Switch Expansion joint

( Types, Laying & maintenance )

Sandeep Nerella
( SSE/RVNL/SC )

With Guidance

SJB CHARY
(DGM/RVNL/SC )
Long Welded Rails (LWR)

 It is a welded rail, the Central Part of which doesn’t undergo any Longitudinal
Movement due to temperature Variations.
L > 500m MG
L > 250m BG Normal functions as LWR

 Breathing Length : It is the length at each end of LWR Which is

Subjected to Expansion/Contractions on
account of temperature Variations
Switch Expansion Joint (SEJ)

 SEJ is an Expansion Joint installed at Each end of

LWR/CWR to Permit expansion/Contractions of the
adjoining breathing lengths due to temperature
variations
 Types of SEJ’s

 Conventional SEJ  IMPROVED SEJ

a) SEJ with One Gap
b) SEJ with Two Gap
 Why Improvements is Required in design ?

 To avoid two bends involved in the design of Stock rail and tongue
rail in Conventional type of SEJ.
 To avoid fractures in the Bent Portion of stock rail and tongue rail
in Conventional type of SEJ.
 To Meet other requirements like wide gap at bridge approaches.
 Suitable to lay on curves sharper than 0.5 deg. and up to 4.0 deg.
 SEJ with one Gap

 Design developed by M/S Rahee Industries, Calcutta.

 It is also called as “ Improved SEJ”
 Comprises of a pair of two non bent rails mounted on C.I. Chairs
with a expansion gap between the two juxtaposed rail ends.
 A third rail ( gap avoiding rail ) is securely bolted to the stock rail
by HTS Bolts to form an extension of the stock rail.
Schematic diagram of SEJ
 Fittings of SEJ (RDSO/T-6902 )

Sl. Drawing Qty. /

     
Description

No. No. Set

1 Stock rail Right (6180 mm) RDSO/T-6902/1 1

2 Stock rail Left (6180 mm) RDSO/T-6902/1 1

3 Tongue Rail Right (6780 mm) RDSO/T-6902/2 1

4 Tongue Rail Left (6780 mm) RDSO/T-6902/2 1

5 GAP Avoid Rail Right (2380mm) RDSO/T-6902/3 1

6 GAP Avoid Rail Left (2380mm) RDSO/T-6902/3 1

7 Check Rail (2700mm) 52Kg. RDSO/T-6903 2

8 C .I. Chair RDSO/T-6904 10

9 M.S. bracket RDSO/T-6905 6

10 M.S. bracket RDSO/T-6906 10

11 M.S. bracket RDSO/T-6907 2

12 M.S. bracket    RDSO/T-6908 2

 Contd..

Sl. Drawing Qty.

Description
     

No. No. Set

HTS Bolt with Nut 10.9 (M27 X
13 RDSO/T-6909 8
90)
14 Bolts (25 X 90) with SCS washer RDSO/T-8604 10

15 Bolts (25 X 95) with SCS washer RDSO/T-6910 20

16 Bolts (25 X 145) with SCS washer RDSO/T-6911 30

17 Plate screw RDSO/T-3916 20

18 Plate screw RDSO/T-3915 20

19 Single Coil Spring Washer T - 10773 40

20 Split pin (Ø 6.3 x 40mm long) -- 40

21 Plain Washer for 25 Ø bolt -- 10

22 Hardened washer RDSO/T-6912 8

23 Hardened washer RDSO/T-6913 8

Lay out of SEJ
Insertion of SEJ on Running line
PREPARATORY WORKS :-

 Details plan of LWR track showing exact location of SEJ to be decided.

 Distance between the ends of adjoining LWR between in which Modified
SEJ to be laid shall be equal to length of Modified SEJ-2x13
Material required as follows :-

 Material required for one set of Modified SEJ as per drawing.

 Sufficient number of 6.5 m long ultrasonically tested closure rails of same section.
 Rail cutting equipment.
 Sufficient number of 1 m fishplates with suitable clamps.
 Equipment for protection work.
 Sufficient manpower with tools.
 INSTALLATION WORKS

 Impose SR of 30 KMPH on the particular KM where SEJ to be inserted.

 SEJ shall be pre-assembled as per drawing on PSC sleepers and kept ready beside of
proposed location with suitable arrangement to shift on to track.
 Minimum 1 hr. block to be obtained and both ends of rail shall be cut as per marking.
 The existing PSC sleepers and rails to be removed.
 Ballast shall be leveled.
 Pre-assembled SEJ to be inserted in track & joined with suitable fish plate & clamps.
 Ballast shall be recouped and track shall be attended to correct line and level.
 Welding of both ends to be done as per availability of block.
 SEJ gap to be adjusted as per LWR manual during distressing temperature.
 REFERENCE MARK AND MEASUREMENT

 Pillars shall be erected at Centre of SEJ and reference marks shall be

marked on these pillars on either side of track during distressing.
 SEJ gap to be provided 40 mm.
 Marking on pillars be shall be in form of saw marks.
 A string shall be stretched across track over the saw marks of
reference for measuring SEJ gap with respect to tip of Tongue
rail/Edge of Stock rail.
ROUTINE MAINTENANCE & SPECIAL MAINTENANCE

 All fastening shall be complete and well secured.

 Fastening shall be renewed on not more than one rail seal at a time.
 Once in fortnight the SEJ shall be checked, packed and aligned if
necessary.
 Oiling and Greasing of Tongue rail & Stock rail shall be carried out once
in fortnight.
 During daily patrolling, the Key man shall keep special watch on the SEJ.
 SEJ gap to be adjusted during distressing which shall be carried out as per
provisions laid in LWR manual.
 INSPECTION & RECORDS

 Inspection shall be carried out on every fortnight during the two

coldest and hottest months of the year during minimum and
maximum temperatures at supervisory level and senior level.
 Alternatively once in two months during other months at
supervisory level.
 Recording of inspection notes as per preformat given in LWR
manual.
 Compliance of observations of deficiencies is also entered in the
inspection register.