Thick Web Switch

Laying and
Maintenance

Anil Choudhary
Sr Prof/IRICEN
Turnout Components & Features

SRJ ANC and TNC

Lead rails

Point Of Intersection
Throat

Motors
Switch Assembly Lead Assembly Xing Assembly
 Curved Switch

TTS ATS Tongue Rail

Stock Rail

R
 Curved Switch

TTS ATS

Switch Entry Angle

R
 Switch Entry Angle for Switches

1 in 8.5 straight 1° 34’ 27”

1 in 8.5 curved PSC 0° 46’ 59”
1 in 12 straight 1° 08’ 00”
1 in 12 curved W/ST 0° 27’ 35”
1 in 12 curved PSC/TW 0° 20’ 00”
1 in 16 curved PSC/TW 0° 20’ 00”
1 in 20 curved PSC/TW 0° 20’ 00”
Theoretical Evaluation of Speed Potential
on Turnout

The permissible speed over the turnout is the minimum of the following
three speeds –
Permissible speed to obtain desirable values of lateral forces and
acceleration at entry (SEA)
Permissible speed due to non transitioning of the lead curve
Permissible speed due to non-canting of lead curve

(Check lateral acceleration due to SEA, Transition or non canting or

combined)
 Permissible speeds for various
criteria
Speed (Km/h) due to absence of
Lateral
Turnout Type SEA Super-elevation
Forces
Transition
(Taking Cd as 75 mm)

1 in 8½ 10 kmph
134’37” 43.6 35.8
(Straight Switch)

25 kmph
1 in 8½ 30 Kmph (If
047’27”
(Curved Switch no Turn in 45.0 36.0
wooden ) curve like
crossover)

1 in 12 16 kmph
108’00” 68.0 50.0
(Straight Switch)
1 in 12 027’35” 40 kmph 69.4
51.0
(Curved Switch wooden) (martins formula)
1 in 12 (Curved PSC) 0’20”00” 60 Kmph 69.4 51.0
1 in 16 (Conventional) 024’27” 55 95.4 68.8
1 in 16 (Curved PSC) 020’00” 85 95.4 68.8

1 in 16 -
012’13” 138.0 97.0
(Symmetrical split)

1 in 20 (Conventional) 024’27” 55 122.0 86.4

 Permissible speeds for various criteria

1. At high SEA, the lateral force becomes the guiding criteria for speed
potential.

2. At Low SEA, lateral force is less & it is the non existence of cant and thus
Cd becomes the guiding criteria.

So no advantage of reducing Switch entry angle for current design of T/o

Throw of Switch

Throw
 Minimum Throw of Switch
(SOD 2004)
For existing works (BG) : 95mm

For new works/alterations to existing works (BG): 115mm

Note-
The clearance can be increased up-to 160mm in curved
switches in order to obtain adequate clearance between gauge
face of stock rail and back face of tongue rail at JOH
(Same done for thick web switch)
 Heel Divergence

c = heel clearance
d = heel divergence

d c

Fixed Heel Switch

Joint Formed Ahead of
Heel
 Heel Clearance/Divergence
c = G – g – tmin
c = 1673-1600-16
c = 57 mm

d = c + head width
(head width)
67 mm (52Kg IRS)
74.3 mm (60Kg UIC)

So Dmin is 124 mm for 52 Kg and 131.3 mm for 60 Kg rail

 Components/Features of Points & Crossings

Heel Divergence
BG (1 in 8.5 ST SW) 136mm

BG(1 in 8.5 CU SW, PSC sleeper) 182 mm

BG(1 in 12 ST & CU SW-W/ST sleeper) 133 mm

BG(1 in 12, CU/TW SW, PSC sleeper) 175mm

 Tongue Rail
(for Over-Riding Switches)
Over-riding Switch
How a SWITCH works ?
Tongue
Rail
 Vertical Planning Of Tongue Rail
60 Kg UIC, 1 in 12 Turn Out
Level Point Top of Tongue Top of Stock
Head Width 13mm Head Width 43.4 mm Rail Rail

