SOUTH CENTRAL RAILWAY
Safety.387/Fly Leaf/03/2025
Fly Leaf No. 03 / 2025
REVISED JOINT PROCEDURE ORDER FOR LOADING & UNLOADING AND
TRANSPORTATION OF BALLAST DEPARTMENTAL MATERIAL TRAINS (DMTs).
(Ref : Railway Board’s letter No. 2023/CE–II/Safety/Instructions dated 19.12.2024.)
(Ref : JPO No. 2 / 2025 dated 13/18.03.2025 issued by CRSE/Freight/SCR, CELE/SCR,
CFTM/SCR and CTE/SCR.)
No.W.506/General/Track/Ballast loading-Unloading/JPO/2025 Date: 13/18.03.2025.
This Revised JPO is issued to curb the cases of derailments involving the Departmental
Material Trains w.r.t. Railway Board’s Lr. No. 2023/CE–II/Safety/Instructions dated
19.12.2024
Derailments of ballast trains occur primarily due to the following reasons :
i. Obstruction of running rails with excess ballast / heaps during unloading of
ballast.
ii. Ballast between the running rail and check rail at the locations like Points &
Crossings, Level Crossings, etc.
iii. Partial unloading of wagons leading to uneven loading.
iv. While backing of Ballast DMT during block without ensuring clear flange way
clearance towards the gauge face side.
1. General :
i. All the relevant rules given in G&SR chapter IV, GR No's. 4.62, 4.63, & 4.64 and the
relevant SRs pertaining to Working of material trains and Para 806 (I) of IRPWM-
2020 are to be scrupulously followed.
ii. Sr. DEN / DEN / ADEN should counsel the P. Way staff responsible for
loading/unloading of ballast hopper wagons. Trackmen with sufficient
experience only should be deputed for DMT working.
iii. In case Ballast is unloaded by contractual agency, ensure that contractor’s
supervisor is available with authorized photo identity card. Contractor’s
Supervisor / workmen should be trained to work on the ballast train and
properly counselled about the safety measures to be followed during loading /
unloading.
iv. Staff overdue for Medical / refresher course should not be deputed to undertake
the DMT work.
v. Ensure proper planning and preparation before going for block working and
ensure sufficient block before going for unloading.
vi. Any defect noticed on the wagons which may endanger the safety should be
brought to the notice of C&W department i.e., Control & Base depot for immediate
attention by Engineering Department officials during the course of DMT
(Departmental Material Trains) working.
2. Duties of SSE / (P. Way), Train Manager / Loco Pilot :
i. Respective SSE / JE / P. Way supervising the unloading shall be responsible for
efficient functioning of the unloading operation of ballast train.
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ii. The Guard & Loco Pilot shall observe the instructions contained in G&SR Para No.
15.09 for working of Ballast DMT.
iii. The Sectional P. Way Engineer, not below the rank of JE/P. Way shall be
responsible for :
a. Supervising safe unloading of ballast.
b. Clearing of unloaded ballast, so that ballast does not infringe the Standard
Moving Dimensions.
iv. The loco pilot of ballast train shall be vigilant and follow the instructions of
P. Way Engineer available in loco driving cab, who shall be on constant look out
for signals from sectional P. Way Engineer / Guard while unloading of ballast and
follow the signals given from rear of the train or otherwise.
v. A continuous proceed hand signal shall be shown by the Train Manager
throughout the movement of the train during unloading.
vi. During engine reversal, brakes of entire formation are to be released by P. Way
staff.
