10701-7 M/c. No.

4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 15

C.E.’s Circular No. 209 ( P. Way )

No. 219-W/1Pt. XII Dated 31-01-1986

Sub : Rail Joints-Fish plates welded and glued.

This circular superseeds all previous instructions on the subject including C.E. circular No. 153 (P. Way).

1.0 Rail joints may be either fish-plated, welded or glued. Due to discontinuity of the rail, rail joint is the
weakest link in track and should be given special attention with regard to its structure and maintenance.

2.0 STRUCTURE OF RAIL JOINTS.

2.1 The following structural requirement of rail joints shall be ensured.

Type of Type of Structured requirement at joints

joint Sleeper in
Aproach Sleeper type Fitting
track & spacing (mm.)

(a) *Fish Plated Wooden (300) Max. Canted bearing plate with
4 rail screws or ACB
plate with 4 plate screws.

CST-9/ST BG/ST (380) Max. MLJ, rubber pad, thicker

keys.

MG/W/(300) Max. As on wooden sleeper

track.

PRC (340) Max. Rubber pads, liners, elastic

*Note.– Spacing of shoulder sleepers at fish plated joints should be kept as per RDSO Drawing Nos. EDO-516 & 517
for BG, EDO-518 & 519 for MG.

(b) Thermit Welded :

(i) Fresh ... Same as approach To be joggle fish plated with 2 or

(till tested with track. 4 bolts (using existing holes) or
USFD) 4 clamps, well supported on
wooden blocks and wedges (see
sketcdh) till tested and declared
good.

(ii) Defective ... Same as approach To be joggle fish plated with 2 or,
track. 4 bolts (using existing holes) or.
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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 16

D-1 or D-2 4 Clamps, Defective weld should

be replaced at earliest by 50 mm
Thermit weld.

Note.– Flash-butt welded joint is treated as a continuous rail.

(c) Glued : W ‘U’ (SAL) Normal Canted bearing plates with 4 rail
spacing, sleeper screws.
symmetrically placed
about the centre of
the joint.

PRC Normal spacing Rubber pads, liners elastic rail

sleepers symmetrically clips (Fitted in reverse).
placed about the centre
of the joint.

2.2 Wooden Sleepers at joints in non-wooden sleeper, track should be progressively replaced by permissible categories
of sleepers as per para 2.1.

3.0 MAINTENANCE OF FISH PLATED JOINTS :–

3.1 Following are the guidelines for maintenance of Fish Plated Joints :

(a) Abundant spikes holes in wooden sleepers should be plugged properly as per para 648 F (c) of IRPWM.
Bearing plates should be fixed centrally and not near one edge of the width of the sleeper, Wooden sleepers
at joints should be maintained by MSP. Approach track sleepers should also be packed as required.

(b) Rubber pads on PRC & ST sleeper should be affixed with glue of approved quality.

(c) Expansion gaps and creep should be within permissible limits as laid down in IRPWM and Manual of Instructions
for Laying and Maintenance of SWR (Provisions) May 1976.

(d) Rail closure less than 5.5 meters long should not be allowed except under suitable speed restriction not
exceeding 75 KMPH on BG and 60 KMPH on MG.

(e) Every Fish–plated joint in track must have 4 fish–bolts when ever the speed allowed is 30 KMPH or more.

(f) The edge of all fish bolts holes should be work hardened by chamfering, Chamfering of rail holes shall be done
as detailed in Annexure-I.

(g) All fish-plated rail joints in track should be lubricated once a year. Lubrication of rail joints shall be done as
detailed in Annexure-II.

(h) While tightening fish-bolts, bolt head should be maintained square so that loose bolts can be spotted and
rectified.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 17

(i) Fish bolts breakage should be treated as a failure in maintenance. In all such cases, action shall be taken in
the case of rail fracture, with a report to be submitted by PWI, giving cause, responsibility by MSP.

(j) PRC sleepers at fish-plated joints should not be beater packed but maintained by MSP.

(k) After through packing, wooden/steel sleepers at joints shall be given a second round of beater packing as per
para 622 of IRPWM.

(l) Blowing/pumping joints should be given special attention as detailed below :–

(i) Old and rounded ballast at the joint be removed and stacked on the cess.

(ii) Ballast at the joint should be screened with 25mm square mesh sleve and the muck thrown out :

(iii) Joint sleepers should be ballasted with hand picked pieces of big size ballast. These will improve drainage
and also ensure greater life of ballast at the joint.

(iv) Joint sleepers should be throughly packed followed by 2 more rounds of packing.

(v) In the 3rd and last packing the shoulder sleepers should also be packed. PWIs should personally
demonstrate to each gang the methodology of joint maintenance.

(m) Unserviceable sleeper at any joint should be replaced within one week of its being noticed. Where both joint
sleepers are unserviceable these should be replaced immediately on detection.

(n) Drainage at joints should be specially ensured. Cess levels should be correctly maintained using a template.
Ballast should be adequate and clean.

4.0 WELDED RAIL JOINTS.

4.1 Wilded Rail joints are either Flash-Butt or Thermit welded. Flash-Butt welded joints, found good by USFD testing,
are treated as continuous rail can call for no special precautions. Thermit welding is essentially a field process
and calls for greater care in welding and precautions in maintenance.

4.2 Thermit Welded Joint :–

(a) Thermit welding of joints should be carried out strictly in accordance with the Maual-for Welding of Rail Joints,
by the Alumino Thermit Process, August, 1976.

(b) Thermit welding should be done by a qualified welder holding competency certificate issued by Assistant
Engineer, Thermit Portion Plant/Lucknow.