Q
22
28
6
156.4 166 172
12R
144 Bottom of Tongue Rail

6
6 mm High Tongue
1682 Bottom of Stock Rail
Rail 4244
5840
JOH

13 43.4
 Junction of Heads (JOH)

The location where tongue rail acquires full head width

is called JOH. Minimum clearance at JOH is an
important parameter in design & manufacture of
tongue rail
Fixed Heel Switch
Clearance at JOH
Min. Clearance at JOH

HEEL
BLOCK

Joint Formed after

Heel

23
Minimum Clearance at JOH © is
c = G – g – tmin
c = 1673-1600-16
c = 57 mm
 Clearance at JOH for 1 in 12 Curved Switch

Cause : Longer length of tongue rail (Flexibility)

Effect : Grazing of back of tongue rail, vibrations in tongue rail

and stretcher bars

Remedy :
 Double pull arrangement
 Spring Setting Device
 Increased Heel Divergence / Throw of Switch
Slide Chairs
Pre-curving of Tongue rail
Tongue Rail
(for Thick Web Switches)
Thick Web Switch
 Pre-curving
TWS Vs ORS
 Thick Web Switch

Rails of
Asymmetrical Section
(Zu-2-49, Zu-1-60)

Web
Thickness
40/44 mm
 TWS

ORS
Slide Chairs for TWS with leaf
Spring
6
60 Kg UIC Tongue Rail
machining
38
ZU-1-60Kg Tongue Rail Machining
 Dimensional comparison of
TWS and ORS Switch

Item ORS TWS

Head level 4244 4958

reached at

JOH (Head 5840 5837

machining
Length)

Heel Block 10125 10125

 Advantages of Typical profile of
TWS

1. Undercut in SR provides margin for more thickness of TR at tip thus more

wear margin and greater resistance to breakage.

2. However it reduces SR thickness and increasing metal flow towards gauge

line (more prominent in heavy haul) may be creating burr and issue of setting
of switch.
Some maintenance
issue
Grinding Requirement
 Point Machine

Machine stroke
◦ Rotary type - 143 mm
◦ Clamp type - 220 mm; and

For rotary type of point machines

◦ Adjustment of stroke from 143 mm to 94 mm possible

The closed switch adjusted to be just in contact with the stock

rail. Then the connections tightened further by 2 mm - 3.5 mm to
impart a springing action to the tongue rail
 Clamp Lock

Clamps closed switch against the stock rail to lock switch.

Throw bar of points machine provided with a total of 220 mm
stroke
◦ 60 mm for the unlocking,
◦ 100 mm for the throwing of points; and
◦ 60 mm for the locking of closed switch.
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
08:17

