TRACK STRUCTURE

CHAPTER IV
BALLAST
1. INTRODUCTION
Track ballast is a granular material, usually broken stone, which is laid on the formation to form a bed
for the sleepers. Importance of ballast has grown with increased axle loads and speed of trains. Use of
concrete sleepers and increasing use of machines to maintain the track has brought the ballast into
forefront. Life cycle economics of track is largely dependent on type, quality and quantity of ballast.
2. FUNCTIONS OF BALLAST
(a) Transfer and uniform distribution of the wheel set forces on the formation (As uniform and as low
intensity of pressure as possible).
(b) Elastic behavior to reduce dynamic impact stresses.
(c) Holding the track in vertical, lateral and longitudinal direction without much of permanent
deformations.
(d) Efficient drainage.
(e) Media for track geometry correction.
3. REQUIREMENTS OF GOOD BALLAST MATERIAL
To achieve the functions as described in para-2, the ballast should have following properties :
(i) It should be tough and wear resistant.
(ii) It should be hard without getting crushed under the moving loads.
(iii) It should be generally cubical having sharp edges.
(iv) It should be non-porous and non-absorbent of water.
(v) It should resist attrition.
(vi) It should be durable and should not get pulverized under the weather conditions.
(vii) It should provide good drainage of water.
(viii) It should be cheap and economical in price.
3.1 Strength and durability
Ballast should have sufficient strength to resist all types of loads it receives. No single parameter can
describe the strength of ballast to satisfy various types of loading patterns viz. Compression, impact,
abrasion, attrition, etc. therefore, different railways use different strength parameters to specify the ballast
towards strength parameters.
Durability of ballast is governed by its mineral composition and porosity. Since ballast is used in large
quantities, therefore, it is always advisable to use local material, if it satisfied other requirements of the
ballast. However, durability may be determined indirectly, by water absorption test and the specific gravity
of ballast.
3.2 Voids
Voids in ballast plays a key role in providing elasticity to the track. Quantity of voids depends upon
shape, size and grading of ballast. Cubical shape, larger size and uniform grading provides more voids to
ballast. However, to achieve stability profile, slight grading of ballast is necessary. Flakiness and elongation
index affects the stability of profile and wear & tear of ballast.
It is not only necessary to provide more initial voids but also it should be ensured that these voids are
not reduced (ballast fouling), in service, within a reasonable time of 10-12 yr. by way of wear & tear of
ballast or otherwise.
3.3 Surface Friction
Load distribution and holding up of the track with minimum plastic deformations are mainly facilitated
by the inter-particle friction (shear strength) of the ballast. This inter-particles friction depends upon :
1. Shape of Ballast Particles (Pieces)
2. Surface Texture.
3. Conditions of Surface like Dry, Wet Etc.
4. Presence of Friction Reducing Material like Clay (Due To Mud Pumping etc.).
5. Level of Compaction and Consolidation of Ballast.
6. Quantity and Ballast Profile.
4. BALLAST CAKING
Wear and tear of ballast causes caking up of ballast there by reducing voids and inter particle friction.
This further reduces the elasticity and hence more impact loads are transferred to the formation leading to
mud pumping situation. Wear and tear of ballast may be due to transfer of wheel-set loads, maintenance
operations and climatic disintegration.
5. SCREENING OF BALLAST
Removal of the material from ballast to restore its voids is called screening of ballast. It may be
shoulder screening, shallow screening or deep screening as the case may be, as decided as per extent of
ballast fouling and maintenance problems. Screening of ballast is very costly and inconvenient work.
Therefore, enough preventive measures in terms of quality of ballast shall be taken to reduce the incidence
of screening of ballast.
6. BALLAST PROFILE
The design of ballast profile depends upon :
(a) Length of sleeper and type of sleeper.
(b) Shoulder width (width beyond the end of sleeper)
(c) Slope of ballast (side slope)
(d) Ballast cushion (depth measured below bottom of sleeper, see cushion).
(e) Transverse slope of formation.
(f) Type of track structure like LWR, SWR or fish plated track.
Out of above, ballast cushion and type of track structure are dependent on traffic density (GMT), speed
& Axle loads.
Various ballast profiles, adopted by the Indian Railways are given in Figure-4.1 to Figure 4.6
attached in the last of this chapter.