(c) Thermit welding should be done only under the supervision of PWI Gr. III/PWM having a valid competency
certificate issued by AEN/TPP/LKO.
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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 18

(d) For every thermit welded joint done the supervisor-incharge of welding should complete the check list at site.
Copy of the Check List is at Annexure-III.

(e) Second-hand rails should not be welded not be welded without end cropping.

(f) Rail tensor must be used for maintaining correct gap while thermit welding in decreasing range of temperature
and also while doing repair welding in LWR/CWR.

(g) Thermit welding in running line should not be done in a block of less than 75 minutes. SKV/SPW weld should
not be done in a block of less whan 55 minutes.

(h) Thermit welding in the field should, as far as possible, be done on the cess to ensure good quality.

(i) After thermit, the joint should not be left unfinished. If filing cannot be done on the same day, speed restriction
should be imposed till the joint is finished.

(j) After thermit welding in LWR the joint should be Joggle fish-plated and supported on wooden blocks till tested
good by USFD.

Any thermit welding found defective (D-1 or D-2) must be redone.

(k) Information regarding all new welds should be given in the sectional PWI to PWI/USFD for arranging testing.

(l) Every sectional PWI shall maintain a register of Thermit welds, in which complete record of every thermit weld
done on the section should be kept. Proforma for the Thermit welds register shall be as per Annexure-IV.

5.0 INSULATED RAIL JOINTS.

5.1 Insulated rail joints are provided for track circuiting. They are of two types :–

(a) Insulate-fish-plated rail joints; insulating components of these are provided and maintained by the S&T
Department.

(b) Glued insulated joints which do not have any loose components. Due to greater strength, rail is treated as a
continuous through the joint. These are provided and maintained by the Civil Engg. Department. The ultimate
objective is to have only glued insulated joints.

5.2 Insulated Fish-Plated Rail Joint.

Its insulating components are shown in FIG-1. For laying and maintenance of insulated fish-plated rail joints the
following instructions and guide lines should be ensured.

(a) Insulated joints, should be provided as square joints. However, where unavoidable, the stagger of joint should
not exceed the minimum wheel base of the vehicle.

(b) Rail ends at insulated joints should be square and smooth, battered ends should be rectified and gap between
rails, if large, must be adjusted.

(c) Rail should be kept free from brake-dust, dirt, sand, rust and other foreign matter. All edges and burrs at rail
ends must be removed with a hacksaw blade.
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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 19

(d) Fish-bolts at joints must be kept and ballast well packed in the vicinity of joints to prevent undue rail movement.

(e) Ballast should be clean and proper drainage should be provided to prevent stagnation of water at joints.

(f) Permanent Way Inspector and Signal Inspector shall carry out a joint check of all the insulated fish plated
joints in their jurisdiction once a year and ensure that the requirements as laid down in the IRPWM, Signal
Engineering Manual and other directions issued by the Engineering and Signal Departments are fully complied
with. During the joint check every insulated joint should be opened, all components inspected and those
found in bad conditions replaced. Steel ferrules should be specially checked and provided if not there. Joint
Inspection of all insulated joints should be completed well before the onset of Monsoons.

(g) Certificate of joint Inspection of Insulated fish plated joints as per (f) Above should be sent by Permanent Way
Inspector and Signal Inspector to Sr. DEN/DSE and Sr. DSTE, who should send a joint certificate regarding
satisfactory condition of all insulated joints on the Divison to Headquarters office by 30th June every year.

5.3 Glued Insulated Joints.

Six bolts glued joints G3 (L) Fig.2(a) should be provided on all run through lines. Four bolt glued joint G3 (S)
Fig.2(b) should be provided on all other Lines. Guidelines for insulated joints are detailed below.

(a) Adequate care should be taken while transporting glued insulated joints from the assembly shed to the site of
laying and during insertion in track to avoid only damage to the joint.

(b) Before a glued insulated joint is laid in track it should be tested to satisfy the criteria of electricl resistance as
given in sub-para below.

(c) Atleast ten sleepers on either side of the joint should be properly packed to the correct level before the glued
insulated joint is laid.

(d) For inserting glued insulated joint in track, one of the following methods may be adopted.

(i) When a G3 (L) type of joint has been made from a 4m long (or about 1/3 rail length) suitable length of the
existing rail in track should be cut and the glued insulated joint welded in at the two ends by alumino
thermic process.

(ii) In case the G3 (L) type of joint is made out of full rail length and the existing track is fish plated, full rail
length can be replaced.

(iii) In case a glued joint is to be inserted in an existing LWR, the method used for rectifying a rail fracture as
per Para 8.2 of Manual of Instructions on LWR (1979) should be adopted. Instead of a 6m rail piece, a
glued insulated joint of 4m minimum length may be inserted.

(iv) During rail renewals where 3 or 20 rail panels welded in Flash Butt. Welding plant are used, the glued
insulated joint may first be made on a full rail length and the same then welded in the 3 or 20 rail length
panel. In this case considerable planning will be needed to ensure that the welded rail panel when placed
in position in the track has the glued insulated joint at its correct location, and there is no damage to the
joint during handling and laying at site.
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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 20

(e) A register for glued insulated joints should be maintained by the sectional PWI in which details of glued
insulated joints and annual record or its maintenance and performance shall be kept on the Proforma at
Annexure ‘V’.
(f) Thermit welding at ends of glued insulated joint should be done as to avoid its direct or indirect heating.
Heating applicance shall not be applied within 1 metre of the glued insulated joint.