IRS TYPE POINT MACHINE IRS CLAMP TYPE POINT MACHINE

SUITABLE FOR OVER RIDING SWITCH ONLY THICK WEB SWITCH ONLY

SWITCH OPENING 115±3 MM 160±3 MM

CLAMPING ARRANGEMENT NOT APPLICABLE YES

MOVEMENT BOTH SWICHES CAN MOVE TOGETHER SWITCHES MOVE INDEPENDENTLY

STRECHER BAR LEADING AND FOLLOWING ONLY LEADING

STROKE 143 MM 220 MM

IDLE STROKE 25 TO 28 MM NOT APPLICABLE

DETECTION SWITCH RAIL ONLY BOTH SWITCH AND STOCK

SSD NOT APPLICABLE MANDATORY

SPEED POTENTIAL UPTO TO SPEED 140 KMPH 160 KMPH

STD. OF INTERLOCKING UPTO III UPTO IV

SAFETY MODERATE HIGHER

DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN

08:17

SWITCH OPENING
T
O H
V I
E C
R K

115+3
I
-
D
160+3
W

I
N
- E
B

DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN

 R C
N

RE
BOTH SWITCHES MOVE TOGETHER 55000

50
RE

RE
RE
G F N L

N L
G F N

RE
G F
L

DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN

 L R
H H

08:17 S
BOTH SWITCHES MOVE INDEPENDENTLY TOTAL STROKE
S
T T
O
O
C C
K K

L
H
S STROKE R
W H
I
DISTRIBUTION
T OF THICK WEB S
C SWITCH WITH W
H CLAMP TYPE I
T
ARRANGEMENT C
H
STROKE DISTRIBUTION:
Switch opening (IN mm)
100
1600 mm + 100 + 60
08:17 DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN

49
 DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
OVERRIDING POINT MACHINE R
DETECTS SWICH RAIL ONLY
N
L
0 A NE
LP
RO
3 2 1 1 2 3

NT
CO

50
08:17
TOTAL STROKE

STROKE DISTRIBUTION:
(IN mm)
Switch opening LH SWITCH & STOCK
60 + 100 + 60 100
1600 mm
08:17 RAIL
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
 08:17
TOTAL STROKE

RH
OPENING SWITCH &
STROKE DISTRIBUTION: 100
160
0 STOCK
(IN mm) 60 + 100 + 60 RAIL
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN

08:17
Stretcher Bars (ORS)

SB
Sleeper

Tongue Rail
IRS-Clamp Type Point Machine Layout with TWS
Spring Setting
Device
 Spring Setting Device

It is a reversible mechanical spring device connected

to the foot of two tongue rails at or near JOH
The device actuates after the movement of TRs
initiated by the point motor reaches about half way
At this stage, one connecting rod of the SSD pulls the
open TR away from SR and simultaneously the other
connecting rod pushes the closed TR firmly against the
SR
Spring Setting Device
 Spring Setting Device

This prevents the rattling of TRs between TOE

and HEEL under moving wheels and ensures
adequate clearance between TR and SR.
Hence, enhanced life of switches and better
riding comfort can be achieved.
◦ RDSO Drg No. RT-6216 (60 kg)
RDSO Drawing on SSD
SSD IS POVIDED IN THICK WEB SWICH
JOH (SL NO.13) FOR FLANGE WAY
CLEARANCE 60+-2

SPRING SETTING DEVICE

(SSD)
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
08:17

SPRING SETTING DEVICE

(SSD)
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
60+2 mm 60+2 mm

SPRING SETTING DEVICE

(SSD)
DESIGNED BY N.K. MEHER Sr.INSTRUCTOR/S&T-1/IRICEN
 Special features of Thick-web Switches

• Elevated slide chair – TR foot 38 mm higher

• Switch Entry Angle – 0° 20’ 00”
• Tip of Tongue Rail is housed in recess under head of Stock Rail
formed by machining of the head of the stock rail
• Top of Tongue Rail is at level with Stock Rail – No twist
• End of Tongue Rail forged to match lead rail
 Special features of Thick-web Switches

• Relief planning of foot of Tongue Rail near heel to improve

flexibility (Throw = 160 mm)
• Inside foot of SR is anchored through wedge & leaf spring
• Double Pull Arrangement using GRE-5E Point Machines and Spring
Setting Device for increased clearance at JOH (57 mm)
• Tongue Rails are Fabricated from thick web Asymmetrical Rail
Section.
 Thick-web Switch
Technical Superiority over ORS
Feature Advantage End benefit

No undercutting of foot Enhanced safety

required
Lower height of
asymmetrical tongue rail Use of Elastic fastening on Less maintenance
(134 mm Vs 172 mm) both sides of stock rail effort

No twist Improved running

Higher lateral rigidity Less maintenance

Thick Web resulting in less distortion effort &
(44 mm Vs 16.5 mm) under lateral load More service life
 Thick-web Switch
Technical Superiority over ORS
Feature Advantage End benefit

