Chipped/cracked over small lengths aggregating to
200 mm within a distance of 1000 mm from its toe
(Chipped length will be portion where tongue rail has worn
out for a depth of more than 10 mm over a continuous length
of 10 mm)
(Note: Knife edge provision removed)
(TR Can be reused after reconditioning and repair)
 Badly twisted or bent → Improper housing on one &
& In-sufficient gap at JOH for other T/rail → Hitting
of wheel flange leading to flickering track circuit
 A. Maintenance of Switches contd..
 Housing of T/rail to be checked by operating
points jointly with S&T staff
 T/rail to bear evenly on slide chairs & against
slide blocks
 Leading stretcher bar to be jointly maintained by
SE/JE(P.Way) & SE/S&T. Remaining stretcher
bars by SE/P.Way
 Gap between top of leading stretcher bar &
bottom of Stock rail to be between 1.5 to 5mm –
coupled with loose packing leads to point failure
 Lubrication of Gauge face of curved T/rail for
reducing wear.
 A1. Maintenance of Stock Rail
 Wear on Stock Rails should not exceed the following
limits:
(Para 702 of IRPWM)
 Vertical Wear → 13 mm (for 60 Kg)
→ 8 mm (for 52 Kg)
 Lateral Wear (at 13-15 mm from Rail top table)
a. For Curve → 8 mm (for Group A and B Routes)
→ 10 mm (for Group C and D Routes)
b. For Straight → 6 mm (for Group A and B Routes)
→ 8 mm (for Group C and D
Routes)
Burred stock rail likely to obstruct lock bar should be
replaced
Thick Web Switch
Rails of
Asymmetrical Section
(Zu-2-49, Zu-1-60)

Web
Thickness
40/44 mm
 IRS-Clamp Type Point Machine Layout with TWS

 No stretcher bars
 Rodding arrangement at toe of switch to be maintained by S&T
 SSD is mandatory & to be maintained by Engg. Jointly
inspected with S&T
17:46
17:46

SPRING SETTING DEVICE

(SSD)

02-06-2021 (1530-1630) 03-06-2021 (1415-1630) DESIGNED BY N.K. MEHER SI/S&T-1/IRICEN

35
FOR IRICEN
B. Manitenance of Lead Curve and
Turn-in-curve
Correct Sleeper spacing for achieving correct
alignment of lead curve
Station to station (at 3m on 6m chord)
variation in versine ≤ 4 mm;
Versine at each station to be within ± 3mm
from its designed value
Conditions of sleepers, fastenings and
availability of ballast on outer side to also
checked.
 Crossings

• Types
 Built-up Crossing

 Cast Manganese Steel

(CMS)
Crossing
 C. Maintenance of
•
Crossings
Any damage to crossing be examined for
presence of tight or loose gauge or excessive
check rail clearance
• Check rail clearance opposite to nose of
crossing = 41 to 45 mm
• In Diamond crossing →
 Obtuse crossing to be laid square to avoid two route.
 Distance between throat & nose must be maintained
correctly.
 Check rail (25mm raised at Obtuse crossing) and wing
rail clearances & Gauge at Obtuse crossing is quite
important
 Check Rail

227.5 1500 875 1500 227.5

68.75
41

1415 1415

4330

Running Rail Check Rail

Gauge Face
Double Slip Diamond Crossing
 C. Maintenance of
Crossings contd..
• Vertical Wear on crossing (Wing Rail & Nose)
→Measured at 100 mm from ANC
• Rajdhani & Shatabdi Routes
– As a good maintenance practice, Crossing and wing
rails should be planned for reconditioning on reaching
following values:
• Built –up/welded crossing : 6 mm
• CMS crossing : 8 mm
• Other Routes: 10 mm
• Deduction in wear to account for 1 in 20 cant in CMS
X-ing
a. In case of CMS crossings
2.0mm in case of 52kg section; and
2.5mm in case of 60kg section
b. for heat-treated welded crossing – 3.5 mm
CMS Crossings
Inspection of Points and Crossings
• Miscellaneous Items
 Gauge
Uniform Gauge to be maintained
Gauge in crossing portion shall be 0 mm to 4 mm
with respect to prescribed gauge (1673 for PSC)
 Throw Of Switch
In OR switch : 115 mm
In TWS : 160 mm
 Miscellaneous Items contd..
 Superelevation
A) On Main Line
 Uniform through P&C and at least 20m on either
side of ATS and ANC.
B) On Turnout side
 Same cant as the M/line curve
 Cant to be changed after HOC at Rate<2.8mm/m
 T/Os not to be taken off from transition portion of
curve. If unavoidable, specific relaxation may be
obtained from CTE.
 Above provisions shall stand good in such case also
 Miscellaneous Items contd..
• Painting
 Date of Laying Points and Crossings–
 painted in white BLOCK LETTERS on the webs of
switches about 500 mm from the heel joint and the webs of
crossings about 500 mm from the joint connected to the lead
rails.
 When second hand points and crossings are subsequently
laid at another site, initial dates to be retained for indication
of the total life.
 In the case of reconditioning of switches and crossings, the
date of reconditioning should also be painted.

 Insertion or removal of P & C in a running line affecting

layout must be carried out only after obtaining sanction of
CRS.
 Miscellaneous Items contd..
 LWR through Points and Crossings
The turnouts shall be isolated from LWR/CWR
by provision of SEJs on either side.
However, in case of LWR/CWR taken through
turnouts the provisions contained in RDSO
report no. CT-48 shall be followed.
However, before permitting LWR through
turnouts (already adopted in DFCCIL) specific
approval of RDSO is required
 RECAP
 Schedule of Inspections – SrDEN/DEN, ADEN,
SSE/SE P.Way
 Inspection & Maintenance of Switches i/c S&T
items – Condition, housing, fittings etc of T/rail
 Inspection & Maintenance of lead curve and
turn-in curve – Sleeper spacing & Versines
 Inspection & Maintenance of Crossings – Wear,
check rail clearance
 Miscellaneous items – Gauge, Superelevation,
painting, LWR continuance etc
Thank You