(g) For the replacement of a defective glued insulated joint procedure as mentined in sub paras (a) to (f) above
should be followed.

(h) Ballast at glued insulated joint and its vicinity should be kept clean with efficient drainage. Ballast must be
kept clear of the under side of rail by not less than 50 mm.

(i) Glued insulated joint may be maintained in a manner similar to track on approaches.

(j) As is the case in insulated fish plated rail joints, metal burrs at the ends of the rails should be removed well
in time to avoid short circuiting. The burrs should be sawn off vertically with a hack-saw avoiding damage to
end posts or to the rail ends.

(k) No relative movement occurs between rails and fish plates at a glued insulated joint. In case a joint fails by
separation of the rail fish plate surface with consequent relative movement, the defective glued insulated joint
should be replaced as early as possible.

(l) Glued insulated joints which give trouble in track should be attended to by trained artisan staff under the
sectional PWI. If the trouble persists, defective glued insulated joints should be referred to AEN/Track Depot/
Ghaziabad, who will send a team for in-situ repairs or advice its replacement.

(m) At the Track Depot, Ghaziabad the damaged glued insulated joints shall be stripped off the glue and rails, fish
plates and fish bolts reclaimed. This is done by heating the joint with a blow lamp to a temperature of over
2000C. As soon as the glue clinging to the threads of fish bolts pushed out the fish plate may be removed by
hammering a chiesel between the rail and fish plate. The usable rails, fish plates, fish bolts, nuts and washer
should be cleaned of glue, dried and re used.

(n) Testing of glued inasulated joints.

(i) Insulation resistance test should be conducted on every glued joint and should satisty the following
criteria.

In Dry Condition :–

After the glued insulated joint is prepared, maggering voltage of 100 VDC shall be applied across the
joint. The value of the insulation resistance shall not be less than 25 Mega-ohms.

The Wet Condition :–

The value of resistance shall not be less than 3 kilo-ohms.

(ii) Every glued insulated joint in the field should be tested annually by the sectional PWI and Signal
Inspector and a certificate recorded in the glued insulated joint register.

Sd/-
General Manager/Engg.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 21

ANNEXURE “I”
CHAMFERING OF BOLT HOLES

1. As a measure to check the time of rail through bolt holes, work hardening of all bolts holes should be done by
chamfering. This work shall be carried as under :-

(a) falsh Butt Welding Plant Meerut should do chamfering of bolt holes in welded in rail panels before dispatch.

(b) When rails in track are end cropped, new bolts holes should be chamfered at site.

(c) Bolt holes in new rails received directly from steel plant should be chamfered before rails are laid in track.

(d) In fracture-prone zones bolts should be chamfered if they are already not elongated excessively.

(e) Chamfering should be done only on round bolts holes and not on elongated bolts holes. In the case of
elongated holes the chamfering bit will not be in contact with the full edge of the bolt holes and there will be
uneven hardening of the metal resulting in dtrees concentration in weaker zones.

2. Equipment for chamfering of bolt holes :- Work hardening of bolt holes should be done with chamfering kit
of approved make. The chamfering kit consists of the following :-

High Tensile bolt M-20 1 No.

High Tensile nut for M-20 bolts 1 No.

Sets of 2 H.S.S chamfering bolts 1 Set

3/4” sq. drive sockets size 32mm 2 No.

Set of two packing piece 1 set.

T-400 torque-wrench with built in 1 No.

ratch mechanism 1.25 metre length

3. Procedure for chamfering of bolts holes (fig. 3-a)- The following procedure shall be followed for chamfering
of bolt holes :-
(a) Remove the nut of high tensile steel bolts and insert one packing piece in the shank followed by one side of
the H.S.S chamfering bit.

(b) Insert the high tensile steel bolt with the 2 piece in the rail hole.

(c) On the other face of the rail hole, insert the second half of the HSS chamfering bit over the shank followed by
the second packing piece.

(d) Replace nut on the high tensile steel bolts.

10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 22

(e) Apply torque-wrench on nut. Pre-set torque wrench at torque value of 52 kgs-M or 370 Ibs-Ft which is equivalent
to an axial force of 12.5 tones. Tighten the nut with the torque-wrench. As soon as the pre-set torque is
attained, the torque-wrench will automatically trip indicating that tightening to pre-set torque has been achived.

(f) Unscrew nut by reversing the torque-wrench and remove H.T steel bolts Repeat the process on other rail
holes.

(g) Chamfering of rail joints should be done under the direct supervision of at least a qualified Permanent Way
Mistry. The work should be carried out under Caution order, arranged to be issued daily by the PWI and under
the protection of Engineering-Signals as per GR 15.09 and Para 1504 of IRPWM.

4. Chamfering of bolts holes during Lubrication of rail joints (Fig. 3)- Procedure for lubrication of rail joints has
been detailed in Annexure-II. After one side fish-Plate has been removed and rail surface has been examined
and lubricated as in Para 3 (e) of annexure-II, chamfering may be done as under :-

(a) Remove the nut and high tensile steel bolts and insert one packing piece in the shank followed by one side of
the HSS chamfering bit :-

(b) Insert the H.T. steel bolt with these two piece in the rail hole from the side with fish plate removed.

(c) As the H.T. Steel bolt shank comes out of the fish plate hole on other side, put second packing piece on the
shank.

(d) Replace nut on the H.T. steel bolt.

(e) Apply torque-wrench and tighten nut till it trips.

(f) Unscrew nut and repeat the process till one face of all bolt holes is chamfered.