No hole required No possibility of bolt hole Improved safety

in stock rail crack

More opening of Proper housing of tongue Improved running

toe (160 Vs 115) & rail & Adequate flange & Improved service
Provision of SSD way at JOH life

Direct locking of tongue

Point Clamp Lock rail with stock rail Improved safety
 Distance Blocks

To connect two different rails at desired distance and/or at desired

inclination
◦ Fishing Fit Block (acts like Fish Plate)
 All Machined Joint
 Block connecting CMS crossing to Rail

◦ Web Fit Block

 Heel Block of Fixed Heel Switch
 Distance Block Behind Heel of Switch
 Check Block between Running Rail and Check Rail
Distance Blocks
(Fishing Fit)
Distance Blocks
(Web Fit)
 Slide Blocks

In curved switches (other than 1 in 8.5 CU SW) slide blocks are provided
to increase lateral support to tongue rail

These are bolted to Stock Rail against which Tongue Rail will bear evenly
in closed position
Slide Blocks
Spherical Washers

Used to obtain flush fit of the head or the nut of bolt with the web
of Rail

Required if axis (shank) of bolt is not at right angles to the axis of Rail
(surface against which bolt will rest)
Effect of absence of Spherical Washers
Spherical Washers
 Spherical Washers
To be used on skew side

 Heel and Distance block : on left side

Tapered Washers
Crossings
 Crossings

 Cast Manganese Steel

(CMS) Crossing
 Crossings – CMS Crossings

Advantages
 Comparatively Shorter length and Monolithic construction - No
differential movement
 Better wear resisting properties
 Lower maintenance cost, Longer life
 Cross slope of 1 in 20 on the top of wing rails of CMS crossings

Limitations
 Rapid initial wear
 In situ reconditioning cannot be done (Now robotic reconditioning)
Crossings Comparison
 Explosive Hardened CMS Crossings

The initial hardness of CMS Crossing is about 180 BHN while that of cast
wheels is 320-340 BHN
By the time its hardness increases through work hardening {350-450
BHN (20/40 GMT)}, wear of (2 mm - 3 mm) takes place; thus reducing its
service life
Explosive hardening process increases initial hardness to about 350 BHN
in wear prone areas which delays wear and consequently increases service
life
Recommended for high GMT & heavy axle load route
Wear in EDH Crossings is more regular
 Weldable CMS Crossings
CMS crossing having different metallurgy compared to rail cannot
be welded by conventional method. It is welded to rail section using
an intermediate piece made normally of Ni-Cr Steel
Check Rail at Crossing
 Check Rail Clearance

c < G – g – tmax
c < 1673 – 1600 – 28.5
c < 44.5 mm
 Check Rail at Crossing

Check Rail Clearance

= 1676 - 1600 - 28.5
= 47.5 mm ( max.)

Limits as per SOD 48 to 44 mm.

(For Gauge 1673 mm - 45 to 41 mm)

Tighter clearance causes wear on check rail & slackness causes wheels
to strike & wear down ANC
In
Locomotive
32 mm
 Check Rail

227.5 1500 875 1500 227.5

68.75
41

1415 1415

4330

Running Rail Check Rail

Gauge Face
Check Rail Distance Blocks

Three Piece Block

X + 3.15 + 3.15 mm
 IR Vision on Turnout Developments
Present Near Future
Over-riding Switch Thick Web Switch

Cast Manganese Steel (CMS) Weldable CMS Crossing (LWR)

Crossing Explosive Depth Hardened (EDH) Crossing

In-situ reconditioning of CMS Crossing

Reconditioning at PWI Workshop (Already started robotic reconditioning)

PSC fan-shaped sleeper layout Improved fastening in TWS

06 joints ; 03 on Main line LWR through P&C

 TRACK STRUCTURE
REQUIREMENT (IRPWM-Para 202)
 LIFE OF TWS
(IRPWM-Para 717)
FANSHAPED LAYOUT
IRS Design
 Turnouts on Concrete Sleepers