N.B. LWR (long welded Rails)

SWR (short welded Rails)
7. SUB-BALLAST
Whenever, the requirement of ballast cushion exceeds the manageable/economical limits because of
either higher traffic density or poor formation, a layer of sub-ballast (refer unit on Track Formation) is
placed between ballast & formation so that the depth of ballast cushion is limited within manageable limits
of 30-35 cm.
8. ASSESSMEANT OF BALLAST REQUIREMENTS
8.1 The requirement of ballast shall be assessed separately for:-
(i) Making good the deficiencies as existing in track.
(ii) Making good the deficiencies arising out of overhauling, through Packing & deep screening.
(iii) For providing adequate cushion in the case of mechanical tamping.
(iv) For providing extra cushion while converting into LWR
8.2 The ballast required for maintenance purpose shall be estimated by assessing the quantity
approximately, if necessary by a survey, in every 1 kilometer. Care should be taken that the core (ballast
below the sleeper) under the sleeper are not disturbed.
8.3 In case of deep screening, assessment of ballast required for recoupment and providing standard
section should be made by Deep Screening the ballast section to the full depth in a rail length for 2-3
sleepers at every ½ to 1 km.
9. BALLAST SPECIFICATINS
9.1 Basic Quality Ballast should be hard, durable and as far as possible angular along edges/corners,
free from weathered portion of parent rock, organic impurities and inorganic residues.
9.2 Particle Shape : Ballast should be cubical in shape as far as possible. Individual pieces should not
be flaky and should have generally flat faces with not more than two rounded/sub rounded faces.
9.3 Physical Properties: Following physical properties as determined in accordance with Indian
standard codes as specified by Indian Railways are shown in Table below
Specifications for Physical properties of Ballast
Specification BG, MG & NG NG & MG (Other than those
(Planned/sanctioned for planned for conversion)
conversion)
Aggregate Abrasion Value As per 30% max* 35% max
IS:2386 (Pt. IV)-1963
Aggregate Impact ValueAs per 20% max* 30% max.
IS:2386 (Pt.IV)-1963
*Relaxable up to 35% and 25% respectively on techno-economic grounds by CTE on open Line and
CAO/C for construction projects.
Flakiness index
(As per IS: 2386 pt.1-1963) Max 50% NA
(As per IS: 2386 pt. III-1963) Max 1% NA
Water absorption
9.4 SIZE AND GRADATION
9.4.1 Ballast should satisfy the following size and gradation
(a) Retained on 65mm Sq. mesh sieve 5% Maximum
(b) Retained on 40mm Sq. mesh sieve* 40%-60%.
Not less than 98% for machine crushed
(c) Retained on 20mm Sq. mesh sieve
Not less than 95% for hand broken

* For machine crushed ballast only.

9.4.2 Oversize ballast
i) Retention on 65mm square mesh sieve.
A maximum of 5% ballast retained on 65mm sieve shall be allowed without deduction in payment.
In case ballast retained on 65mm sieve exceeds 5% but does not exceed 10% payment at 5%
reduction in contracted rate shall be made for the full stack. Stacks having more than 10% retention
of ballast on 65mm sieve shall be rejected.
ii) In case ballast retained on 40mm square mesh sieve (machine crushed case only) exceeds 60%
limit prescribed in 2.3.1 (b) above, payment at the following reduced rates shall be for the full stack
in addition to the reduction worked out at i) above.
 5% reduction in contracted rates if retention on 40mm square mesh sieve is between 60%
(excluding) and 65% (including)
 10% reduction in contracted rates if retention on 40mm square mesh sieve is between 65%
(excluding) and 70% (including)
iii) In case retention on 40mm square mesh sieve exceeds 70% the stack shall be rejected.
iv) In case of hand broken ballast supply, 40mm sieve analysis may not be carried out. The executive
may however ensure that the ballast is well graded between 65mm and 20mm size.
9.4.3 Under size ballast
The Ballast shall be treated as undersize and shall be rejected if-
(a) Retention on 40mm sq. Mesh sieve is less than 40%.
(b) Retention on 20mm sq. Mesh sieve is less than 98% (for machine crushed) or 95% (for hand
broken)
9.4.4 Method of Sieve Analysis
i) Sieve size mentioned in this specification are nominal sizes. The following tolerances in the size of
holes for 65, 40 and 20mm nominal sieves size shall be permitted.
 65mm Square Mesh Sieve Plus Minus 1.5mm
40mm Square Mesh Sieve Plus Minus 1.5mm
20mm Square Mesh Sieve Plus Minus 1.0mm
Mesh sizes of the sieves should be checked before actual measurement. The screen for sieving the
ballast shall be of square mesh and shall not be less than 100cm in length, 70cm in breadth and
10cm in height on sides.
ii) While carrying out sieve analysis, the screen shall not be kept inclined, but held horizontally and
shaken vigorously. The pieces of ballast retained on the screen can be turned with hand to see if
they pass through but should not be pushed through the sieve.
iii) The percentage passing through or retained on the sieve shall be determined by weight.

