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DETAILS OF FACILITIES AND EQUIPMENT AVAILABLE FOR MANUFACTURING CONCRETE SLEEPERS


The various facilities and the equipment available with the plant at Banmor are described in details as follows:-

CONCRETE MIXERS
The concrete mixer used for mixing the aggregates and the cement, is a cyclo-pan mixer, in which the drum and the blades rotate in opposite direction, thus ensuring homogeneous mixing in the least possible time. The capacity of the drum is 250 litres (2 cement bags), this can produce mix sufficient for 2 sleepers, in one batch.




  Cyclo-pan Concrete Mixer

The aggregates are weighed using a state of the art Micro-processor based Load Cell automatic weigh batcher, which ensures accuracy of the weight of the aggregates. The bin-doors of the aggregates are controlled by the Micro-processor, using pneumatically operated cylindrical jacks, thus eliminating any chances of human error.The water is added by using electronically controlled water measuring tank.


  Micro-processor based Weigh-Batcher

Besides the main mixer, the factory has got another standby mixer, with manual weighing, which can be used in case the main mixer breaks down.


STEAM BOILER AND STEAMING CHAMBERS
The boiler used for generating steam is a Coal fired, fire tube type boiler with evaporating capacity of 500kg/hr. The water is first filtered and softened using Zeolite resin based water softner and LDPE Filter media based water filters.

The factory has got 7 steaming chambers sufficient for curing 75 benches at a time. Each chamber is 13m long and about 6m deep. It can hold 11 benches vertically on top of each other. Thus, 300 sleepers can be cured in one shift, meaning a capacity of producing 15,000 sleepers per month, considering two shift working and 25 working days in a month.


Steam Boiler


STRESS BENCHES AND SLEEPER MOULDS
 At present, the factory possesses 70 stress benches. Each stress bench contains 4 moulds. Besides the moulds in the benches, 20 moulds are kept extra, so that any repair and periodical maintenance can be carried out.


FREQUENCY CONVERTERS AND HIGH FREQUENCY VIBRATORS
2 frequency converters are used to change the frequency of current from 50Hz to 150Hz and to step down the voltage from 440V AC to 48V DC. The High Frequency Shuttering Vibrators of 9000 RPM then use this current. 16 such high frequency vibrators are there in the factory.


TENSIONING MACHINE AND HYDRAULIC JACKS
The tensioning machine and the hydraulic jacks are used to give required load to the HTS Wires. 3 sets of machine and hydraulic jacks are available with the plant.


GANTRIES AND ELECTRICAL HOISTS
Electrical hoists and gantries are used to handle and transport the sleepers from one place to another. The benches, after casting, are put in the steam chamber with the use of electrical hoists.2 electrical hoists, each of 3- tonnes capacity, at both the ends, are used to put the bench into steam chambers after casting. 2 stand-by hoists are also there in case of a break-down.


A Bench being put in Steam Chamber using Electrical Hoists

A 2 ton hoist is used to take out the sleepers from
the moulds at the time of demoulding. For loading purpose and for keeping and taking out the sleepers from the water curing tanks, 4 gantries with electric hoists are used. The Main Gantry, with a span of about 20m, and electrical hoist of 4 ton capacity, can handle 10 sleepers at a time. It is driven by 2 electric motors of 7.5 HP each. The other gantries have handling capacity of 4 sleepers at a time. 




Main Loading Gantry with Electrical Hoist


ELECTRIC GENERATORS AND VOLTAGE STABILISERS
The unit has electric connection from State Electricity Board for 100H.P., but for self sufficiency, the factory has captive power generation facility using Diesel Generators for 102.5KVA. To get quality power and voltage, the factory has also installed an online Servo Power Stabiliser of 100HP capacity.


CEMENT GODOWN AND SHED FOR STORAGE OF HT STEEL WIRE
The factory has a large godown of waterproof structure to store 800MT of cement. The cement is normally received by railway rake, which is unloaded using our own railway sidings.The High Tensile Steel wire is stored under GI Sheets shed. The shed is sufficient to store about 200MT of wire after cutting it to required length. Besides this, another shed can be used to store about 100MT of wire in coils.


WATER CURING TANKS
There are 8 Nos. of water curing tanks, each of 15m 
long X 10m wide X 3m deep.
Each tank can hold about 11,000 nos of sleepers. 
The curing tanks are made of RCC with waterproof linings. 
These curing tanks are sufficient for a monthly production 
of 15,000 sleepers.

 


Water Curing Tanks

MECHANICAL WORKSHOP
The workshop houses a lathe machine, a bench grinder, a tower drilling machine, welding plants, gas cutting equipment etc. All the regular maintenance of the machines, benches and moulds is carried out in the factory workshop itself. For this purpose, the unit has employed technically qualified electricians and the foremen.


LABORATORY AND THE TESTING FACILITIES
The factory has a fully equipped laboratory to test the cement, the aggregates and the sleepers.The cement testing facilities consist of checking the fineness by Blain’s Air Permeability Apparatus, checking the Initial and Final Setting time by Vicat’s apparatus, finding strength of cement by casting cement mortar cubes of 50MM with standard sand. The cement is checked for all these parameters once every week.


Mortar Cube Making Machine

The tests for aggregates consist of Sieve Analysis, Flakiness and Elongation Index, Moisture Absorption Test, Crushing Strength test etc. All these tests are carried out once in a week, except moisture absorption test, which is carried out daily

The testing facilities for the sleeper available 
at site are as under:-      

  • Dimensional Checking

  1. Length of the sleeper  

  2. Width-at rail seat, at ends and at center 

  3. Height-at rail seat, at ends and at center 

  4. Outer to outer Guage-distance between the outer inserts 

  5. Between Gauge-distance between inserts
      at the rail seat  

  6. Slope at the rail seats

  7. Toe Load at the rail seats


Sieve Analysis Test Using Sieve Shaker

  • Static Bending Tests

  1. Load at the Rail Seats

  2. Load at Center Top

  3. Load at Center Bottom

  4. Moment Failure Test


Testing Outer Guage of the Sleeper

  • Concrete Strength Tests
  1. Cube Strength at Demoulding
  2. Cube Strength after 15 days Water Curing
  3. Flexural Beam Test for tensile strength of the Concrete.


Checking Load at Center Top

  • Checking electrical resistance between the Rail Seats using Resistance Meter and by comparing Bulb Glow method.
  • Checking the Profile of the Moulds using various templates and gauges.
  • Calibration of all the Gauges and meters using master gauges and Proving Rings.

Checking Concrete Cube Strength

LOADING FACILITIES
The factory site is located on Main trunk route of Central Railways at Banmor, which lies between Agra and Gwalior of the Jhansi Division. The factory has its own railway siding which can accommodate 15 BFR/BRH/BCX or 30 MKCs at a time. It is possible to load almost 2000 sleepers into railway wagons in a single placement.




Loading gantry

Banmor is located on NH-3 i.e. Agra- Bombay National Highway. It is very well connected by road to Agra, Etawah(N.R.), Bharatpur(W.R.), Jhansi(C.R.) and Shivpuri, which all lie within a distance of about 100 KM from the factory site. Thus this factory has the unique advantage of serving 3 Zonal Railways of Central, Northern and Western Railways in case of a need. The sleepers can easily be loaded into road lorries/trucks using the available gantries and hoists.


 

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