Orientation
 Switch Portion-
 Perpendicular to main line
 Lead Portion-

/2
Laid with their axis at an angle of with the perpendicular to the main line
where,  is the angle between the perpendicular to main line and the perpendicular
to the tangent drawn on gauge face of outer rail of turnout at that point ( goes on
increasing towards crossing)
 Crossing Portion-
 Sleepers axis perpendicular to bisector of crossing angle.
(spacing along the bisector of crossing angle)
Conventional Layout Fan Shaped Layout
Orientation of Sleeper in Fan Shaped Layout
 Salient Features of Fan Shaped Layout

Gauge - 1673 mm
‘SRJ to TNC’ - (Distance same as that of IRS Layout)
Joints
◦ Welded/Machined
Approach Sleepers
◦ Special sleepers on Approach (2750) and Exit (2550);
◦ One sleeper for Signal fitting (Lock Bar) 60 S (2750)
Total No. of sleepers
◦ 1 in 12 - 96 (83 + 3 x 4 + 1) (2750 4900) (3&4)3750
◦ 1 in 8.5 - 67 (54 + 3 x 4 + 1) (2750 4900) (3&4)3750
RDSO Drawing No-
6154
RDSO Drawing No 6155/Alt-5
RDSO Drawing No 4220
 Machined Joint

Diameter of Rail Holes

 26.5 mm (32 mm in normal rail joints)

Initial gap = Zero.

Distance of center of first and second bolt hole

from rail end (for 52 kg and 60 kg Rail Sections)
 83 mm and 249 mm
(80 mm and 246 mm in case of normal joints)
 Gapless Joint
Fishplate

Rail Hole in Rail

Dia 26.5 mm

83mm
166 mm
56 mm 3.5
Fishplate hole
Dia 27 mm Fish Bolt dia 25 mm
 Laying
of
Points and Crossings
on curves
Laying of Fan-shaped Layout on
Curves
Fan-shaped Layout on Curves

The turnouts are supposed to be laid on

straight track as spacing are given according to
ML as straight
But it may be required to be laid on curve in
field due to existing track geometry/constraints
 Problems observed in Laying of
Fan-shaped Layouts on Curves
• It may not be possible to insert liner at few sleepers.
(Photo)
• Track circuiting may fail because of rail touching to insert.
• Breakage of Pendrol clip.
• Incorrect gauge.
• Inadequate toe load. (Photo)
• Breakage of GFN liners.
• Inadequate holding of CMS Xing. (Photo)
• At few places rail foot may even cut the inserts. (Photo)
Modification Required in the Existing Layout

•Change in spacing of sleepers to suit

curved M/L track.

•Pre-curving of stock and tongue rail to

suit the curvature.
 Re-spacing of sleeper
Sleeper are to be
rotated by an angle θm
(angle between tangent
at SRJ and tangent on
main line curve).
Orientation of Sleeper in Fan Shaped Layout
 Modification Required
•X Area - Change in spacing of sleeper in switch portion
(ORS) is not possible because of pre-drilled hole in the
switch. However the same is possible in TWS
•Y Area - The first sleepers in the lead is to be shifted by
an amount equal to difference of inner/outer rail from
SRJ to first sleeper in lead.
•Z Area (Crossing portion) Constant spacing to be
retained.
•Z Area (After crossing ) ,the outer rail spacing shifted by
an amount equal to difference of inner/outer rail in
individual spacing.
B SIDE

A SIDE

A SIDE

B SIDE
SLEEPER SPACING
MODIFICATIO
 1 in 12 in Similar Flexure
after new manual provision

Calculation for 1 in 12 Similar Flexure Upto 2 Degree

Degree SR ML TR ML TR TO SR TO

A B C D E F G H

0 0.0 0.0 0.0 0.0 43.2 32.4 40.0 30.0

0.5 5.0 3.8 5.5 4.1 48.7 36.5 45.0 33.8

1 10.0 7.5 10.9 8.2 54.1 40.6 50.1 37.6

2 20.1 15.1 21.9 16.4 65.0 48.8 60.2 45.2

LAYING OF PANEL BY T-28 Machine
 LIKELY PROBLEM

Connecting straight fabricated panel to curved track.