9.5 METHODS OF BALLAST MEASUREMENT

9.5.1 Stack Measurement
Ballast stack shall be made neat, plane, well drained and firm ground at a site prespecified by accepting
authorities. Edges of stack shall be uniform and the minimum height of stack shall be 1 m except in hilly
areas where it may be 0.5 m. The side slopes of stack shall not be flatter than 1:5:1 (H:V), the cubical
content of stack shall not be less than 30m3 in plain area and 15m3 in hilly areas, Stack measurement may
be recorded in ballast depot or along the side of railway track as the case may be.
9.5.2 Wagon Measurement
Ballast can also be measured after it is directly loaded into the wagons provided the cubical content are
determined and recorded and top fill line is marked over the wagon.
9.5.3 No shrinkage allowance for voids is to be provided for while recording measurements.

9.6 SAMPLING AND TESTING

9.6.1 Acceptance
Fulfillment of size, gradation, and physical properties shall be the criteria for acceptance of supply in
the field.
9.6.2 Norms for supply of ballast.
On supply of the first 100 cum. The test for size, gradation, abrasion value, impact value, flakiness
index and water absorption shall be carried out by accepting authority. Further supply shall be carried out
only after this ballast satisfies the specification for these tests.
9.6.3 Subsequent test shall be carried out as follows :-
Table 2 : Frequency of Sampling and sample size for Acceptance of Ballast.
Supply in stacks
For each stack of For each stack of
Volume less than volume more than Supply in
100 cum. 100 cum. Wagons
Size and Gradation
Test
Testing Frequently One for each stack One for each stack One for each wagon
Sample Size **0.027 cum. **0.027 cum. For **0.027 cum
Every 100 cum. or Part
thereof
Abrasion Value
Impact Value,
Flakiness Index
And Water Absorption
Test
Testing Frequently One for every 2000 cum.
Sample size 45 kg.
** Sample should be collected from different part of the stack/wagon using a wooden box of internal
dimension 0.3x0.3x0.3m.
Recommended Depths of Ballast requirements Fish plated track.

Quantity of Ballast Required/Meter

Group Recommended On Straight and Curves of Radius Sharper
Depth Ballast Curves of Radius than 600 M.
Cushion ‘Y’ Flatter than 600 M.
A 300 mm. 1.588 M3 1.636 M3
B&C 250 mm. 1.375 M3 1.416 M3
D 200 mm 1.187 M3 1.202 M3
E 150 mm. 0.956 M3 0.996 M3
Note
1. In the case of ordinary fish-plated track ballast cushion to be increased to 400 mm. on outside of
curves sharper than 600 M. Radius.
2. In short welded panel track ballast cushion to be increased to 400 mm on outside of all curves flatter
than 875 Radius and to 450 mm in the case of curves sharper than 875 M. radius.
3. To be increased to 550 mm on the outside of turn in curves of turnouts in passenger yards.
4. In case of S.W.R track, the minimum depth of cushion shall be 200 mm.
 Recommended Depths of ballast requirements for fish plated track
Routes Quantity of Ballast required per Metres on
Recommended Straight & Curves of Curves of Radius
Depth of Ballast Radius flatter than 600M sharper than 600M

Q Routes 100 kmph 300 mm 1.070 M3 1.145 M3

Q Routes of less than

100 kmph 250 mm 0.965 M3 1.033 M3

R-1 Routes 250 mm 0.965 M3 1.033 M3

R-2 Routes where

LWR is contemplated 250 mm 0.965 M3 1.033 M3
R-2 Routes where LWR is

not contemplated 200 mm 0.817 M3 0.905 M3

R-3 Routes 200 mm 0.817 M3 0.905 M3
S Routes 150 mm 0.673 M3 0.725 M3
Note :
1. In case of fish plated track ballast cushion to be increased on the outside of curves to 400 mm for
curves sharper than 600 m Radius.
2. In short welded panel to be increased to 350 mm in case of all curves flatter than 600 M radius and
to 380 mm in case of curves sharper than 600 M radius.
3. To be increased to 550 mm on the outside of turn in curves of turn-outs in passenger yards.
4. In the case of S.W.R. track, the minimum depth of cushion shall be 200 mm.
Gauge Type of A B C* D E* F F1 H
Sleeper
BG Wooden 250 350 500 2270 2420 6850 6250 540
300 350 500 2270 2420 6850 6250 590
200 over
150 350 500 2270 2430 6850 6250 640
Sub-Ballast
1676 Steel 250 350 500 2280 2430 6850 6250 550
Trough 300 350 500 2280 2430 6850 6250 600
200 over
150 350 500 2220 2430 6850 6250 650
Sub-Ballast
PRC 250 350 500 2525 2675 6850 6250 640
300 350 500 2525 2675 6850 6250 690
200 Over
150 350 500 2575 2675 6850 6250 740
Sub-Ballast