3. Examination of rake before sending to ballast depot for loading :
i. All ballast wagons / sleeper carrier wagons of material trains should have a
nominated Base depot and name of the nominated depot should be clearly
stencilled on these wagons.
ii. These trains should be offered for examination at the Base depot at least once in
a month where they will be thoroughly examined as per prescribed maintenance
instructions.
iii. Door operating mechanism of all the ballast wagons should be maintained
properly to ensure smooth and trouble-free operation of doors.
iv. The rake should be offered for checking in empty condition at the time of issue of
BPC, train examination staff should ensure that all the doors are kept in working
condition with door fittings & gears intact. All the doors should be properly
closed. BPC should be clearly endorsed by hand or with Stamp as “All unloading
gears of hoppers have been lubricated, checked and doors found in working
condition".
v. The originating Brake power of these trains should not be less than 90%. The
validity of the BPC for DMT is 30 days.
vi. The SSE / JE / P. Way shall take over the rake at TXR depot and examine that all
unloading gears are in working order to avoid any problem at loading point. A
joint note will be prepared by both SSEs.
vii. The SSE / C&W will keep stock of necessary fittings for maintaining rakes. The
SSE / JE / P. Way will then be responsible for fittings available in the rake till the
rake is in his charge. When the rake is sent for TXR examination after expiry of
BPC, the list of missing fittings will be prepared w.r.t. previous joint note drawn
between SSE / C&W and SSE / JE (P. Way) at the time of taking over.
viii. The BPC is valid for movement of the rakes over SCR jurisdiction only.
ix. It is the responsibility of SSE / P. Way in-charge of Ballast depot to move the rake
to Base depot in Empty condition prior to expiry of BPC, so that running of these
trains with invalid BPC is completely avoided.
x. After loading / unloading, TMLP check should be conducted for ensuring safe
running of DMT.
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4. Pre-loading of the Ballast at depot :
i. SSE / P. Way in-charge of Ballast Depot must ensure oiling and greasing of door
operating mechanism in all the wagons of BOBYN rakes at Ballast Depot before
loading of every trip and must keep a proper record in the form of a Log Book.
The sectional ADEN and Sr. DEN during their inspection at ballast Depot should
check the Log Book and ensure that the same is properly maintained.
ii. Door operation of all the wagons should be checked before offering the rake for
loading of ballast.
iii. Wagon with defective doors should not be permitted for loading and prominently
marked as “Not to be loaded” and the same to be informed to C&W control for
attending repairs.
iv. Defective wagon should be examined and attended by C&W staff. If it is not
possible to attend the repairs, same should be booked to Base depot for attention.
v. SSE / P. Way / In-charge of Ballast Depot will maintain a Log Book in the
following pro-forma in which deficiencies observed before loading of rake should
be entered :
Deficiencies observed
BOBYN Nos. in BOBYN Nos.
BOBYN which door in which
BOBYN Nos. Oiling and Any other
Nos. in opening Signature
in which Greasing remark of
Date of doors are which gap assembly is of the
Checking observed very tight and done and the
inspecting
badly doors inspecting
even in is not working officials
jammed and
closed smoothly and handles have officials
could not be free
position of doors opened
opened movement
doors with a lot of
extra effort
1 2 3 4 5 6 7
vi. In case, any partially unloaded wagon is noticed after placement of empty rake
for loading of ballast, the wagon(s) should be examined for defective doors.
vii. If the left-over ballast is due to defective doors, the quality should be measure
and record kept separately for adjustment / accounting of ballast at a future date
by SSE / P. Way in-charge of Ballast Depot. The wagons with defective doors will
not be loaded further.
viii. While loading the ballast, it must be ensured that there is no uneven loading in
any hopper.
ix. Before entering into block section, opening of doors should be checked and if
some of the doors of any BOBYN are not opening properly, unloading should not
be done from that wagon and C&W staff should be booked on the next day to
attend the same in the depot.
x. The list of deficiencies should be handed over to TXR when rake goes for issuing
BPC.
5. Action to be taken prior to departure of Ballast DMT from depot :
The In-Charge of the Ballast Depot should ensure that the BOBYNs are loaded &
levelled up to the pre-determined paint mark depending on the Carrying Capacity
of the BOBYN.