Transportation of curved fabricated panel

These needs to be taken care of

 CONNECTION PROBLEM- Similar Flexure (1 in 12)

X
X
L2
M/L L1

SRJ Sl No 83
Degree of M/L R(m) X value (mm) X/2

1 1750 75 37.5
2 875 150 75
3 583.33 225 112.5
4 437.5 300 150
5 350 375 187.5

SIMILAR FLEXURE
Degree L1 L2
0 45179 45179
1 45288 (+39 mm)
2 45326 (+147 mm)
3 45365 (+186 mm)
 TRANSPORTATION OF FABRICATED PANEL ( 1in 12)

X/2

MT NMT NMT MT X/2

L2
M/L L1

SRJ Sl No 83
Degree of M/L R(m) X value (mm) X/2

1 1750 75 37.5
2 875 150 75
3 583.33 225 112.5
4 437.5 300 150
5 350 375 187.5

MT LATERAL SHIFTING CAPACITY IS 300 mm

No Problem when shifting on crawler
 CONNECTION PROBLEM- Contrary Flexure (1 in 12)
TO

X L1

L2 ML

CONTRARY FLEXURE Degree of R(m) X value

M/L (mm)
Degree L1 L2
1 1750 75
0 45179 45179
2 875 150
1 45210 (-39 mm)
3 583.33 225
2 45172 (-77mm)
4 437.5 300
3 45133 (-116 mm) 5 350 375
 TRANSPORTATION OF FABRICATED PANEL ( 1in 12)

32437
L2
M/L
L1
MT NMT NMT MT X/2
SRJ
T/O
Degree of R(m) X value
M/L (mm)

1 1750 75
2 875 150
3 583.33 225
4 437.5 300
5 350 375

More symmetrically placed than even straight panel

MT lateral shifting capacity is 300 mm
No Problem when shifting on crawler
 (Para 429-431 of IRPWM-June 2020)

Inspection and Maintenance

of
Points & Crossings
 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

All Points and Crossings on Other lines and Yard lines

– Once in 6 months by rotation
For Points and Crossings on PSC Sleepers (Proforma)
Detailed inspection
Intermediate inspection
 Inspections

•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

•DEN to inspect certain number of points (Discretion) in running lines and those
recommended for renewal

•Results of Inspections to be recorded in Points & Crossings Register using prescribed

pro-forma. The same to be entered in TMS.
CMS Crossings
POINTS AND CROSSING TAMPING
Tamping of Turnouts by UNIMAT

•Planned to cover sufficient length of

approach track taking into account special
track features on either side
•Turn-in curve should also be tamped with the
Turnout
•Minimum 10-15 mm lift to be given.
•Choose proper rail as reference rail.
 Points and Crossing
Tamping Machine

Reference Rail
 Main Line
Main Line Loop Line Loop Line

If LL side not supported

Cross-levels will be disturbed, when machine is brought on LL
While packing main line So the Turnout side needs to be
Turnout side also gets lifted packed manually or supported on
wooden blocks/wedges
 UNIMAT

Main line tamped first

while tamping main line alignment, XL, LL attended

Then machine moved to loop line

for only Tamping
Tamping of Turnout
AL, LL and XL
Tamping of Main Line Corrected

Tamping of Turnout
Side
Only Packing Done
 3rd rail
lifting

UNIMAT 08- 475 4S

Points and Crossing
 Machine
moving on
When both the packing Turnout side Machine
are superimposed all moving on Main
Rail-seats are covered line
 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 specific approval of RDSO is
required till the trials are completed
Thank You