Bullet Train project: Track construction for Gujarat portion progressing swiftly

New Delhi: State-owned National High Speed Rail Corporation Ltd (NHSRCL) recently confirmed that the track construction work for the Gujarat portion of the Bullet Train project is progressing at an impressive pace, with several significant milestones already achieved.

The initiation of rail welding on the viaduct in Gujarat marks a critical phase in this ambitious project.

The rails, sourced from Japan and each measuring 25 meters long, are meticulously welded together using advanced Flash butt welding (FBW) machines on the Mumbai–Ahmedabad high-speed rail corridor (MAHSR) viaduct to form 200-meter-long rail panels. Currently, 298 such rail panels have been successfully welded, covering approximately 60 kilometres of track.

Established in 2016, the NHSRCL is tasked with managing high-speed rail corridors in India. As a wholly owned subsidiary of Indian Railways, it operates under the Ministry of Railways and the Government of India.

The rail welding process is of paramount importance for ensuring passenger comfort, durability, and safety at high speeds. Before welding, the rail ends undergo a thorough grinding and surface preparation to ensure a flawless surface for joining. Each rail is carefully checked to meet the precise dimensional requirements for welding. Once perfectly aligned, the rails are joined using flash butt welding technology. The welds are then subjected to rigorous inspection using magnetic particles and ultrasonic testing to detect any flaws. If any defects are found, the weld is promptly replaced. The alignment is further verified using special rail tread measuring equipment procured from Japan.

After passing through this stringent procedure, the 200-meter-long rail panels are spread by a specialised rail feeder car to lay a temporary track at Standard Gauge. This facilitates the movement of sophisticated high-end machinery such as Slab Laying Cars and CAM Injection Cars. Subsequently, these rails are fixed on the track slab through rail fasteners for the final track.

To support the track construction, Dedicated Track Construction Bases (TCBs) are being strategically planned and constructed. These bases will handle rails, track slabs, machinery, and equipment both on the ground and at the viaduct.

They will also serve as a base for engineers and other personnel working on track construction. Currently, four TCBs have been made operational in Gujarat, with two located between Surat and Bilimora and two between Vadodara and Anand.

The entire track installation process is highly mechanized, utilizing cutting-edge machinery designed and manufactured to Japanese specifications, either in India or directly purchased from Japan. Four sets of track construction machinery have been arranged for the project, including rail feeder cars, track slab laying cars, related wagons and motor cars, CAM laying cars, and flash butt welding machines.

RC track bed construction has commenced at multiple locations in Anand, Vadodara, Surat, and Navsari districts in Gujarat, with nearly 64 kilometres of RC track bed construction completed.

Track slabs are being separately cast in dedicated track slab manufacturing facilities set up in Kim (near Surat) and Anand. These facilities are equipped with state-of-the-art technologies and infrastructure to produce precise slabs for track construction. To date, more than 23,000 slabs have been cast, equivalent to 118 track kilometres.

To ensure the highest standards of track installation and maintenance, extensive Training and Certification (T&C) courses are being organised for engineers, work leaders, and technicians. Approximately 1,000 engineers will receive world-class skills under the guidance of Japanese experts in relevant fields.

This comprehensive approach to track construction underscores the commitment to delivering a high-speed rail system that meets international standards, ensuring safety, comfort, and efficiency for passengers.

The meticulous planning, advanced technology, and rigorous training programs are setting new benchmarks in railway infrastructure development, promising a future of seamless and sustainable high-speed travel in India.