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6. Action to be taken prior to departure of Ballast DMT before taking the block :
i. When the rake arrives, it shall be checked by the concerned SSE / JE (P. Way) for
jammed doors / defective door opening mechanism. If after making all efforts to
open the door fails, all such wagons with defective / jammed doors shall be
reported to C&W control through SM / Control message.
ii. If the wagon cannot be attended at site, the wagon should be marked as “NOT FIT
FOR UNLOADING”. Such wagons should then accordingly be planned to be
detached and sent to C&W depot by SM concerned for necessary attention.
iii. The ballast train should be accompanied by a qualified Engineering Official in-
charge not below the rank of JE (P. Way) and one efficient Blacksmith with
required tools. He should be well conversant with the rules & regulations
pertaining to the working of DMT. The Official-in-charge should have the details
of exact location at which the ballast has to be unloaded, duly approved by SSE /
P. Way or ADEN. Proper planning for unloading of ballast hoppers TP wise should
be done by SSE / JE / P. Way in advance and clear signal should be shown to
drivers to stop at exact required locations.
iv. SSE / JE / P. Way should always be available during unloading of Ballast DMTs.
SSE / JE should remain at site after completion of unloading and clear the track
from heaps of ballast which obstruct DMT movement duly ensuring closing of the
doors of empty hopper wagons.
v. Adequate trained / competent experienced labour shall be made available during
unloading of Ballast DMT.
vi. Ballast train should not be taken in to section for unloading if any hopper is
having uneven load. The unevenly loaded wagon should be adjusted before
taking in to the section.
vii. Ensure that the safety equipment and first aid boxes are available with
supervisor and are in good working order and in updated condition.
viii. In case of non-operation of doors detected after loading of ballast / movement of
DMT, a message to be given to C&W control for arranging staff to attend.
ix. Manpower Requirement:
a. 02 SSE / JE / (P. Way) should always be available during unloading of ballast
DMT. One SSE / JE (P. Way) should remain at site after completion of ballast
unloading for ensuring clearance of track and S&T gears from unloaded
ballast.
b. Sufficient (minimum12-15) labours should be available.
c. A Blacksmith for handling jammed gears of door flaps, if any, shall also
accompany the ballast DMT.
7. Action to be taken during unloading of Ballast DMT by SSE/JE (P. Way) for
unloading :
i. Unloading should be done during daylight hours from sunrise to sunset.
ii. Direct unloading of ballast on Platform lines should not be undertaken.
Ballast may be first unloaded on the adjoining non-platform lines in phases
and then taken to Platform lines.
iii. DMT should not be moved at higher than 8 to 10 KMPH speed while
unloading ballast. Also, DMT shall move only in one direction and no pushing
back without clearing flange way is permitted.
iv. Protection of the ballast train as per GR 15.09 and IRPWM Para 806 must be
ensured.
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v. While ballast train is working, it should be ensured that all the doors are
opened slowly to avoid sudden discharge and uneven spreading of the
ballast. On curves, inner side door should be adjusted so that the required
quantity of unloading is ensured on both the sides of the track.
vi. While unloading ballast from hoppers, care should be taken in Point and Xing
Zones, so that check rails and gap between tongue rail and stock rail are clear.
(Motors of points be covered with any wooden / MS sheet to avoid dropping
of ballast between point rods)
vii. DMT should not be stopped while unloading is in process. If the ballast train
has stopped during unloading, it should be ensured that the ballast is clear off
the top table of rail and flange way before starting the train.
viii. All TL JB (Track Lead Junction Box) should be kept clear off ballast. OHE mast
should be clear off ballast so that it can be checked whether bonding of mast
with rail is intact or not.
ix. If for any reason one side door is not opened opposite door should also be
closed so that uneven unloading is avoided.
x. Due to poor visibility at the time of unloading, if it becomes difficult to
exchange signal between LP and Train Manager / SSE / JE / P. Way, Walkie
Talkie sets should be made available to the LP and Train Manager / SSE / JE /
P. Way for proper and safe working of DMTs. Walkie-Talkie sets should have
particular channel for Engg. staff so that loco pilot will not get disturbed and
loco pilot will be advised of movements through the person available on
engine orally. Sufficient Nos. of P. Way staff should be provided to exchange
signal between driver and Guard / SSE / JE / P. Way.
xi. Wagons which cannot be opened / unloaded even with the help of
Blacksmith, empty rake with such unloaded wagons shall be taken to nearest
yard / stabling lines for getting the door attended by TXR. After repair of
defective doors, ballast from these wagons shall be unloaded at convenient
locations, ballast accounted for and empty rake dispatched to loading depot.