(g) Replace the fish plate, remove the fish bolts one at a time and put back in reverse direction after oiling.
Remove outside fish-plate and lubricate as the inside fish plate.

(h) Chamfer outer face of bolt holes in like manner as inside face of holes as per sub-paras (a) to (f) above.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 23

ANNEXURE-II
LUBRICATION OF FISH PLATED JOINTS

1. Lubrication of fish-plated rail joints is required to :-

(a) facilitate expansion of rails.

(b) Retard wear on the fishing planes of rail and fish-plate.

(c) Enable visual examination of rail ends for any crack/defects All fishplated joints in track should be lubricated
once in a year on a programmed basis. During rail renewal, all joints should be lubricated.

2. The following instructions and guide-lines shall be kept in view while lubricating rail joints.

(a) Lubrication of rail joints should not be done in of weather, hot or cold, or during rainy season. Creep where
heavy, must be adjusted before lubrication of joints.

(b) Lubrication of rail joints should generally be carried out by Permanent Way Gangs under the direct supervision
of atleast a qualified Permanent Way Mistry. The work should be carried out under CAUTION ORDER,
arranged to be issued daily by the PWI and under protection of Engineering Signals as per GR 15.09 and para
14.04 of IRWWM. In order to minimise the possible detentions to trains this work should not be under taken
at more than one place on any section, at a time.

(c) Two consecutive joints on the same rail or two opposite joints should not be opened for lubrication at any one
time. The two gangmen should sit on diagonally opposite joints facing of rail each other.

(d) Each man doing the lubrication of rail joints should also carry a magnifying glass and a mirror for inspection
of rail to detect crack/defects.

3. Procedure for Lubrication of Rail Joints :- Lubrication of rail joints involved graphiting of the fishing planes of
rails and fish-plates and oiling of fish-bolts. This sould be carried out as follows :-

(a) Unscrew the nuts and place them opposite each bolt to ensure that they are not inter-changed while being
replaced in position.

(b) Lightly tap and remove the inside fish-plate.

(c) Clean the fishing surface of the rails and fish-plate with wire bruch and wipe off the rust waste cottan.

(d) Examine the cleaned surface of rails and fish late for any crack with the help of magnifing glass and mirror.

(e) Apply a than layer of a mixture of plumbago and kerosene oil mixed to form a fine paste) on the fishing-planes
of the rail and fish-plates, simultaneously chamfering of rail holes should be done on the face of rail from which
fish-plate has been removed as described in Para 4 of Annexure-1. Replace the fish plate.

(f) Remove the fish-bolts one at a time and after oiling put each back in the reverse direction.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 24

(g) Lightly tap and remove the out-side fish plate.

(h) Treat the other fish plate and fishing surface of the rails similary. Do chamfering on second face of rail as holes
detailed in para 4 of Annexure-I.

(i) Replace fish-plate and nuts. Tighten to the extent possible with the standard fish-bolts spanner without over-
straining the bolts.

(j) Care should be taken to ensure that all the time there is one fish plate and not less than three fish-bolts
without connecting the two rails. Both the fish-plates should be fitted and atleast one fish-bolts and nut on
either side of each joint should be tightened when a train is approaching the site of work. This must be done
before the banner flag protecting the site of work is, ordered to be removed.

(k) Re-tightening of fish-bolts should be done after fish plates have taken bearing under traffic.

(l) Particular of work of lubrication done with dates should be recorded in the section Register of Permanent Way
Inspector.

4. Materials for Lubricatyion :- Requirement of lngradients for lubrication of rail joints is as follows :-

Material required for

100 Single 125 Single

Joints
(BG) Kg. (MG) Kg.

Plumbago (Dry Graphite Powder) 5 5

Kerosene oil (Second Quality) 3.5 2.5

Black or reclaimed oil 2.75 2.75

Plumbago and kerosene oil should be mixed to form a fine paste for lubricating the fishing planes of rail
and fish-plates. Black or re-claimed oil should be used for lubricating fish-bolts.

5. Certificate of Lubrication :- Every year in April, PWI incharge should submit to the Assistant Engineer,
Certificate of lubrication of fish-plated joints with exceptions, if any, giving reason, Copies of these certificates
should be forwarded by AENs, with comments to the DEN/Sr. DEN/DSE for scrutiny and record.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 25

lĘ́É]õ ´Éè±b÷ ®úÊVɺ]õ®ú Eäò ʱÉB |ÉÉä¡òɨÉÉÇ Annexure - IV

PROFORMA FOR THERMIT WELD REGISTER
Gò¨É ÊiÉÊlÉ ºlÉÉxÉ ÎºlÉÊiÉ Ê´É´É®úhÉ ®äú±É ({ÉÉä®ú¶ÉxÉ Ê´É´É®úhÉ)
ºÉÆJªÉÉ Date Location details Rail Bolt Hole Portion Details
S. No. ¤±ÉÉEò ºÉäC¶ÉxÉ ºÉèºÉ/{ÉlÉ Eäò ]õÒ.{ÉÒ. +{É/b÷É=xÉ ºÉäC¶ÉxÉ/ ¤ÉÉä±]õ Uäônù BVÉäxºÉÒ/¤ÉèSÉ {ÉÉä®ú¶ÉxÉ xÉÆ. ¤ÉxÉÉxÉä EòÒ
Ê{ÉUô±ÉÉ +MɱÉÉ +xnù®ú/ TP =±]õÉ/ºÉÒvÉÉ ªÉÚ.]õÒ.BºÉ. EòÒ nÚù®úÒ EòÉäb÷ xÉÆ. Portion ÊiÉÊlÉ
º]äõ¶ÉxÉ º]äõ¶ÉxÉ ÊEò.¨ÉÒ. U/T Section Dist. Agen. No. Date of
Block Section Cess/KM DR UTS Batch Manuf.
Stn. (B) Stn. (F) Situ Code No.
1 2 3 4 5

