Our Products #3102672

The country's first ballastless track system
PATIL RHEDA is an in-house design and development based on RHEDA system designed in Germany. Our R&D team has customised this for the requirements of the Indian market. It was used in Jammu & Kashmir and for Delhi airport. Ballastless track system can be integrated optimally into traffic flow and the urban landscape whether for tram systems, underground railways or surface commuter train lines.
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 maintenance-free track system is indeed the more cost-effective solution over the long run.
With Indian Railways still undertaking trial runs with these sleepers, implementation of PATIL RHEDA sleepers has not been widespread. The advantage of these sleepers is its use where ballast cannot be used and especially in tunnels, elevated tracks and station aprons.
The use of PATIL RHEDA sleepers is ideal for laying washable aprons at railway stations thereby improving the cleanliness of the station yards. The station aprons where the PATIL RHEDA sleepers have been implemented include Bhubaneshwar and Kacheguda.
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.

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.
The Plinth Solutions can be implemented in the following situations:
Elevated track
Depots
Tunnels & viaducts
Plinth system of Urban Metro is meant for speeds up to 80 kmph. Presently, the company is executing the construction and laying of Plinth Type Ballastless Track for the Mumbai Metro in partnership with national and international agencies of repute.
Our varied references in this product make us hopeful to aspire for further forthcoming urban metro projects in various cities.

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:
Heavy Haul
High Speed
Mass Rapid Transit Systems in urban areas
All required gauges
All track systems as slab track and ballasted track
All required rail fastenings
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.

Automation in the sleeper industry aims at improving productivity, achieving zero defects and meeting just-in-time supply requirements of the customers. As in the past, Patil Group has emerged as a pioneer in the field of automation also. It is the only group in the country to set up new automated manufacturing facilities to cater to the exacting standards of Indian Railways and other vendors.
The Long Line Technology as the manufacturing process is called, is used to manufacture Pre-Stressed Concrete Sleepers in an automated environment.
Some of the biggest advantages that this technology brings over the conventional technology are reduced dependency on manpower and substantial improvement in quality. Also, the casting time comes down by nearly 25% thereby increasing productivity. This technology helps in manufacturing large quantities of sleepers in least possible time. The regular operations of the sleeper plant such as de-moulding of sleepers, cutting of pre-stressed wire, HTS wire drawing are automated using machines.
This technology permits relaxation and cutting of the prestressed strands and shakeout of the sleepers with no movement of the shuttering, thus eliminating all problems of maintenance or clearance adjustment connected with the moving parts.
The long line system can be applied to any type of fastening: Pandrol, Vossloh, Stedef, D.E. Clips, Denik, KB, etc. The moulds have been designed and created in such a way as to allow changing of the necessary type of fastening simply by replacing the plates with the required cast and housing, the plates being screwed onto the structure of the mould.
The adherent wire system provides considerable savings in sleeper production based on the use of normal market products (pre-stress strands or rods) that do not need special processing or accessories - they are simply drawn between the pre-stressing heads, fixed with ordinary prestressing clamps and then pre-stressed.

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.
Being environmentally friendly since it keeps a check on deforestation, composite sleepers help keep sound pollution low and offer 100% insulation. Even its fasteners are similar to those of wooden sleepers. One of the biggest advantages of these sleepers is that it is 40% cheaper than cost of steel channel sleeper used in girder bridges.
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.
With increasing rail traffic and faster train speeds, railway boards across the globe are migrating to composite sleepers because of their increasingly obvious benefits. Also as the loads per car are increasing and availability of old growth hardwood trees is drastically reducing, the use of composite sleepers has witnessed a huge growth trajectory.
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 selfinsulated.
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.

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 3x3 and 3x7 strand wires for track sleepers and turnout sleepers from its four factories located at Medchal and Bobbilli (in Andhra Pradesh), Ajmer (in Rajasthan) and Patna (in Bihar).
The total production capacity of the three ISO 9002 certified manufacturing plants is 30000 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.
The wire division of the Patil Group has exported over 33, 000 MTs of steel wire to Iraq Railways besides having executed the single largest order for Indian Railways.
PRODUCT DESCRIPTION & SPECIFICATIONS
3 Ply x 3 mm High Tensile Steel Stranded Wires as per IS 6006-1983 (Un-coated) used in Pre-stressed Concrete Industry
7 Ply x 9.5 mm High Tensile Steel Stranded Wires as per IS 6006-1983 (Un-coated) used in Pre-stressed Concrete Industry. This is used in large bridges, Flyovers, Ports and Road Dividers.
4 mm H.T. Wire (Indented) as per IS 6003-1983 Hard Drawn and Stress Relieved for use in Pre-stressed Concrete Industry. This is used in manufacture of Poles & Spun Poles for electrification and telecommunication
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
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)
Shutter Spring Wire for manufacturing of Rolling Spring as per Customer specifications

Aluminum conductor steel reinforced core wire is widely used in overhead transmission line for primary and secondary distribution.
It is manufactured of one or more aluminum as outer wire & wire stranded with zinc coated high strength steel core wire as per IS 398 Part 2 & Part 5

Patil Group is the country's largest supplier of concrete suppliers to the Indian Railways. The company manufactures these pre-stressed concrete (PSC) sleepers across its 12 Plants including two new automatic production plants across the country with a total installed capacity of 4.85 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 cement, 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 company has manufacturing plants located at Anara, Bhubaneshwar (Kaipadar Road), Bilaspur (Kargi Road), Madurai (Tirumangalam), Tumkur, Udwada and Wadiyaram while the new automated plants are coming up at Badi Khatu and Bhurwal. The company is also the country's first ISO certified concrete manufacturing plant.
THE SLEEPERS MANUFACTURED BY THE COMPANY ARE SUITABLE FOR THE FOLLOWING:
Normal Broad Gauge: This sleeper has a trapezoidal cross section having a width of 154 mm at the top and 250 mm at the bottom and a height of 210 mm at rail seat.
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.
Guard Rail: These are used at the approaches to girder bridges to prevent a derailed train from capsizing.
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.
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.
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.
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.

