Track Machines
Track Machines – Complete Railway GK Capsule
1. What are Track Machines?
Track machines are self-propelled or attachable railway vehicles designed to perform specific maintenance, renewal or inspection tasks on the track structure so that manual labour is reduced, accuracy is improved and traffic blocks are minimised. Indian Railways owns the world’s largest fleet of on-track plant (OTP) – more than 7,000 units.
2. Broad Categories (as per Indian Railways’ “Permanent Way Manual 2022”)
| Category | Typical Speed (working) | Power | Main Tasks |
|---|---|---|---|
| Tamping Machines | 0–2.5 km/h | 1,000–1,800 hp | Packing, aligning, leveling, stabilising |
| Ballast Cleaning Machines (BCM) | 0–600 m/h | 1,200–1,600 hp | Screening & restoring clean ballast |
| Ballast Regulating Machines (BRM) | 0–10 km/h | 400–600 hp | Profiling, shoulder cleaning, boxing |
| Dynamic Track Stabiliser (DTS) | 0–2 km/h | 400–600 hp | Post-tamping consolidation |
| Rail Grinding Machines (RGM) | 3–20 km/h | 1,200–1,500 hp | Rail profile correction, fatigue removal |
| Switch Grinding Machines (SGM) | 1–8 km/h | 800–1,000 hp | Turnout grinding |
| Rail Flaw Detection Cars (USFD) | 30–40 km/h | Dual-mode (DEMU) | Ultrasonic internal flaw detection |
| Track Recording Cars (TRC) | 100–180 km/h | Self-propelled | Geometry recording, video-imaging |
| Flash-Butt Welding Plants (FWP) | Stationary | 400–600 kVA | Factory / site welding of LWR/CWR |
| Mobile Flash-Butt Welding Units (MFW) | 20–80 km/h (travel) | 400 kVA | Field welding, short-possession blocks |
| Portal / Material Handlers | 0–5 km/h | 300–400 hp | Sleeper / panel replacement |
| Rail Head Profile Milling Train | 0–1.5 km/h | 1,000 hp | Precision milling (0.2 mm accuracy) |
3. Technical Specifications (Latest IRS & RDSO Circulars)
-
Tamping Machine (09-3X model)
- Tamping banks: 3 × 16 tools (48 tools)
- Working radius: ±2.5 m from track centre
- Lifting range: 150 mm; aligning range: ±150 mm
- Computer: ALC / GVA-3 system with 10 m chord versine calculation
- Output: 650 m/h (plain track) / 250 m/h (turn-out)
-
Ballast Cleaning Machine (RM-80)
- Excavating chain width: 3,350 mm
- Screening capacity: 650 m³/h
- Ballast reclaim: 95 % of reusable stone
- Minimum curve radius negotiable: 150 m
-
Dynamic Track Stabiliser (DGS-62N)
- Vertical exciting force: 2 × 310 kN @ 35 Hz
- Settlement achieved: 15–25 mm in 2–4 passes
- Allows 50 % speed restriction relaxation immediately after tamping
-
Rail Grinding Machine (RGM-20)
- Grinding stones: 96 (20-stone modules)
- Metal removal: 0.1–0.3 mm/pass
- RMS surface finish: ≤10 µm
- Grinding angle: ±70° (gauge / field side)
-
USFD Car (Mini-TRC)
- Probe frequency: 0°, 37°, 70° (4 MHz)
- Test speed: 40 km/h max; defect resolution: 2 mm
- GPS tagging accuracy: ≤1 m
4. Historical Milestones
| Year | Event |
|---|---|
| 1956 | First 2 tampers (Jackson type) imported by IR under IInd Five-Year Plan |
| 1964 | RDSO issues first “Specification for 08-16 plain-track tampers” |
| 1972 | Indigenous manufacture started at BEML, Bengaluru (collab. Plasser & Theurer) |
| 1986 | First BCM (RM-80) commissioned on SER |
| 1990 | Introduction of computer-aided tamping (ALC) on Rajdhani route |
| 1995 | First CSM (Continuous Action Tamping) Machine – 09-32 CSM |
| 2007 | Launch of “Mission Track” – target 2,500 tampers by 2020 |
| 2012 | First DTS (Plasser 62 N) used prior to 160 km/h trial of Semi-High Speed |
| 2016 | IR contracts 188 new machines (₹2,300 cr) under “Track Machine Procurement-17” |
| 2018 | RDSO approves indigenised “Make-in-India” 09-3X tamper by BEML |
| 2020 | First rail-milling train imported (Linsinger, Austria) – deployed on WCR |
| 2022 | Highest-ever allocation ₹3,992 cr for track machines in Pink Book |
5. Present Fleet & Deployment (as on 31-03-2023)
| Machine Type | Holding (IR) | Zone with Max Nos | Avg. Age (yrs) |
|---|---|---|---|
| Tampers (Plain + UNO) | 1,420 | CR (192) | 14 |
| BCM | 210 | SER (38) | 18 |
| DTS | 102 | NR (22) | 9 |
| RGM (main-line) | 42 | NR/WR (10 each) | 12 |
| USFD cars | 61 | NCR (11) | 11 |
| TRC/SRC | 29 | NR (6) | 15 |
- Vision-2024 target: 1 tamper per 125 km of track (present 1:152 km)
- Outsourcing: 30 % of annual tamping output now done by private machines under “MMO” contracts (Machine-Mode-Output)
6. Recent Policy Updates (2021-23)
- Automatic Block Prohibition (BPAC): tamper/DTS block automatically approved in ICMS (Integrated Crew Management System) – no manual TRR required.