´Éèϱb÷MÉ Ê´É´É®úhÉ VÉÉäc÷ xÉÆ. ¤±ÉÉEò ºÉ¨ÉªÉ ÊPɺÉÉ<Ç EòÒ Dimentional toler ´Éèϱb÷MÉ Eäò ¤ÉÉnù ªÉÚ.BºÉ. B¡ò.b÷Ò.
Welding Details Weld Block time ÊiÉÊlÉ on finished joint ÊxÉ®úÒIÉhÉ
No. Date of USFD Testing after welding
Finish
BVÉäxºÉÒ/ ÊxÉ®úÒIÉEò ´Éè±b÷®ú EòÉäb÷ ºÉä iÉEò ÊPɺÉä VÉÉäc÷ ]õÉä±É®äúxºÉ ÊiÉÊlÉ xÉiÉÒVÉÉ/({ÉɺÉ/¡äò±É)
Grinding
iÉ®úÒEòÉ EòÉäb÷ EòÉäb÷ Welder From To {É®ú 1 ¨ÉÒ. 10 ºÉå¨ÉÒ {É®ú Date Result (P/F)
Agen. Super Code {É®ú On 10
Process Code On 1m cm Top
Code Lat. Ver. side
6 7 8 9 10 11

VÉÉäc÷ ºÉÌ´ÉºÉ Eäò +xnù®ú {Éä±É ½þÉäxÉä EòÉ ]äõº]õ VÉÉäc÷ ÊxÉEòɱÉä MɪÉä VÉÉäc÷ EòÉ ºÉÆnù¦ÉÇ ´Éèϱb÷MÉ EòɪÉÇ ÊxÉ®úÒIÉEò Eäò ½þºiÉÉIÉ®ú
Ê´É´É®úhÉ Test Joint Repl. Weld Ref. Signature of PWI Welding
in service Failure details
¡äò±É ½þÉäxÉä ÊxÉEòɱÉxÉä EòÒ ÊiÉÊlÉ VÉÉäc÷ xÉÆ. 1 VÉÉäc÷ xÉÆ. 2
Failure Date removed Weld 1 Weld 2
ÊiÉÊlÉ iÉ®úÒEòÉ Gò¨É ºÉÆ. ÊiÉÊlÉ Gò¨É ºÉÆ. ÊiÉÊlÉ
Date Type S. No. Date S. No. Date

12 13 14 15

]äõº]õ VÉÉäc÷ xÉiÉÒVÉÉ Test joint Results

]äõº]õ VÉÉäc÷ ¦ÉäVÉxÉä xÉiÉÒVÉä |ÉÉ{iÉ Hardness Transverse Load ÊUôpùiÉÉ Date of Marking Ê]õ{{ÉhÉÒ
EòÒ ÊiÉÊlÉ ºÉÆnù¦ÉÇ Eò®úxÉä EòÒ ºÉÆnù¦ÉÇ Poro ‘X’ for extended Remarks
ºÉʽþiÉ ºÉʽþiÉ ÊiÉÊlÉ ®äú±É ´Éè±b÷ MɨÉÇ =¹¨ÉÉ ¦ÉÉ®ú ZÉÖEòÉ´É sity guarantee
Date of Date of Rail Weld |ɦÉÉÊ´ÉiÉ ½èþ Load Deflection
Sending Test Receipts of HAZ (t) (mm)
Jt. with Ref. Results with Ref.
16 17
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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 26

Record of Glude Joints

Division Sub-Division

PWI Glude Joints No.

Detail of structure of Glued Joint

1. General :-

(i) Type of Glude joint

(ii) Kilometre

(iii) Between Stations

(iv) UP/DN Single line

(v) Date of laying

(vi) Manufacturing workshop alongwith joints number and date of manufacturing

2. Track Structure

2.1 Rails-Sectional weight.

2.2 SLEEPERS : TYPE

2.3 Ballast Cushion

Annexure-V

Annual record of maintenance and performance of Glude Joints.

1. Maintenance Details. Year Year Year Year

(i) Insulation Resistance

(a) In Dry condition.

(b) In wet condition.

(ii) Packing condition

(up 10 sleepers on
each side).

(iii) Condition of drainage.

(iv) Removal of burrs.

(v) Ballast gap from rail bottam

(vi) Position/condition of fittings

3. Casual occurences : (with Date)

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NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 28

Drawing
10701-7 M/c. No. 4 (1 to 82)
30 =kÉ®ú ®äú±É´Éä ¨ÉÖJªÉ <xVÉÒÊxɪɮú EòÉ {ÉÊ®ú{ÉjÉ

ʴɦÉÉMÉ uùÉ®úÉ ®äú±ÉÉå EòÉä lĘ́É]õ ´Éèϱb÷MÉ

DEPARTMENT THERMIT WELDING OF RAILS

|ÉÉlÉʨÉEò ºÉÚSÉxÉÉ
PRIMARY NOTICE

VÉÉÆSÉ ºÉÚSÉÒ
CHECK LIST

¨Éhb÷±É ºÉäC¶ÉxÉ +{É/b÷É=xÉ ÊEò.¨ÉÒ.

Division Section Up/Down Km.

