Corporate Brochure
Corporate Brochure
Pathri
Sholaka
Bharatpur Burhwal
Roopangarh Bongaigaon
Mirza
Gaya
Bokaro Anara
Kargi Road
Udwada
Khurda Road
Wadiyaram Bobbili
Kallakal
Medchal
Hyderabad
Hubli
(JV)
Tumkur
Sleeper
Wire
Tirumangalam
Fastening Unit
Foundry Unit
Flash Butt Welding
CME
Innovation &
Design Center
Design and Engineering
LRPC Cable Plinth Design RHEDA on viaducts FS 336 - Plinth
Services for Box Guiders
FS 300 - Rheda Rail Welding TurnOuts for Urban Metros Point Machine for Turn Outs
Urban Metro
One stop shop for all
Urban Metro Track Solutions
Ballasted Tracks Ballast Concrete - Sleepers New Tech Sleeper Plant High Tensile Wire
Ballastless Tracks
One stop shop for High Speed and
Heavy Haul Ballastless Track
Sleeper for Ballastless Track Fastening 300 Fastening Rail Welding Turn Outs - Rheda Turn Outs Point Machine for Turn Outs
About Patil Group
Patil Group is an established business house engaged in developing pioneering and innovative
Railway Track Engineering Solutions. It started its journey in 1971 by setting up its first
sleeper plant to supply concrete sleepers to the Indian Railways. Today it has 20
manufacturing locations with an annual capacity of 5 million sleepers and a Design &
Competency Centre in Delhi, catering to the needs of all balastless track solutions for
metros and high speed lines The adoption of modern technology and major infrastructure
upgrade by the Indian Railways has poised the group for a leap into a fast growth trajectory.
Patil Group supplies ballast from its nine crusher units spread across the country and has
more than 200 acres of prime mining land under its control.Today, the group is the one-stop
Patil group ready for
solution provider for all railway track needs – heavy haul, high speed or urban metro and also
BULLET TRAIN - one of the largest manufacturers of HTS wires
NEW REVOLUTION
It has several firsts to its record - the first indigenous manufacturer of modern turnouts to
IN INDIA
RVNL (Railway Vikas Nigam Ltd.) for heavy haul track, first alternate material developed in
lieu of steel channels sleepers for girder bridges, first to offer ballastless track solutions and
the first to provide alternate designs for railway station aprons thus reducing maintenance
time and improving cleanliness.
l Railway WeldingYard Management with South Central Railway, North East Frontier Railway
l Delhi Airport Metro Express line from Delhi International Airport T-3 to Connaught place
Key Partnerships
l Rail Welding: SMH, Malaysia
Patil Group is the country's largest supplier of concrete sleepers to the Indian Railways. The company
manufactures these pre-stressed concrete (PSC) sleepers across its nine existing and two new automatic
production plants across the country with a total installed capacity of 5 million sleepers per annum.
The design for concrete sleepers had been constantly undergoing change in conjunction with the R&D of Indian
Railways to suit the changing requirements.With the adoption of M60 grade concrete, the life of these sleepers
increased. With the base width increased, the ballast pressure came down by 10% leading to proportionate
savings on ballast and maintenance costs.
Indian Railways has plans to go for higher axle loads in coming years and the new design for concrete sleepers
will suit future requirements of the railways. The company also envisages the use of special strand wire with
higher UTS by which the overall weight of steel per sleepers will be brought down by 25%.
The sleepers manufactured by the company are suitable for the following: New
Wider Base
1. Normal Broad Gauge:This sleeper has a trapezoidal cross section having a width of 180 mm at the top and Sleeper
280 mm at the bottom and a height of 230 mm at rail seat.
2. Points & Crossing: These specialized sleepers are used to hold switches, CMS crossings and lead rails for
main line and turnouts. High speed trains can run on these PSC layouts with utmost safety.
3. Guard Rail:These are used on girder bridges to prevent a derailed train from capsizing.
4. Switch Expansion Joints:These are PSC sleepers for switch expansion joints (with 120 mm maximum gap)
for long welded rails for 52 kg & 60 kg rails using corresponding chairs.
5. Check Rail on Curves: Check rails are absolutely essential to offer an inner side for sharper curves, which
are more than 50 to prevent derailment.
6. Level Crossings:This is formed at various points where a road crosses a railway track at the same level and
sleepers used here are made with 60 kg UIC or 52 kg check rail.
