Date: 19-06-2025

Observation after Installation of Check Rail at Depot Ramp

Sl. No. Observation Comment of DDC
1. Tightness of M-24 Bottom Stud Bolt Minimum engagement
length of 20mm is
After tightening of nuts, few Bottom Studs bolts sufficient according to the
have been found not flushing to the nut, design. Since the thickness
of nut is 26mm, it is
As per Drawing 65 mm to be projected above the satisfying the minimum
concrete, the utilization of 65 mm is as follows. engagement length when
Base plate thickness – 16 mm the nut is flush with the
Base Plate Pad thickness – 4mm bolt. The calculations are
Nylon Bush thickness -10 mm given in further sections.
Single Coil Spring Washer thickness – 5 mm
Plain Washer thickness - 4 mm
Total = 59 mm
In ideal condition 6 mm to be left after
tightening of nut, but in some cases this 6 mm is
used for vertical adjustment of check Rail height
or due to construction error.

Now few stud bolts found under tight about 5

mm resulting to not flushing with the nut, at this
case it is proposed to remove a single coil spring
washer and tight the nut.

Following observation found the bolts.

Total No of Bolts: 3380 Nos

[Link] coil spring washer to be removed 68 Nos

Hence its observed 1%

[Link] Bolt: 108 Nos

Bolt Flash Without spring

Requesting DDC to share consent.

2. Splicing of Check Rail The length of each check
Dimension of gap is not mentioned in the rail provided is 12m and
drawing at fish plated joint of check rail, in ideal the gap is said to be 3mm
condition 3 mm gap is kept. to [Link] on that
After installation of check Rail, a gap of 7 mm or Expansion Gap is calculated
0 mm is found at some locations. (L*α*t) in further sections.

Due to thermal expansion & contraction the gap

is varied.
It may please be mentioned the minimum and
maximum gap is permitted at fish plated joint.

Total No of joints 74 Nos

It is observed at 10 locations.

Hence its observed 14%

Check Rail Gap Check Rail Gap

3. Gap Between Check Rail Bracket and Check

Rail
Since the Check rail is
After installation of Check Rail, a gap is observed fastened to the Bracket on
in between Check Rail and check rail bracket at a curve of 120m to 190m
the edge of check Rail Bracket. radius, there will be a
single point of contact
As it is single bolt connection, one side of the between the check rail and
check Rail is touching to the bracket and another bracket. Force will transfer
side not touching to the bracket, due to to the bracket through this
curvature effect of check rail. contact point.

Total No of Brackets 847 Nos

It is observed hardly 15 Nos of the bracket.

Hence its observed 2%
 1. Tightness of M-24 Bottom Stud Bolt

As per federal strandard ( FED-STD-H28/2B), screw-thread strandards for federal services and
ISO 898 part-1
D Bolt Dia 24 mm
p screw thread pitch 3 mm
At The screw thread tensile stress area ( According to ISO 898-Part1)
mm
At= π/4 ( D- 0.938194 p)2 353 2

dp pitch circle diameter of thread

dp= ( D-0.64952 p) 22 mm
Le Length of thread engagement
Le ( min) = 2* At / (0.5. π * ( dp) 20 mm

Since the thickness of nut is 26mm, [Link] of thread engagement i.e., 20mm is satisfied
even if the bolt is flush with the nut. Hence, it is safe.
EDGE DISTANCE CALCULATION REPORT:
Depth of embedment= 115 mm
Minimum edge distance= 110mm
Tension force per anchor bolt= 17.39/2= 8.7 KN

It is assumed that out of the four anchor bolts, the ones nearer to the rail takes 50% of the
shear force and the farther ones takes 50% equally.
The force due to vertical loads are very small, hence negligible.
Shear force on two bolts= 50% of total shear force= 0.5*15.65=7.825 KN
Shear force on each bolt= 7.825/2= 3.91 KN.
BOLT CALCULATION

Ref Clause Description Symbol Value Unit

Design Inputs :

Bolt dia d = 24 mm
Embedded depth of shank hef = 115 mm
Concrete grade f ck,cube = 35 MPa
cl . [Link] Relevant load application on
EOTA = Cracked Concrete
a) concrete type
Member thickness h = 185 mm
EOTA cl . [Link] Installation Standard = Normal Installation safety
No. of bolt in tension = 2
No. of bolt in shear = 4
Edge distance c1 = 110 mm
Edge distance c2 = 335 mm
Bolt c/c dist s1 = 180 mm
Bolt c/c dist s2 = 180 mm
Min. member thickness hmin = 185 mm

Input Dimension in Diagram

Force 180
Plinth edge (Transverse)

Check
Rail
bracket 335
base
plate

180 110
OK
Plinth edge (Longitudinal)