ÊiÉÊlÉ ºÉ¨ÉªÉ ÊxÉ®úÒIÉEò

Date Time Inspector

´Éè±b÷®ú
Welder

´Éè±b÷®ú EòÒ ªÉÉäMªÉiÉÉ Eäò |ɨÉÉhÉ-{ÉjÉ EòÒ ¨ÉÉxªÉiÉÉ ÊiÉÊlÉ

Validity date of competency Certificate of Welder

®äú±É ]õÉ<{É =ºÉEòÒ ®úºÉɪÉxÉ ´É ÊxɨÉÉÇhÉ EòÒ ÊiÉÊlÉ {ÉÖ®úÉxÉÒ/xÉ<Ç

Rail section its chemistry and date of manufacturing

ÊEòºÉ ʱÉB ´Éèϱb÷MÉ EòÒ MÉ<Ç

Reason for welding

±É¨¤ÉÒ ´Éè±b÷ ®äú±ÉÉå ¨Éå ¤Énù±ÉxÉÉ UôÉä]õÒ ´Éè±b÷ ®äú±ÉÉå ¨Éå ¤Énù±ÉxÉÉ `öÒEò ´Éèϱb÷MÉ
Conversion into LWR Conversion into SWR Repair Welding

´Éèϱb÷MÉ ]õÒ¨É EòÉ Ê´É´É®úhÉ

Details of welding Team

¤±ÉÉEò EòÒ ={ɱÉΤvÉ

Availability of block

®äú±ÉÉå EòÉ +±]ÅõÉäºÉÉÊxÉEò VÉÉÆSÉ ´ÉMÉÔEò®úhÉ

Ultrasonic Test Classification of Rails

®äú±É iÉÉ{ɨÉÉxÉ iÉlÉÉ ¨ÉÉèºÉ¨É

Temperature and season

|ɪÉÉäMÉ ÊEòªÉä MɪÉä ¨ÉÉä±b÷ úEòÉ |ÉEòÉ®ú

Type of Mould Used

´Éèϱb÷MÉ Ê´ÉÊvÉ
Welding Technique
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 30

ʴɦÉÉMÉ uùÉ®úÉ ®äú±ÉÉå EòÉä lĘ́É]õ ´Éèϱb÷MÉ

DEPARTMENT THERMIT WELDING OF RAILS

|ÉÉlÉʨÉEò ºÉÚSÉxÉÉ
PRIMARY NOTICE

VÉÉÆSÉ ºÉÚSÉÒ
CHECK LIST

¨Éhb÷±É ºÉäC¶ÉxÉ +{É/b÷É=xÉ ÊEò.¨ÉÒ.

Division Section Up/Down Km.

ÊiÉÊlÉ ºÉ¨ÉªÉ ÊxÉ®úÒIÉEò

Date Time Inspector

´Éè±b÷®ú
Welder

´Éè±b÷®ú EòÒ ªÉÉäMªÉiÉÉ Eäò |ɨÉÉhÉ-{ÉjÉ EòÒ ¨ÉÉxªÉiÉÉ ÊiÉÊlÉ

Validity date of competency Certificate of Welder

®äú±É ]õÉ<{É =ºÉEòÒ ®úºÉɪÉxÉ ´É ÊxɨÉÉÇhÉ EòÒ ÊiÉÊlÉ {ÉÖ®úÉxÉÒ/xÉ<Ç

Rail section its chemistry and date of manufacturing

ÊEòºÉ ʱÉB ´Éèϱb÷MÉ EòÒ MÉ<Ç

Reason for welding

±É¨¤ÉÒ ´Éè±b÷ ®äú±ÉÉå ¨Éå ¤Énù±ÉxÉÉ UôÉä]õÒ ´Éè±b÷ ®äú±ÉÉå ¨Éå ¤Énù±ÉxÉÉ `öÒEò ´Éèϱb÷MÉ
Conversion into LWR Conversion into SWR Repair Welding

´Éèϱb÷MÉ ]õÒ¨É EòÉ Ê´É´É®úhÉ

Details of welding Team

¤±ÉÉEò EòÒ ={ɱÉΤvÉ

Availability of block

®äú±ÉÉå EòÉ +±]ÅõÉäºÉÉÊxÉEò VÉÉÆSÉ ´ÉMÉÔEò®úhÉ

Ultrasonic Test Classification of Rails

®äú±É iÉÉ{ɨÉÉxÉ iÉlÉÉ ¨ÉÉèºÉ¨É

Temperature and season

|ɪÉÉäMÉ ÊEòªÉä MɪÉä ¨ÉÉä±b÷ úEòÉ |ÉEòÉ®ú

Type of Mould Used

´Éèϱb÷MÉ Ê´ÉÊvÉ
Welding Technique
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 31

´Éè±b÷ Eò®úxÉä EòÉ iÉ®úÒEòÉ Procedure of Welding

Gò¨É ºÉÆ. Ê´É´É®úhÉ ½þÉÆ xɽþÓ
Sl. No. Description Yes No

1. EòɪÉÇ ºÉƪÉÆjÉ Working Equipments

1.1 ºÉ¦ÉÒ EòɪÉÇ ºÉƪÉÆjÉ ={ɱɤvÉ ½éþ iÉlÉÉ EòɪÉÇ Eò®úxÉä ¨Éå `öÒEò ½èþ*
All Working equipments are available and in working condition

2. ®äú±É EòÒ ºÉèË]õMÉ +Éè®ú MÉè{É

Rail Setting and Gap

2.1 ªÉÊnù {ÉÖ®úÉxÉÒ ®äú±ÉÉå ´Éè±b÷ EòÒ VÉÉxÉÒ ½éþ iÉÉä CªÉÉ ÊºÉ®äú EòÉ]äõ MɪÉä?
If the old rails to be used for welding, whether ends have been cut?