7. Dual Gauge:The unique pre-stressed concrete dual gauge sleepers have been designed to cater to handle
meter and broad gauge trains so that both trains can run on the same track. All the sleepers are
manufactured under stress bench system with very strict quality control measures.
HTS Wire
Patil Group has the distinction of being the country's largest HTS wire manufacturer for
the concrete sleeper industry. In line with the group's backward integration strategy, the
company manufactures 3ply 3mm and 9.5mm x 7ply strand wires for track sleepers and
turnout sleepers from its factories located at Bobbilli (Andhra Pradesh), Ajmer (Rajasthan)
and Patna (Bihar).
The total production capacity of the three ISO 9001 certified manufacturing plants is
60000 MTPA. This capacity has helped the group emerge as one of the single largest
suppliers of steel wires to ports,
tunnels and major bridges being
developed across the country.
l 9.5mm x 7ply mm High Tensile Steel Stranded Wires as per IS 6006-2014 (Un-coated)
used in Pre-stressed Concrete Industry.This is used in large bridges, Flyovers, Ports and
Road Dividers.
l 4mm Wire (Indented) as per IS 6003-2010 Hard Drawn Stress Relieved Wire for use in
Pre-stressed Concrete Industry. This is used in manufacture of Poles & Spun Poles for
electrification and telecommunication
l 2.50-8.00 mm as drawn wire as per IS 1785-Part I of 1983-Plain Hard Drawn Steel Wire
for Pre-stressed Concrete Industry
l 2.50-5.00 mm as drawn wire as per IS 1785-Part-II of 1983-Plain Hard Drawn Steel Wire
for Pre-stressed Concrete Industry (Stress Relieved)
l Shutter Spring Wire for manufacturing of Rolling Spring as per Customer specifications
SGCI Insert
In continuation with its long-term strategy to be a one stop provider of all Rail Track and
Metro Rail track related components Patil Group has achieved another milestone. We
have recently established a Foundry near Kallakal, Hyderabad & Bokaro, Jharkhand for
manufacturing of Base plates, SGCI Inserts.
Insert is a metallic part which is kept in the sleeper used to insert the clip that connects
Concrete sleeper with Rail track.We manufacture Inserts in our foundry at Kallakal near
Hyderabad. Insert production involves steps like preparation of molten metal, Mould
formation in Dies by pouring molten metal, De-gating , Shot blasting and final grinding to
remove excessive metal formation. The factory has been established with State of art
manufacturing facilities and modern techniques like Robotics and Internet of things (IOT)
are being implemented.
This unit has recently received approval from QA- RDSO( Drg. RT 381 Alt9) and started
full scale manufacturing. At Kallakal Foundry (KFCPPL) we will very soon also start
manufacturing of SGCI insert for the wider base sleeper, which is the latest sleeper
product that can enable increased speed of locomotive with high axle capacity. Base plates
for Metro Rails are another critical component that we manufacture in this foundry.
We are proud to announce our continued association with Indian Railways and happy to
be a part of Make in India philosophy.
Patil Paul Muller Under Sleeper Pads
Patil Paul Muller have been supplying Under Sleeper Pads for over 20 years. These were
originally developed as soft pads in order to reduce ground borne noise being transmitted
through the ground to adjacent building structures. New techniques have been
successfully developed for integrally fixing Under Sleeper Pads during the production of
concrete sleepers, producing a composite sleeper/pad solution.
Research undertaken in Europe on mixed mode and heavy rail tracks has established that
resilient Under Sleeper Pads with a relatively high stiffness have a significant positive effect
on track quality with a significant reduction in the costs of maintenance. The payback
period for the increased cost of sleepers has been estimated to be between 3 and 7 years.
For heavy haul lines the use of Under Sleeper Pads to improve track quality will give a
quick pay back by reduction in the frequency of rewinding, less frequent ballast tamping
and cleaning. Additional benefits include reduced wear on wheels and it is anticipated that
there will be lower incidents of rail breakage.
It has been proven that by fitting a resilient pad to the sleeper soffit face, the ballast stones
embed themselves into the pad and as a result there is a greater surface area now
supporting the track load thus reducing the loads transmitted to the ballast.The resilient
pad acts as a spring to reduce the level of dynamic impact reducing the peak loading on the
ballast. This combination of effects significantly reduces the track deterioration and
increases the time between grinding and ballast cleaning and tamping.
