Mumbai Ahmedabad Bullet Train project will have J- Slab ballastless track system based on Japanese Shinkansen track system which will be used for the first time in India. This track system consists of four main components viz. RC Track Bed, Cement Asphalt Mortar (CAM), Pre-cast Track Slab and Rails with Fasteners.

To produce these J-slabs, two state-of-the-art Track Slab Manufacturing Facilities (TSMF) have been set up in Kim near Surat and Anand in Gujarat. These factories are designed to produce high grade concrete slabs with accurate dimensions to ensure a steady supply of this critical component used in the project. The track slabs produced in these factories are kept in the stacking area at the factory and are transported in trailers to Track Construction Base (TCB) which serve as a base for handling track slabs, machineries, equipment on the ground and at the viaduct.

To facilitate the track construction including handling of rails, track slabs, machineries and equipment on ground and at the viaduct, dedicated Track Construction Bases (TCBs) are set up. At present, ten track construction bases, four in between Surat- Bilimora - Vapi and six in between Vadodara – Anand - Ahmedabad are operational.

Details of track construction work completed

Sr. No.  Track Activity                                   Status (in route km)

1.                     RC Track Bed Laid                                185

2.                     Track Slab Manufactured                 188

3.                    Track Slab Laid and CAM Injected         70

 

The process of track installation is fully mechanized with cutting edge machinery especially designed and manufactured, as per Japanese construction practices (most of them manufactured in India).

Details of track construction machinery:

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 at the TCB (track construction base) over the viaduct. The same have to pass through stringent approval methodology, prior to commencement of rail welding, fit for high speed train operation at 320 kmph. The training & certification for rail weld finishing and rail weld inspection & testing have been done by the JARTS (Japanese company), which is pre-requisite to start the welding works.

 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.

Rail Feeder Car (RFC)

200 m long panels are loaded in RFC 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, bed.

Cement Asphalt Mortar Injection Car (CAM Car)

After placement of track slabs on the RC bed, CAM car runs on the other track (i.e. on both UP and DN line temporary track at standard gauge is to be laid). This CAM car mixes the CAM ingredients in designed proportion and thereafter, CAM mix is injected under the slab (in special bags) to maintain the required line and level of the final track.

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