2.2 CªÉÉ ®äú±É ]äõxºÉ®ú |ɪÉÉäMÉ ÊEòªÉÉ MɪÉÉ?

Is rail tensor used

2.3 ®äú±É ʺɮäú ºÉÒvÉä JÉcä÷ +Éè®ú ºÉ¨ÉÉxÉÉxiÉ®ú ½éþ?

Rail ends are vertical and paralledl?

2.4 MÉè{É ÊxÉvÉÉÇÊ®úiÉ ºÉÒ¨ÉÉ ¨Éå ½éþ?

Gap is with in limits?

2.5 ®äú±ÉÉå Eäò ʺɮäú ºÉÉ¡ò ½éþ?

Whether the rail ends are properly clean?

2.6 +MÉ®ú ´Éèϱb÷MÉ ±ÉÉ<xÉ ¨Éå EòÒ VÉÉxÉÒ ½þÉä iÉÉä {ÉÉÆSÉ º±ÉÒ{É®úÉå Eäò ¤ÉÆvÉEò føÒ±Éä ÊEòªÉä MɪÉä ½éþ?
If welding is to be done in track then whether the fastening of five sleeepers are loose?

2.7 ®äú±ÉÉå EòÒ ÊºÉvÉÉ<Ç (=vÉç +Éè®ú IÉèÊiÉVÉ) `öÒEò ½éþ ªÉÉ ÊxÉnùÉÇÊ®úiÉ ºÉÒ¨ÉÉ Eäò +xnù®ú ½éþ?
Whether rail straightness (Verticaly and Laterally) is correct or within limits?

IÉäÊiÉVÉ Lateral ...................................

=vÉæ Vertical .....................................

3. iÉèªÉÉ®úÒ Preparation

3.1 OÉÒxÉ ¨ÉÉä±b÷ (+MÉ®ú |ɪÉÉäMÉ ÊEòªÉä ½éþ) iÉÉä =ÊSÉiÉ ¨ÉÉäϱb÷MÉ ®äú±É ºÉä iÉÉVÉä iÉèªÉÉ®ú ÊEòªÉä ½éþ*
The green mould usedf whether it is freshly prepared with proper moulding sand.
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 32

´Éè±b÷ Eò®úxÉä EòÉ iÉ®úÒEòÉ

Procedure of Welding

Gò¨É ºÉÆ. Ê´É´É®úhÉ ½þÉÆ xɽþÓ

Sl. No. Description Yes No

3.2 ¨ÉÉä±b÷ ¤ÉCºÉÉ MÉè{É Eäò ¤ÉÒSÉ ¨Éå +Éè®ú {Éè®ú EòÒ è±ÉÉ<xÉ ¨Éå ½èþ?
is mould Box is perpendicular and Central with respect to gap?

3.3 GÚòºÉÒ¤É±É (±ÉÉ<ËxÉMÉ) `öÒEò B´ÉÆ ºÉÚJÉÒ ½èþ +Éè®ú ºÉ½þÒ Êlɨ¤É±É |ɪÉÉäMÉ ÊEòªÉÉ MɪÉÉ ½èþ?
Is Crucible Lining is proper, dry and is proper thimble is use?

3.4 +ɴɶªÉEò ±ÉÚË]õMÉ ®äúiÉ |ɪÉÉäMÉ ÊEòªÉÉ MɪÉÉ?

Is Proper Luting sand being used?

3.5 CªÉÉ GÚòºÉÒ¤É±É +ɴɺªÉEò ºÉÖvÉÉ®ú Eäò ¤ÉÉnù {ɽþ±ÉÒ ¤ÉÉ®ú |ɪÉÉäMÉ ÊEòªÉÉ MɪÉÉ?
Has crucible been used first time after repair?

3.6 CªÉÉ Ê¤ÉxÉÉ ÊEòºÉÒ PÉ]õÉ´É-¤ÉgøÉ´É Eäò {ÉÚ®úÉ {ÉÉä®ú¶ÉxÉ `öÒEò ʨɱÉÉEò®ú |ɪÉÉäMÉ ÊEòªÉÉ MɪÉÉ?
If full portion has been used. Is portion mixed properly & without any alter-
ation?

4. ®äú±É Eäò ʺɮúÉå EòÉä {ɽþ±Éä ºÉä MɨÉÇ Eò®úxÉÉ?

Preheating of Rail ends?

4.1 ]éõEò ¨Éå ºÉ¤É½þÒ nù¤ÉÉ´É +Éè®ú MɨÉÇ Eò®úxÉä Eäò {ÉÚ®äú ºÉ¨ÉªÉ ¨Éå ºÉ½þÒ nù¤ÉÉ´É ®úJÉÉ MɪÉÉ ½èþ?
Has pressure in the tank been maintained correctly & constantly during thje
operation of preheatring?

4.2 ¤ÉxÉÇ®ú EòÒ ±ÉÉ]õ ºÉ½þÒ +Éè®ú ÖÊSÉiÉ EòÉähÉ {É®ú ºÉvÉÒ ½èþ?
Is Burner flame fixed correctly and at proper angle?

4.3 MɨÉÇ Eò®úxÉä EòÉ ºÉ¨ÉªÉ ÊEòiÉxÉÉ lÉÉ .................................. ʨÉxÉ]õ?

Preheating time .............................................. Minute?