Total Tension Forces on Anchor Bolts Fy = 17.39 kN

Total Shear Forces on Anchor Bolts Fz = 15.65 kN

 Tension Forces on bolts Fy = 8.70 kN
Shear Forces on bolts Fz = 3.91 kN
Characteristic values for tension loads in cracked concrete
ETA-13 Ta bl e - 8 Char. tension resistance for 8.8 grade NRk,s = 282 kN
Factor of safety γms = 1.5
Resistance to steel failure = 188 kN
Char. bond in cracked concrete (M25) τRk,ucr = 6 N/mm2
Increasing factor for M35 (Interpol a ted) ᴪc = 1.14
Tension safety factor γmc = 1.9
Pull-out failure

Characteristic resistance in case of combined pull-out

EOTA cl .[Link]

Initial characteristics resistance

N0Rk,P = p  d  h ef  tRk

= PI()*24*115*1.14*6)/1000
cl .[Link]
EOTA a) = 59.31 kN
Eccentricity of resulting tensile force eN = 0 mm
c1 = 110 mm
c2 = 172.5 mm
s1 = 180 mm
s2 = 180 mm
cl .[Link]
EOTA b) Reference projected area A0p,N = 345*345
= 119025 mm2
Actual projected area Ap,N = (172.5+180+172.5)*(172.5+90)
= 137812.5 mm2
Projected length Scr,Np = 20*24*(1.14*6/7.5)^0.5
= 458.39 mm
(condition check) Scr,Np = 345.00 mm
Projected edge distance Ccr,Np = 172.50 mm
cl .[Link]
EOTA
d)
Load transfer factor k = 2.3
cl .[Link]
EOTA
c)
Disturbance of stress distribution factor ᴪs,Np = 0.7+(0.3*Min(110,172.5/172.5))
= 0.90
cl .[Link]
EOTA Fastener group factor ᴪg,Np = 1.00
d)
ᴪ0g,Np = 0.92
Eccentricity factor ᴪec,Np = 1
Shell spalling factor ᴪre,Np = 1
EOTA cl .[Link] Tension Safety factor γ2 = 1.2
59.31*(137812.5/119025)*
Pull out resistance NRk,p = 0.9*1*1*1
= 61.81 kN
 Factored Pull out resistance = 61.81/1.9
= 32.53 kN
Actual Tension in bolt = 8.70 kN
SAFE
Concrete cone failure

Characteristic cone resistance

EOTA cl .[Link]
Load transfer factor k1 = 7.2
cl .[Link]
EOTA a) Initial characteristic resistance N0Rk,c = k1 *√f ck,cube*hef1.5
= (7.2*SQRT(35)*115^1.5)/1000
= 52.54 kN
Eccentricity of resulting tensile force eN = 0 mm
c1 = 110.00 mm
c2 = 172.50 mm
s1 = 180.00 mm
s1 = 180.00 mm
EOTA Fi g.5.4a Reference projected area A0c,N = 345*345
= 119025 mm2
EOTA Fi g.5.4b Actual projected area Ac,N = (172.5+180+172.5)*(172.5+90)
= 137812.5 mm2
cl .[Link]
EOTA b) Projected length Scr,N = 345 mm
cl .[Link]
EOTA b) Projected edge distance Ccr,N = 172.5 mm
cl .[Link] Disturbance of stress distribution
EOTA
c)
ᴪs,N = 0.7+(0.3*Min(172.5,110/172.5))
factor
= 0.90
cl .[Link]
EOTA d) Eccentricity factor ᴪec,Np = 1
cl .[Link]
EOTA e) Shell spalling factor ᴪre,N = 1
52.54*(137812.5/119025)*
Cone resistance NRk,c = 0.9*1*1
= 54.75 kN
Factored Cone resistance = 54.75/1.9
= 28.82 kN
Actual Tension in bolt = 8.70 kN
SAFE
 Splitting failure
Check For Splitting failure
Characteristic Splitting resistance

EOTA cl .[Link]
ETA-13 Ta bl e 7 Projected length Scr,sp = 410 mm
ETA-13 Ta bl e 8 Projected edge distance Ccr,sp = 205 mm
Member depth factor ᴪh,sp = (185/185)^(2/3)
= 1.00 1.16
EOTA eq.5.4b ᴪh,sp = 1
52.54*(137812.5/119025)*
Splitting resistance NRk,sp = 0.9*1*1*1
= 54.75 kN
Factored Splitting resistance = 54.75/1.9
= 28.82 kN
Actual Tension in bolt = 8.70
SAFE
Steel Failure Requirements in Shear

ETA-13 Ta bl e - 9 Char. shear resistance for 8.8 grade V Rk,s = 141 kN

Factor of safety γms = 1.25
Design shear force V Ed = 3.91 kN
Design shear resistance V Rd,s = 141/1.25
= 112.8 kN
SAFE
Concrete pry-out failure

EOTA cl .[Link] Char. Pry out resistance for Pull out V Rk,cp = 65.06 kN
Char. Pry out resistance for Concrete cone
V Rk,cp = 57.64 kN
Char. Pry out resistance V Rk,cp = 57.64 kN
Actual Shear in bolt = 3.91 kN
SAFE
 Concrete Edge Failure