Where there are transition zones from ballasted track to slab track or bridges there will
be an abrupt change of track stiffness which can result in deterioration of track quality.
Therefore it is necessary to have a transition zone with an intermediate stiffness.This can
be achieved using different grades of under sleeper pads provided by Patil Paul Muller
Indian Railway is proposing to use Under Sleeper Pads(USP)/ Under Ballast Mats(UBM)
The UBM/USP when provided in the track, should be able to substantially reduce the
ballast thickness requirement on Indian Railway tracks from existing 300/350mm
without compromising or adversely affecting the functional, safety and structural
performance of track for supporting/carrying passenger traffic (axle load of 21T) for a
maximum speed of 160 kmph as well as freight traffic (axle load of 25 T) at 100 kmph.The
proposed system can preferably be either UBM or USP or a combination of both or any
other proven material on any world Railway system
Whilst most USP's are now fitted at the time of the sleeper manufacture, USP's can also
be fitted to wood or concrete sleepers at a later stage. This applies to new sleepers as
well as to reusable sleepers.
Rather than buy new sleepers, this facility allows older rail sleepers to be re-used in less
heavily used lines.
Our in-house design team, technical support and the flexibility of our 1S09001
accredited manufacturing plant makes Patil Paul Muller the ideal supplier of your rail
product requirements.
Canted Turnout & Switches
Modern Turnouts
A modern turnout is a track structure composed of a switch, a frog and closure rails
permitting a train to leave given track for branching or parallel track.The turnout systems can
be applied for different traffic applications like:
l Heavy Haul
l High Speed
The benefit of the turnout systems is based on minimized life cycle costs on account of lower
maintenance, higher reliability and shelf life. Most importantly, turnout systems can be tailor-
made for specific requirements.
Switches
The diverging path geometry of the switches is optimised according to the principles of
vehicle dynamics. These cuts induce forces and thereby improve travelling comfort and
service life.
Composite Sleepers
Patil Group has obtained technology and manufacturing license for composite sleepers
from Tie Tek, USA. These sleepers are manufactured using recycled materials. The group
developed composite sleepers as an alternative material in lieu of steel channel sleepers
for girder bridges.
Indian Railways have begun laying of composite sleepers in 10 railway zones across the
country after successful testing at its laboratory and also at the partner's manufacturing
plant in USA.
With an expected shelf life of over 40 years, composite sleepers score over wooden
sleepers due to usage of recycled materials like HDPE, crammer rubber, glass
reinforcement and fillers. Also, these sleepers are not susceptible to rupture, decay or
insect infestation and drive down the overall operating costs for Indian Railways besides
being easy to maintain as well.
With its R&D team working in conjunction with Tie Tek, USA – Patil Group has brought a
product which has found wide acceptance even for the exacting standards set up by the
Indian Railways.
The ability to recycle these sleepers due to its composition has won approval from railway
boards across countries. Even as the functional properties are similar to wooden sleepers,
these are not subjected to corrosion and don't need insulation since they are self-
insulated.
Composite sleepers have less components than steel channel sleepers, hence rendering
inspection and maintenance easier. Painting is also not required on composite sleepers and
it possesses the additional benefit of reduced noise pollution due to the natural
dampening effect of the product.
Fasteners
Fasteners are link systems that hold the track to the sleepers. Different types of fasteners are used for different railway tracks. Patil
Group has long standing association with world leaders in fastening and excelled in developing, manufacturing and marketing of
various types of Fastening Systems.
With Indian Railways deciding to upgrade railway infrastructure in line with requirements of global standards and safety of passengers,
a change was required in the fastening systems for railway tracks. Patil Group supplied slab track Fasteners (fastening system 336) to
Delhi, Chennai, Bangalore, Jaipur, Mumbai and Hyderabad Metro Track Projects and other fasteners (fastening system 300-1 and 300-
1U) of Station aprons and various main line tunnels to Indian Railways
Key advantages:
l Cost effective as the majority of the components are manufactured locally
Patil Group of Industries has introduced a complete Ballastless track solution for urban
metro rail on viaducts and underground tunnels. PATIL RHEDA Solutions are being used in
many places and guaranteed under single point responsibility wherein the complete track,
fastening and turnouts are integrated and delivered on a single source making it cost
competitive and hassle free for customers and clients.