4.4 ºÉ¦ÉÒ (SÉÉ®úÉå) ´ÉɪÉÖ {ÉÉ<{É `öÒEò EòɪÉÇ Eò®ú ®ú½äþ ½éþ {ÉÉ®ú¨{ÉÊ®úEò ´Éèϱb÷MÉ Eäò ʱÉB?
All (four) air pipes are working properly in case of conventional welding?

5. ´Éèϱb÷MÉ
Welding

5.1 º±ÉèMÉ ½þMÉÉäxÉä EòÒ ÊGòªÉÉ EòÉ `öÒEò ÊxÉ®úÒIÉhÉ +Éè®ú ºÉ½þÒ ]äõË{ÉMÉ ÊEòªÉÉ MɪÉÉ?
Has slag seperation observation been done properly and material tapped in
time?

5.2 CªÉÉ {ÉnùÉlÉÇ +{ÉxÉä +É{É ]èõ{É ½Öþ+É?

Whether it was automatic tapping?

5.3 CªÉÉ {ÉÉä®ú¶ÉxÉ EòÒ |ÉÊGòªÉÉ ºÉ½þÒ ®ú½þÒ?

Is reaction of portion normal?
10701-7 M/c. No. 4 (1 to 82)
NORTHERN RAILWAY CHIEF ENGINEER CIRCULAR 33

´Éè±b÷ Eò®úxÉä EòÉ iÉ®úÒEòÉ

Procedure of Welding

Gò¨É ºÉÆ. Ê´É´É®úhÉ ½þÉÆ xɽþÓ

Sl. No. Description Yes No

6 Ê{ÉPɱÉÉ ¨ÉÉ±É ¨ÉÉä±b÷ ¨Éå b÷ɱÉxÉä Eäò ={É®úÉxiÉ

Operation after Pouring

6.1 ¨ÉÉä±b÷ JÉÉä±ÉxÉä ºÉä {ɽþ±Éä CªÉÉ {ÉÚ®úÉ |ÉiÉÒIÉÉ ºÉ¨ÉªÉ ÊnùªÉÉ MɪÉÉ?
Has proper mould waitingh time been given?

6.2 ¨ÉÉä±b÷ JÉÉä±ÉxÉä ¨Éå ®äú±É Eäò´É±É ʺɮäú {É®ú ºÉä ½þ]õɪÉÉ MɪÉÉ?
(+ºÉ¨ÉÉxÉ `Æöb÷Ò ÊGòªÉÉ EòÒ ®úÉäEò Eäò ʱÉB)
Is moulding sand removed from the rail head only?
(To avoid irregular cooling)

6.3 ®äú±É ½èþb÷ EòÒ vÉÉiÉÖ iÉlÉÉ ®úÉ<ÇVÉ®ú ºÉ½þÒ EòÉ]õÒ MÉ<Ç ½èþ ʤÉxÉÉ ÊEòºÉÒ ¡òɱÉiÉÚ +±É½þ Eò]õÉ´É Eäò?
Have extra metal on the head of rail and risers been cut properly,
without any undercut?

7. ºÉ¡òÉ<Ç
Cleaning

7.1 ºÉ¦ÉÒ iÉ®ú½þ EòÒ ºÉ¡òÉ<Ç `öÒEò |ÉEòÉ®ú EòÒ MÉ<Ç ½èþ?
Has cleaning of all sides been done properly?

7.2 +±]ÅõɺÉÉäÊxÉEò ´ÉMÉÔEò®úhÉ CªÉÉ ®ú½þÉ?

Classification of ultrasonic?

xÉÉä]õ Note :

1. ªÉ½þ ¡òɨÉÇ nùÉä EòÉÊ{ÉúªÉÉå ¨Éå ¦É®úÉ VÉÉB, BEò EòÉ{ÉÒ ºÉäC¶ÉxÉ Eäò ®äú±É {ÉlÉ ÊxÉ®úÒIÉEò Eäò ºlÉɪÉÒ Ê®úEòÉbÇ÷ Eäò ʱÉB +Éè®ú
nÚùºÉ®úÒ EòÉ{ÉÒ ®äú±É {ÉlÉ ÊxÉ®úÒIÉEò +±]ÅõɺÉÉäÊxÉEò Eäò ʱÉB*
This form shall be filled in two copies, one copy for permanent record of sectional
PWI’s and other copy for PWI/USFD

2. ªÉ½þ ¡òɨÉÇ Eäò´É±É ´Éèϱb÷MÉ Eò®ú´ÉÉxÉä ´ÉɱÉä ºÉÖ{É®ú´ÉÉ<VÉ®ú uùÉ®úÉ ½þÒ ¦É®úÉ VÉɪÉä*
This form shall be filled by welding supervisor only.

3. Gò. ºÉÆ. 7.2 iɦÉÒ ¦É®úÉ VÉɪÉä VÉ¤É +±]ÅõɺÉÉäÊxÉEò uùÉ®úÉ ]äõº]õ ½þÉä VÉɪÉä +Éè®ú =ºÉEòÉ ´ÉMÉÔEò®úhÉ Eò®ú ÊnùªÉÉ VÉɪÉä*
Item No. 7.2 to be filled after ultrasonic testing and its classification.

4. ´Éèϱb÷MÉ EòÒ ´ÉɺiÉÊ´ÉEò Êb÷]äõ±É <ºÉ ¡òɨÉÇ ¨Éå ¦É®úÒ VÉɪÉä*

Actual detail of welding should be filled in this form.