Minister of railways visited slab track casting factory at Surat on Saturday | File Photo
A track slab manufacturing factory has been established to support the India’s first bullet train projects. The factory is designed to produce high capacity ballastless track slabs using advanced Shinkansen technology.
According to official, this factory is strategically located near the alignment at Kim Village, near Surat. This proximity to the project site ensures efficient logistics and timely delivery of track slabs for the bullet train construction.
Production Capacity
The pre-cast reinforced concrete track slabs are generally 2,200 mm wide, 4,900 mm long and 190 mm thick and each slab weighs about 3.9 tonnes.
The track slab manufacturing factory is designed to produce 120 slabs per day, ensuring high efficiency and a steady supply of critical components for India’s first bullet train project. The production scope of this factory is the manufacturing of 96,000 J-slabs.This facility will produce track slabs for 237 km of high speed rail track for MAHSR corridor in Gujarat& DNH (352 km)
Factory Size and Layout:
The factory is developed in the total area of 19 Acres and out of total area the manufacturing plant spans a significant area of 7 acres of land, with the production building covering 190 meters by 90 meters. Within this space, three dedicated bays will house a total of 120 slab moulds, facilitating the simultaneous production of multiple slabs.
Stacking Capacity:
To support the large production volume, the factory is equipped with an extensive stacking capacity of 10,000 track slabs. This allows for the organized storage of produced slabs, ensuring they are ready for transportation to the construction site as needed.
Production Process Summary:
The production process begins with the preparation of rebar cages, which are crafted using an automatic cut and bend machine. These cages along with inserts and spiral rebars are then placed in the moulds before the concrete is poured. The compaction of poured concreate is achieved by vibrators within moulds. Following casting, the slabs undergo a steam curing process to ensure proper strength development. After curing, the slabs are demoulded and inspected before undergoing wet curing for three days.
Once the slabs have achieved the required strength, they are stacked at the TSMF in a designated storage area. After a 28-day period to ensure required cube strength, the slabs are transported to the respective Track Construction Base for installation . As on 29th November a total of 9775 slabs have been already cast.
Another track slab manufacturing facility is established in Anand, Gujarat for track slab construction for 116 km of MAHSR corridor in Gujarat. More than 22,000 slabs have been cast in both the factories which are equivalent to 110 track km.
The engineers involved in manufacturing of the track slabs have undergone training and certification course under the supervision of Japanese experts based on practices followed in Japan.
J-Slab Track System
The Mumbai Ahmedabad High-Speed Rail corridor will have J- Slab track system of ballastless track based on Japanese Shinkansen track system. This track system consists of 4 main layers viz. RC Track Bed, Cement Asphalt Mortar, Pre cast Track Slab and Rail with Fasteners. The process of track installation is mechanized with cutting edge machinery especially designed and manufactured, as per Japanese specifications.
Over 35,000 MT of rails and four sets (04) of track construction machinery have been received for the project. The fleet of machines include rail feeder car, track slab laying car, related wagons and motor cars, CAM laying car and flash butt welding machines.
How it works
Flash butt welding machine (FBWM)
The 25 m long 60 kg rails are welded using Flash butt welding machine (FBWM) to form 200 m long panels near the TCB (track construction base) over the viaduct. Total 3 FBWM have been procured till now, and the same have to pass through stringent approval methodology prior to commencement of rail welding fit for allowing high speed train running at 320 kmph.
Track Slab Laying Car (SLC)
Precast track slabs are lifted on to the viaduct, loaded on specially designed SLC and moved to the track laying location. By using SLC, which can pick 5 slabs at a time, track slabs are laid in position on the RC track bed. 3 SLC have been arranged for slab laying work.
Rail Feeder Car (RFC)
200 m long panels are fed and laid over RC track bed using Rail Feeder Car. RFC will push the rail pair over the RC bed and temporary track will be laid initially on RC. Total 4 RFC have been procured till now.
Injection Car (CAM Car)
After placement of track slabs at proper place on the RC Bed, CAM car runs on the parallel track. This CAM car mixes the ingredients for CAM mix in design proportion and this CAM mix is injected under the slab to achieve the required line and level of track. 2 CAM cars have been procured till now.