ISSUES FACED IN TRACK AND ITS SOLUTIONS

TYPES OF ISSUES

PRECASTING
ISSUES
TECHNICAL
POST-CASTING
ISSUES
ISSUES
OFFICIAL
GENERAL
MANPOWER
PRECASTING ISSUES
 Anchor bolt gritting issue.
 Anchor bolts are not properly coated / dried
 Reinforcement bar issue.
 After shuttering some times it is found that reinforcement bars are touching the anchor bolts.
 Welding Joint/Fishplate Issue.
 In few cases it is found that welding joints are getting aligned with the position of baseplate,
at the time of casting this may cause non-insertion of the SRC properly.
 Rubber Plug issue.
 Many times it is found that rubber plugs are not being used at site also it is found some rubber
plugs are small in diameter.
 Spacer bush tightening issue.
 Sometimes spacer bushes are found loosely attached with dummy plate of anchor stud.
 Usage of old and broken dummy components.
 In some sites it have seen that the sub-contractors are using old, dirty and broken dummy
components, for this the overall quality of casting may hamper.
 Non-usage of proper protection in dummy components.
 Due to no-usage of proper protection while concrete is being poured dummy component like
spacer bush, dummy plate, shoulder retention clamp can get dirty and concrete can get
clogged in the threads.
SOLUTION
 Anchor bolt Gritting issue:

 There are many reasons for this issue, some times it is seen that
contractors are not using Pandrol recommended bonding agent,
some times after gritting it’s also seen that there is no proper
place or shade in site to dry them off, so anchor studs are kept
beneath open sky and they get soaked in rain.
It is always recommended to keep at least two shades at the
site, one is for site equipment and another one for the labors,
and after gritting he studs should be kept in dry condition and inside
shade and the gritting material should be continually monitored by
PRT.
SOLUTION

 Reinforcement bar Issue

 After installing all the dummy components It should

always be checked by the site engineer that if any of
the stud is touching the reinforcement bar, if so the
TMT bar or the structure should be shifted to free the
stud, else the stud can become non-vertical after
casting or the track circuit can impacted for current
leakage through studs.
SOLUTION

 Welding joint / Fishplate issue

 In very few cases it is seen that a non welded rail joint is

coming aligned with the baseplate assembly. Now as it is
non welded, a pair of fish plate have to be installed on
both side of the rail to keep the rail aligned. Now in this
case there can be issue with fixing the SRC with dummy
assembly and not many options will be there.
In this type of case we can fix the assembly with the rail
by using some strong GI wire. But the engineers and the
labors have to be very careful about this mater that
alignment of the baseplate is perfect as it will be hanging
from the rail and it is recommended not to use vibrator in
particular that region. Instead concrete can be penetrated
by using manual process.
SOLUTION

 Rubber plug issue:

 It’s a common issue in most sites, but it is a vey serious issue

while the dummy component health comes into consideration.
Some times it is found that rubber plugs are not being used at
site, some times it is found that rubber plugs diameter are
smaller than required. In both cases a rubber plug of proper
dimension must be use, else the thread of 2 holes in a 4 hole
baseplate will get clogged and when it will be used to make a
4 bolt assembly casting spacer bush will not get fix on that
thread and studs will become non vertical.
SOLUTION

 Spacer bush tightening Issue and usage of broken

dummy components:

 This is aN issue which cannot be solved with out the

proper co-operation of the contractors, labors and
supervisors. Broken SRCs should always be avoided in
the site and proper tool should be used for tightening
of spacer bush. Without maintaining this parameters
height fluctuation of bolts can come.
POST CASTING ISSUES AND ITS SOLUTION

 Non-Verticality & Short Height

 This issue can be solved by fixing the above-mentioned pre-casting problems. Recently
many steps have been taken to encounter these problems including rectification of
dummy assemblies, giving proper training to the site supervisors and labors.
 Improper Parameter
 Final parameter is a very lengthy process, so with out proper timing and skilled labor it
is not possible to set exact parameter.
 Honeycomb and crack in plinth
 We can avoid this mater by using vibrator properly at site
 Non-Usage of Pan Puller
 This is a very serious issue when it comes to e-clip quality maintaining. Everyone
should maintain this procedure else by using hammer e-clips can get damaged and
after few days it can get corroded.

GENARAL ISSUES

 Labor Issues
 Co-ordination with client Issues
 No shades at site at all
 Curing water at the site
THANK YOU