By mistake, if unloading is done unevenly those rakes should not be taken on
to loop line via turnouts and also try to move such wagons on curves with
restricted speed with all precautionary measures.
8. Action to be taken after unloading of Ballast DMT by SSE/JE (P. Way) :
i. After unloading the ballast, it must be physically ensured that no ballast is left
in the wagon. In case any ballast is left in the wagon for unloading during
next block period, such ballast in the wagon shall be levelled manually duly
taking care of OHE lines and the DMT must be taken to nearest station with
speed restriction as considered necessary ensuring that speed is not more
than 10 kmph.
ii. SEJs should be cleared off stone ballast after unloading.
iii. Ensure clearance of ballast heaps properly to avoid jamming of signal rods,
gears and lock bars after unloading.
iv. Ensure that unloaded ballast from train should be kept clear off moving
dimensions. If required suitable SR may be imposed.
v. SSE / JE / P. Way who is official In-charge of DMT will ensure before leaving
the site that no stone is left inadvertently between the stock rails, tongue rail,
Check rail & nose of crossings etc.
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vi. Ballast which has fallen between the running rail and check rail on curves &
LCS should be cleared invariably before clearance of the block.
vii. Ballast heaps should not obstruct the movement of wheel.
viii. While giving the Memo to SM for clearing the block of unloading of ballast, it
must be ensured by SSE / JE (P. Way) supervising the work that there is no
infringement to moving dimension i.e. unloaded ballast does not infringe the
Schedule of Dimensions (SOD) and shall further ensure that all Engg. and S&T
gears / installations are free from any obstructions which may have been
caused due to unloading of ballast.
ix. Despite all precautions it is likely that some ballast may hit the foot board of
the train resulting in rising of dust etc. It is therefore, recommended that a
speed restriction of 45 KMPH be imposed for the first train which passes over
the portion where the ballast had been unloaded. Caution order shall indicate
the location where the ballast had been unloaded and also that the temporary
engineering indicator Board are displayed at sites.
x. SSE / JE (P. Way) / Mate with gang shall remain at site standing at gaps to
cover entire unloaded length until first train has passed. Without ensuring
unloaded ballast clear off running gears of train Track FIT certificate should
not be issued.
xi. After each unloading, SSE / P. Way in-charge of Ballast depot should ensure
clearing of the ballast dust from gear wheels of door operating mechanism
and then oiling and greasing of door operating mechanism should be carried.
xii. In order to ensure complete unloading of ballast, the hopper doors must be in
working order after unloading of ballast hoppers (BOBYN rakes), SSE / JE (P.
Way) supervising unloading must also invariably record the unloading
details in the following tabular form in a register.
Nos. of Hoppers
Received Empty Partly unloaded Fully unloaded Total
9. (i) Mechanical staff dealing with BOBYN wagons should be well conversant with
the “Technical Guidelines for maintenance of door opening mechanism in
BOBYN Wagons” as issued and circulated by Mechanical Directorate of
Railway Board vide Lr. No. 2005 / M / 204 / 3 (E-3346728) dated
08.11.2004.
(ii) A copy of this JPO should be made available with the Supervisors handling
ballast DMT in the field and engineering control of the Divisions. The Division
engineering control should also be in touch with the supervisors handling the
ballast DMT and keep them reminding time to time about the various
provisions of the JPO. Any discrepancies noticed by engineering control
should be immediately brought to the notice of branch officers positively.
Sd -/- Sd -/- Sd -/- Sd -/-
CRSE / Freight CELE CFTM CTE
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SAFETY ORGANISATION SOUTH CENTRAL RAILWAY
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