- Green Initiatives: Stage-IIIA (Euro) diesel engines & bio-diesel blend up to 20 % (B-20) mandated for new machines.
- IoT-enabled telematics: GPS/OBC data uploaded to “Raksha Kavach” cloud portal for real-time machine monitoring.
- Indigenous “Vande-Metronom” TRC: jointly developed by RDSO & BEML – 180 km/h self-propelled – rolled out Jan 2023.
- Rail-Milling technology: approved for 3 more zones (NCR, ER, SCR) in 2023-24 – tender value ₹1,080 cr.
7. Safety & Standards
- IRS:T-39/2019 – General & safety requirements for OTP
- Minimum crew: 4 (driver, operator, maintainer, lookout)
- Maximum gradient on which machine can work: 1 in 40 (caution) & 1 in 100 (normal)
- Brake system: Dual (air & parking), fail-safe, spring-applied
- Fire-extinguisher: 6 kg DCP × 4, validity 3 yearly
- First-aid & oxygen cylinder: mandatory for BCM (confined-space work)
8. Quick-Fire Data for Exams
- Tamping tools material: Hadfield steel (12 % Mn)
- Ballast shoulder slope maintained by BRM: 1 in 1.5
- USFD probe angle for bolt-hole crack detection: 37°
- Minimum rail temp. for flash-butt welding: < 600 °C of rail
- DTS operation forbidden when ambient temp.: > 50 °C (rail stress hazard)
- Rail-grinding stone composition: Aluminium oxide + resin bond
- IRS coach under-gear clearance: 65 mm (for TRC/SRC)
9. 15+ MCQs (With Answers)
Click to expand MCQs
Q1. Which of the following machines is used for consolidating freshly tamped track?
A. BCM B. DTS C. RGM D. USFD
Ans. B
Q2. The first tamping machines were imported by Indian Railways in
A. 1951 B. 1956 C. 1961 D. 1965
Ans. B
Q3. Screening capacity of RM-80 BCM is approximately
A. 150 m³/h B. 350 m³/h C. 650 m³/h D. 950 m³/h
Ans. C
Q4. The minimum curve radius negotiable by RM-80 ballast cleaning machine is
A. 90 m B. 120 m C. 150 m D. 200 m
Ans. C
Q5. ALC system in modern tampers stands for
A. Automatic Level Controller B. Analogical Lifting Computer
C. Automated Lining Computer D. Analog Loop Control
Ans. B
Q6. Dynamic Track Stabiliser applies vertical exciting force at a frequency of about
A. 15 Hz B. 25 Hz C. 35 Hz D. 45 Hz
Ans. C
Q7. Which machine is deployed to rectify rail surface corrugations?
A. DTS B. BCM C. RGM D. TRC
Ans. C
Q8. The indigenous 09-3X tamper has been developed by
A. BHEL B. BEML C. DMRC D. Texmaco
Ans. B
Q9. IRS:T-39/2019 deals with safety requirements of
A. Loco pilots B. Track machines C. Signalling gears D. Wagons
Ans. B
Q10. Stage-IIIA engines used in new track machines comply with
A. Euro-3 B. Euro-4 C. Euro-5 D. Euro-6
Ans. A
Q11. Vande-Metronom TRC can record track geometry at a maximum speed of
A. 120 km/h B. 160 km/h C. 180 km/h D. 200 km/h
Ans. C
Q12. The 37° probe in USFD equipment is primarily meant to detect
A. Transverse head crack B. Bolt-hole crack C. Web lamination D. Foot fatigue
Ans. B
Q13. Mobile Flash-Butt Welding Units normally need electrical power of about
A. 100 kVA B. 200 kVA C. 400 kVA D. 800 kVA
Ans. C
Q14. Which of the following is NOT a function of Ballast Regulating Machine?
A. Shoulder cleaning B. Sleeper insertion C. Boxing ballast D. Profile correction
Ans. B
Q15. Present Vision-2024 target is to keep one tamper for every ___ km of track.
A. 100 B. 125 C. 150 D. 175
Ans. B
Q16. Rail-milling train achieves metal-removal accuracy of
A. 0.02 mm B. 0.1 mm C. 0.2 mm D. 0.5 mm
Ans. C
Q17. Mission Track was launched in
A. 2005 B. 2007 C. 2012 D. 2016
Ans. B
Remember: Track machines are high-investment, high-technology assets – their productive deployment is key to achieving 160/200 km/h speeds and 30 t axle-load freight corridors. Expect at least 3-4 questions every year across RRB-JE/NTPC/Group-D papers.
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