The advantages of using PATIL RHEDA Ballastless track systems include long life cycles,
high speeds ride comfort and great load-carrying capability. Practically maintenance free,
ballastless track systems ensure 100% availability over many years. In many cases, a The country's first ballastless
maintenance-free track system is indeed the more cost-effective solution over the long track system
run. PATIL RHEDA is an in-house design and
development based on RHEDA system
With Indian Railways still undertaking trial runs with these sleepers, implementation of designed in Germany. Our R&D team
PATIL RHEDA sleepers has not been widespread.The advantage of these sleepers is its use has customised this for the
where ballast cannot be used and especially in tunnels, elevated tracks and station aprons. requirements of the Indian market. It
was used in Jammu & Kashmir and for
The use of PATIL RHEDA sleepers is ideal for laying washable aprons at railway stations Delhi airport. Ballastless track system
thereby improving the cleanliness of the station yards.The station aprons where the PATIL can be integrated optimally into traffic
RHEDA sleepers have been implemented include Bhubaneshwar, Kacheguda and many flow and the urban landscape whether
other stations. for tram systems, underground railways
or surface commuter train lines.
However, as the requirements of these sleepers is not in very high quantities, bulk
production is not very economical or a viable option. Sensing a potential in small quantity
manufacturing, Patil Group worked to set up mini mobile production plants - these can
reach the station where the apron is required. Once there, the required design can be
programmed, manufactured and once the same is laid out, the production van can move to
the next location eliminating the need for setting up bulk manufacturing plants and
transportation of these sleepers to their destination.
PATIL RHEDA Ballastless track was selected for the Jammu-Kashmir railway line. The
company has also introduced complete ballastless track solutions for urban metro rail on
viaducts, underground tunnels as well.
Patil RHEDA -
a proven system with worldwide reference
Maximum reliability and safety in planning, construction, and operation
Over the past 40 years, ballastless railway track has developed from a
niche product to internationally proven standard technology in the new
construction of railway lines with special requirements. One of the most
influential systems for application of ballastless track with main-track
sleepers is the Patil RHEDA family of ballastless tracks.
The Plinth Type Ballastless Track is a well proven design used in more than 10 metro train
projects across the world and in different gauges. This design has been developed by Patil
Group in co-ordination with leading international design consultants.
The continuous plinth track system is a continuously supported rail with discrete shoulders
retained by rail clips.
Pre-cast Plinth
Patil Rail Infrastructure Pvt. Ltd and ITD Bangkok together developed an innovative
modification to the existing plinth type track structure adopted with fastening system.
In this system, we bring in the plinth as a pre-cast element, same as the existing plinth
structure to be used 300-1 fastening system.
Such a system brings in the following advantages:
l Cost effectiveness
l Better quality of work
l Time saving
l Lesser quantum of work on site
Due to the above advantages, many Metro authorities are showing keen interest in this
system and are willing to adopt it in their upcoming projects.
System Test
l Rail Seat Vertical Load Test
l Repeated Load Test
l Shear Resistance Test
l Pull out Test
Installation Test
l Mock – up Test
Control Test
l Coring
l Ultrasonic Test
Flash Butt Welding
Important advantages of
flash butt welding compared
with other joining methods
l Reduces maintenance costs
l Saves track time
l Eliminates corrugation
l No weld filler material
l Smaller heat affected zone
l Smaller annealed zone
l Consistent hardness
l Highest fatigue resistance
Patil Group has proved its presence in the field of Flash Butt Welding for Railway through its l Average life equal to the rail
Flash Butt Welding plants. Patil Group has constructed India's largest welding depots in
Moulali secunderabad and in New Bongaigaon Assam India for Indian
Railways. Adequate infrastructural facilities have been provided in
these plants to facilitate the welding of 20 Rail panels.These Plants have
facilities for mechanised unloading of free rails, movement of welded
panels on rollers, loading and unloading of welded panels by motorized
gantries. We have imported an advance Flash Butt Welding Machine
from USA and deployed in New Bongaigaon Assam FBW depot.
Introduction
In Flash Butt welding process of rails, rails are welded by the heating,
using the Flashing Technique with the help of Hydraulic Control
System, Rail ends are heated as a result of their Electrical resistance
using current with high amperage at low voltage and forging them at an
appropriate temperature and upset force. No foreign material is needed and welding
process is continuous.The heat-effected zone is limited to the smallest possible area.The
pre-selected configuration best suitable for a particular type of rails in accordance to its
metallurgy ensures high quality weld. The welding cycle take place by the lateral
compression of the rail ends by the means of the two pairs of jaws. The jaw clamped rail
ends also act as electrodes for flow of high intensity current.