Note :
1. The minimum clean stone ballast cushion below the bottom of sleeper is 250 mm.
2. For routes where speeds are to be more than 130 kmph ballast cushion is 350 mm or 200 mm
along with 150 mm of sub-ballast.
3. *Extra ballast on outer side of curves only.
4. Suitable slope shall be given for side slope of ballast profile.
5. Dimensions for formation width (F and F1) are given for straight portion only. This should be
suitably increased taking into account extra ballast shoulder on outside of curves and for super
elevation.
6. All dimensions are in millimeters.
 Gauge Type of A B C* D E* F F1 H
Sleeper
Wooden 250 350 500 1760 1930 5850 5250 510
300 350 500 1760 1930 5850 5250 560
200Over
150 350 500 1760 1930 5850 5250 670
Sub-Ballast
MG Steel 250 350 500 1790 1940 5850 5250 520
1000 Trough 300 350 500 1790 1940 5850 5250 570
200 Over
150 350 500 1790 1940 5850 5250 620
Sub-Ballast
PRC 250 350 500 2025 2175 5850 5250 510
300 350 500 2025 2175 5850 5250 560
200Over
150 350 500 2025 2175 5850 5250 610
Sub-Ballast
CST-9 250 350 500 1730 1860 4880 4270 510
300 350 500 1730 1880 4880 4270 560
200Over
150 350 500 1730 1880 4880 4270 610
Sub-Ballast

Note :
1. The minimum clean stone ballast cushion below the bottom of sleeper to A-250 mm.
2. For routes where speeds are to be more than 100 kmph. A-300 mm or 200 mm along with 150mm of
sub ballast.
3. *Extra ballast On outer side of curves only.
4. Suitable slope shall be given for side slope of ballast profile.
5. Dimensions for formation width (F and F1 ) are given for straight portion only. This should
be suitably increased taking into account extra ballast shoulder on outside of curves and on super
elevation.
6. All dimensions are in millimeters
Gauge Type of A B C* D E* F F1 H J
Sleeper
Wooden 250 350 500 2300 2340 12155 11535 570 5300
300 350 500 2300 2340 12155 11535 620 5300
200Over
150 350 500 2300 2340 12155 1535 670 5300
Sub-
Ballast
BG Steel 250 350 500 2320 2350 12155 11535 580 5300
1676 300 350 500 2310 2350 12155 11535 630 5300
200Over
150 350 500 2310 2350 12155 11535 680 5300
Sub-
Ballast
PRC 250 350 500 2525 2450 12155 11535 700 5300
300 350 500 2525 2460 12155 11535 750 5300
200Over
150 350 500 2525 2460 12155 11535 800 5300
Sub-
Ballast

Note :
1. The minimum clean stone ballast cushion below the bottom of sleeper IS 250 mm.
2. For routes where speed are to be more than 130 kmph. Ballast Cushion is 300mm or 200mm
along with 150 mm of sub-ballast.
3. *Extra ballast on outer side of curves only.
4. Suitable slope shall be given for side slope of ballast profile.
5. Dimensions for formation width (F and F1) are given for straight portion only. This should be
suitably increased taking into account extra ballast shoulder on outside of curves and on
super elevation.
6. All dimensions are in millimeters.
 Gauge Type A B C* D E* F F1 H J
Sleeper
Wooden 250 350 500 1790 1850 9810 9210 535 3960
300 350 500 1790 1850 9810 9210 585 3960
200 Over
150 350 500 1790 1550 9810 9210 635 3960
Sub-
Ballast
250 350 500 1810 1960 9810 9210 540 3960
MG Steel 3 00 350 500 1810 1960 9810 9210 590 3960
1000 Trough 200 Over
150 350 500 1810 1860 9810 9210 640 3960
Sub-
Ballast
PRC 250 350 500 2025 1970 9810 9210 595 3960
300 350 500 2025 1970 9810 9210 645 3960
200 over
150 350 500 2025 1970 9810 9210 695 3960
Sub-
Ballast
CST-9 250 350 500 1750 1810 9810 9210 535 3960
300 350 500 1750 1810 9810 9210 585 3960
200 Over
150 350 500 1750 1810 9810 9210 635 3960
Sub-
Ballast

Note :
1. The minimum clean stone ballast cushion below the bottom of sleeper 250 mm.
2. For routes where speeds are to be more than 100 kmph. Ballast cushion 300 mm or 200 mm
along with 150 mm of sub-ballast.
3. *Extra ballast On outer side of curves only.
4. Suitable slope shall be given for side slope of ballast profile.
5. Dimensions for formation width (F and F1) are given for straight portion only. This should be
suitably increased taking into account extra ballast shoulder on outside of curves and on super
elevation.
6. All dimensions are in millimeters.