Check for Edge Failure

The total Edge shear resistance
cl . [Link]
EOTA Eq.5.8

Initial Characteristic resistance

Load transfer factor k1 = 1.7
cl . [Link] (1.7*24^0.11*115^0.08*SQRT
EOTA a) = (35)*110^1.5)/1000
= 24.06 kN
α = 0.1 * (hef/c1)^0.5 α = 0.1*(115/110)^0.5
= 0.11
β = 0.1 * (d/c1)^0.2 β = 0.1*(24/110)^0.2
= 0.08
Assumed angle for Shear αv = 0 °
Eccentricity for Shear ev = 0 mm
Geometric effect of spacing
Limitations
c1 = 110
c2 ≤ 1.5 c1 c2 = 165 mm
s2 ≤ 3 c1 s2 = 180
h > 1.5 c1 h = 165 mm
EOTA fi g.5.6 A0c,V = 4.5 c12 A0c,V = 4.5*110*110
= 54450 mm2
EOTA fi g.5.7 b) Ac,V = (1.5c1 + s2 + c2) * h Ac,V = 165*(180+165+1.5*110)
= 84150 mm2
cl . [Link]
EOTA c) Disturbance of stress distribution factor ψs,V = 0.7+(0.3*165/1.5/110)
= 1.00
cl . [Link]
EOTA d) Member depth factor ψh,V = 1.00
cl . [Link] SQRT(1/(COS 0^2+(SIN 0/2.5)^
EOTA e) Angle factor ψα,V = 2))
= 1.0
cl . [Link]
EOTA f) Eccentricity factor ψec,V = 1/(1+2*0/3/110)
= 1.0
cl . [Link]
EOTA g) Shell spalling factor ψre,V = 1.2
Shear safety factor γ2 = 1
24.06*(84150/54450)*1*1*1*
Edge shear resistance V Rk,c =
1*1.2
= 44.63 kN
 Factored Edge resistance = 44.63/(1*1.5)
= 29.75 kN
Actual Shear in bolt = 3.91 kN
SAFE
7. Combined tension and Shear failure
For steel failure
"βN " (Ratio between tension force
applied and design resistance of bolt
for tension force)
"βv "(Ratio between shear force
applied and design resistance of bolt
for shear force)
βN ≤ 1 = 0.30 OK
βV ≤ 1 = 0.13 OK
βN +βV2 ≤ 1
2
= (0.3^2)+(0.13^2)
0.11 OK

W/O Supp. Rebar (For other failures)

βN ≤ 1 = 0.30 OK
βV ≤ 1 = 0.13 OK
βN + βV ≤ 1.2 = 0.43 OK
βN1.5 +βV1.5 ≤ 1 = 0.21 OK

PULL OUT STRENGTH OF ANCHOR BOLT:

As per IRS CBC-2019- pull out strength of anchor bolt
F
= BD X 3.14 X L X Bond Strength of Concrete to Steel
B m
24
D Bolt Dia m
Pie 3.14
m
110
L Embedded Length m
ultimate anchoarge Bond Stress for M-35 as per IRS CBC Table 21( for
1.7
plain bars)

F
= BD X 3.14 X L X Bond Strength of Concrete to Steel
F 14.0
KN
= 14092.32 9
Reduce 40% for GI 8.46 KN
TIGHTENING TORQURE ON ANCHOR BOLT ( 24MM DIA):

As per ISO-898-1-2013 - Tightening torque on anchor bolt

T= K*D*P
T= Tightening torque in Nm
D Bolt Dia in mm 24 mm
K= Nut factor( for zinc) 0.14
p= Target clamping load in KN( 65% of proof load) 137.8 KN
proof load ( from table 5 of ISO 898-1) 212 KN
Grade of bolt( property class) 8.8

T = K*D*P
T = 463 463.008 Nm
TIGHTENING TORQURE ON ANCHOR BOLT (16 MM DIA):

As per ISO-898-1-2013 - Tightening torque on anchor bolt

T= K*D*P
T= Tightening torque in Nm
D Bolt Dia in mm 16 mm
K= Nut factor( for zinc) 0.14
p= Target clamping load in KN( 65% of proof load) 137.8 KN
proof load ( from table 5 of ISO 898-1) 212 KN
Grade of bolt( property class) 8.8

T = K*D*P
T = 309 308.672 Nm

2. Splicing of Check Rail

Expansion gap between check rails= L*α* ΔT

Where, L= Length of each check rail= 12m=12000mm
α = coefficient of thermal expansion=12*10^-6
ΔT = temperature difference

Minimum temperature difference= 33 C

Maximum temperature difference= 42 C

Minimum Expansion gap= 12000* 12*10-6 *33 = 4.752mm
Maximum Expansion gap= 12000* 12*10-6 *42 = 6.048 mm
So, the gap shall range between 4.7mm to 6.05 mm
 3. Gap Between Check Rail Bracket and Check Rail

Since the Check rail is fastened to the Bracket on a curve of 120m to 190m radius, there
will be a single point of contact between the check rail and bracket. The transfer Force in
FEM is applied as a point load that will transfer to the bracket through this contact point.
Hence, it is safe.

[Link]
Director (Technical)
Primerail infralabs