India’ s vision to grow rapidly endorse Infrasturture, Real Estate and Power Industries for
planned delivery of project in limited timelines and optimized cost without any
compromise in quality standards.
The Precast technology being now present for over 10 decades provides an intelligent
solution to the problem by ensuring that all the parameters related to raw material, quality
& safety are ensured.
The finished products can be transported & installed at site eliminating the hinderances
offered at site during concreting at site like height, atmosphere, etc..
Quality Assurance
Plant Address
Patil Rail Infrastructure Pvt. Ltd. Patil Rail Infrastructure Pvt. Ltd.
Railway Yard, Anara (S.E. Rly) Sy.No.179&180 Yellampet Village,
Purulia b 723 126, West Bengal Medchal Mandal, RR District ,Telangana.
In-Charge: Mr. R.S.Kulkarni, G.M In-Charge: Mr. Sreekanth Patil, DGM
Phone: +91- 83709.48728 Phone: +91- 77997.76648
Mail: [email protected] [email protected]
Patil Rail Infrastructure Pvt. Ltd. Patil Rail Infrastructure Pvt. Ltd.
Opp. Railway Station, Kargi Road, Survey No. 700, Roopangarh, Kishangarh Tahsil
Kota b 495 113 Ajmer Dist. Rajasthan
Dist. Bilaspur, Chhattisgarh In-Charge: Mr.Arun Sharma
In-Charge: Mr.Baljeet Singh Phone: +91-9352115205
Phone: +91-9111007373 Mail: [email protected]
Mail: [email protected]
Patil Rail Infrastructure Pvt. Ltd. Daya Engineering Works (P) Ltd.
Railway Yard, Tirumangalam Buniyadgunj, Manpur
Madurai Dist b 625 706, T.N. Gaya Dist Bihar -823003
In-Charge: Mr. Rajesh Kumar Singh DGM
(Works)
Phone: +91- 70332.97182
Mail: [email protected]
Marketing, Design & Engineering Office Daya Engineering Works (P) Ltd.
Patil Rail Infrastructure Pvt. Ltd. P. O. Mirza, Dist: Kamrup Assam - 781125
412, 4th Floor In-Charge: Mr.Vineet Sharma,Plant
Ansal Chamber-II,Bhikaji Cama Place head/Sr.Manager-Works
New Delhi - 110066 Phone: +91 72176 50161
Telefax: +91 11 2617 8765 Mail: [email protected]
Patil Rail Infrastructure Pvt. Ltd. Patil Rail Infrastructure Pvt. Ltd.
Kaipadar Road Station, Chhatispur PO Plot No. 3B, 4 & 5, APIIC, Growth Centre,
Khurda b 752 060, Orissa Bobbili,Vizianagaram Dist, A.P.
In-Charge: Mr. Eswara Rao.P In-Charge: Mr. Phanikumar
Phone: +91 95834 47767 Phone: +91 63002 70140
Mail: [email protected] Mail: [email protected]
Patil Rail Infrastructure Pvt. Ltd. Patil Rail Infrastructure Pvt. Ltd.(Bokaro wire)
Railway Yard, Wadiyaram, Chegunta Mandal Balidih,phase - 4 &
Medak Dist b 502 255, Telangana. Bokaro Industrial Area
In-Charge: Mr. Nagaraj Sajjan gorabali jaridih
Phone: +91 73373 96269 Thana,,Bokaro,Jharkhand,827014.
Mail: [email protected] In-Charge: Mr. B.N.Sajjan
Phone: +91 93461 80999
Mail: [email protected]
Patil Rail Infrastructure Pvt. Ltd. Icon Sleeper Track Pvt Ltd.
Udwada Rly., Quarry Area, NH b 8 Near Sholaka Railway Station,Vil. Siha,
PO Udwada (R.S.) Dist.Valsad, Taluka: Hodal Dist,
Gujarat b 396 185 Palwal, Haryana.
In-Charge: Mr.Vinod Singh. GM-Works In-Charge: Mr.Gopal Shukla, Sr.Manager (Works)
Phone: +91 96625503308 Phone: +91 98917 61500
Mail: [email protected] Mail: [email protected]