1. Modification & Fixing of INSERT IN CONCRETE SLEEPER for better Track parameters Session No. 10109 Integrated Course Project presented by Project presented by Subir Kumar Moitra Subir Kumar Moitra AEN/Con/1/Bhagalpur/E. Rly AEN/Con/1/Bhagalpur/E. Rly Benu Gopal Basak Benu Gopal Basak AXEN/Con/Jiribam, NF. Rly. AXEN/Con/Jiribam, NF. Rly. Vijay KumarParik Vijay KumarParik ADEN/SETT/Ranchi, SE. Rly. ADEN/SETT/Ranchi, SE. Rly. Project Guided By : Manoj Arora Project Guided By : Manoj Arora Sr. Prof. IRICEN Sr. Prof. IRICEN

2. Introduction Insert has a great significance to maintain gauge, alignment and toe load in PSC track structure This project discusses the problems in fixing the inserts and gives a possible solution to the problems

3. ERC with insert

4. Cross sectional view

7. Top view of sleeper with insert

8. Insert & its function Accuracy of all these parameters also some extent depend on rubber pad, liner and ERC. But major effectiveness completely depend on specific position of inserts in PSC sleepers as per drawing. Other fittings like rubber pad liner & ERC may be replaced whenever required. Insert can not be relocated or changed as per need as it is partially embedded in concrete. Sleepers are costly, hence replacement not desirable on account of insert only.

9. Present system of manufacture Steel Moulds (6mm to 8mm thick)are used by the manufacturers for production of PSC sleepers. There is no standard drawing of RDSO. regarding mould of Concrete sleepers. Manufacturers use their own method for making moulds. Thickness of plate used in moulds are not same in all manufacturing units.

13. Cont. Present system of manufacture Cont. Present system of manufacture Inserts are fixed in moulds before casting during manufacturing of sleepers. Although care is taken about proper positioning of inserts and restraints are provided in all directions but not achieved as required.

14. Uncertainty of improper sitting of inserts inside moulds can not be eliminated completely –Due to shape of insert, improper fixing arrangement in mould, wear, tear and bending of insert fixing pin, elongated pin hole. Due to high frequency vibration (9000rpm)during casting of sleeper inserts may dislocate, tilt, get skewed, especially as insert pocket and/or insert pin get worn out Cont. Present system of manufacture

15. Process of insert fixing at present Insert is placed inside the mould through a pocket in the bottom plate before concreting Pocket size is matching with the insert base Only a strip of insert projected (20mm X 6mm) to rest on mould Balance portion of insert is hanging To counter act the hang portion fixing arrangement one pin inserted through the hole of insert & two M.S. flat fixed either side of insert from the out side of mould at bottom

16. Top view inside the mould

17. View of underside of mould Pins to Fix eyes of inserts

19. Limitations in present system There is every possibility of tilting of insert & leakage of Slurry from the arrangement for fixing the inserts during vibrating of concrete. Very minor tilt in any direction (2 to 3mm) will give negative effect in all aspects (gauge, alignment & toe load.)

21. TILT OF INSERT

22. DEPOSITION OF SLURRY INSERT POCKET FOR FIXING INSERT

23. SLURRY, WEAR IN PINHOLE FORCING INSERT PIN TO FIX INSERT IN SKEW INSUFICIENT CLEANING MAKES INSERTS TILT THUS HIGH UNCERTINTY OF LESS TOE LOAD AND SLAG GAUGE

24. WEARING LEADS TO TILTING OF INSERT, LOOSINING OF INSERT PIN, FALLING OF PIN, DISLOCATION OF INSERT INSERT PIN HOLE INSERT POCKET

25. PARTIALLY CLEAN

26. SUGGESTIONS FOR MODIFICATION OF INSERT AND IMPROVING ITS FIXING ARRANGEMENT A strip of 10mm wide, 6mm th projection to be provided around the insert neck. Bearing area of insert with mould Thus will be increase due to this projection. Hence chance of tilting of insert will be eliminated. Slurry leakage will also be arrested due to coverage of gap between insert & mould in insert pocket At the time of manufacturing of insert, projection as mentioned is to be provided during casting. Extra material required for projection is compensated by changing the shape of insert leg. Thus no increase in cost. Thus no increase in cost.

29. SIDE ELEVATION

33. Cont. SUGGESTIONS FOR MODIFICATION OF INSERT AND IMPROVING ITS FIXING ARRANGEMENT Cont. SUGGESTIONS FOR MODIFICATION OF INSERT AND IMPROVING ITS FIXING ARRANGEMENT Three nos. M.S. Plates of 16mm thick strip to be fixed at the bottom plate from out side of mould at rail seat and both ends of insert pocket. Rigidity of mould will increase resistance to deformation of rail seat thus avoid early defects on rail seat slope. Rotation of insert completely arrested. Relative position of inserts will not be changed.

34. Cont. SUGGESTIONS FOR MODIFICATION OF INSERT AND IMPROVING ITS FIXING ARRENGENMENT Cont. SUGGESTIONS FOR MODIFICATION OF INSERT AND IMPROVING ITS FIXING ARRENGENMENT Special arrangement by using tongs shaped clip for holding two inserts at a time in each rail seat. Hence no need of clumsy box type insert fixing arrangement with insert pin in mould. Elongation of hole of flat & deformation of pin will be eliminated. Relative position of insert fixed firmly. Easy to maintain for assured quality.

36. How this change will be beneficial ? Specific location of Inserts as per drawing will be confirmed. Track gauge, Toe Load and alignment will be more accurate. No leakage of slurry from insert pocket hence, quality of concrete improves. Insert holes will not be jammed with slurry.

37. THANK YOU THANK YOU