Fasteners are link systems that hold the track to the sleepers. Different types of fasteners are used for different railway tracks. Patil Group entered into a strategic collaboration to develope, manufacture, market and sales 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 Fasteners for Delhi and Chennai Metro Track Projects.
Key advantages:
Cost effective as the majority of the components are manufactured locally
Full fledged technical team for support
Maintenance free, fit-and-forget system
Systems available to suit various tow loads up to 12 KN
VARIOUS TYPES OF PATIL VOSSLOH FASTENING SYSTEMS
SKL 14 for Normal Tracks
It is reliable, safe and maintenance free with long spring deflection, high tensioning force, high creep resistance and effective protection against tilting. Fully automatic track-laying is possible through pre-assembly of all components in the sleeper works.
System 300 for Ballastless Track
Slab tracks meet all the requirements for combined highspeed and heavy load traffic. The rail fastening System 300, which can be pre-assembled, is suitable for all methods of slab track installation.
System DB 336 for Ballastless Track
These are rail fastening systems for ballastless concrete and steel structure. They ensure an effective reduction in vibration emission by means of an elastically supported rail. This system is suitable for standard-gauge railways as well as for urban light railways and can be adapted to local conditions as a result of their high flexibility. It reduces transmission of vibration to the concrete and structure and therefore reduces noise to the foundation of adjacent buildings.
System W 14 HH for Heavy Haul
This fastening system on concrete sleepers for ballasted tracks is primarily used for heavy haul. It has rail tilting protection by a middle bend of the tension clamp and special design of the angled guide plate. It helps reduce maintenance costs due to permanent elastic tensioning of the rail with tension clamps.

Patil Group has diversified into a new business vertical - Elastic Rail Clips and GFN Liners Business to serve Indian Railways and Dedicated Freight Corridor Projects.
ELASTIC RAIL CLIPS :
Tiya Industries
ERC Clips: ERC Clips mark III and V manufacturing unit will be setup at survey no 700A, at Roopangarh Kishangarh Tahsil Ajmer Dist. Rajasthan with a capacity of 36 lakhs pieces per annum for supply to Indian Railways and other Freight Corridors as per RDSO Specifications with RDSO approval.

GFN LINERS:
Krishna Plastics
GFN Liner: GFN liner manufacturing unit will be set up at survey no 700B, at Roopangarh, Kishangarh Tahsil Ajmer Dist. Rajasthan with a capacity of 84 lakhs pieces per annum for supplying to Indian Railways and other Freight Corridors as per RDSO specifications with RDSO approval.

Patil Group of Industries has proved its presence in the field of Flash Butt Welding for Railway through its Flash Butt Welding plant at Moulali, Secunderabad, India. But, in order to explore the opportunities in various upcoming Metro Projects and DFC, Management has decided to expand this business. We are in the advance stage of procurement of Flash Butt Welding Plant from USA.
Introduction
Unlike arc welding that is 'line welding' in which the welding point moves along a prescribed line, flash butt welding is 'plane welding' in which the opposed planes are welded at a stroke. Therefore, this welding method is extremely efficient. As far as application of flash butt welding is concerned, on-site welding of line pipes, welding of rails and welding of marine structures etc. can be cited.
Flash-Butt Welding of Rails
Basics
Flash-butt welding is an electrical resistance welding procedure. Electrical current is conducted through the rail butts and is heating them up to the almost liquid phase. Under high pressure, the rail butts are joint-welded.
Flash welding is a development of resistance butt welding and is particularly suitable for butt welding complex or larger sections. It is used for a wide range of component shaped and sizes from bicycle wheel rims to rails. More efficient energy input, and a more localized and evenly heated zone can be achieved, compared with resistance butt welding.
WELDING SEQUENCE
Following sequence is followed during a welding cycle.
Preflash
Flash
Boost
Upset
Forge
Trimming Upset Metal

The individual rails of 13 m. length received from steel rolling plants are initially sent to Flash Butt Welding Plant at Moulali, Secunderabad. The individual rails are then welded into rail panels of 10-rail length by flash butt welding technique, which involves pre-heating of rail ends by passing high ampere low voltage current and then the rail ends are cyclically brought closer and separated, which results in heavy sparking between the rail ends. After the rail ends are brought to a molten state, butting of rail ends is done under pressure.
Flash butt joints have very high fatigue strength and are preferred to other types of welds. The rail panels of 10-rail length and 20-rail length formed by flash butt welding are transported from the Flash Butt Welding Plant to the field locations by loading into specially designed railway flat wagons. These panels are unloaded at the site through specially designed end unloading chutes fitted to the rearmost wagon.
Important advantages of flash butt welding compared with other joining methods
Reduces maintenance costs
Saves track time
Eliminates corrugation
No weld filler material
Smaller heat affected zone
Smaller annealed zone
Consistent hardness
Highest fatigue resistance
Average life equal to the rail