Royal Forgings Private Limited

Our Base Plates are rolled, machined, forged or casted. Base plates may be of various formations and can be used with different type of fittings. Base plates are generally used to take the load of Rail and distribute the load to the sleepers. Base plates offer proven economies and are recommended for all gauges using all different rail sections.


Base plates offer many advantages:

• They distribute the load from the rail to the ties, provide uniform bearing surface for the rail and prevent rail movement.

• They provide proper cant and obtain central loading and more uniform wear on the railhead.

• They hold the rail rigidly to gauge and protect ties against undue wear, thereby prolonging the length of service. Base plates are fabricated from heavy hot-rolled steel sections which are punched and sheared to size and are available in single or double shoulder design. Royal shop facilities offer expert service for punching, drilling, and fabricating track material to exact specifications.

Royal is the biggest manufacturer of quality hot forged Bolts and Nuts in India. Six thousand tonnes of bolts are produced at the purpose-built factory in Raipur every year. The company’s ability to perform the crucial processes of heat treatment in-house means that greater control can be exercised over the finished product resulting in high quality fasteners.

In some critical applications, it can be better to design a fastener to suit the joint requirements rather than settle for a standard part. Every year, Royal manufactures hundreds of thousands of bolts & nuts in accordance with customers' own drawings

We manufacture various types of bolts & nuts namely fish bolt & nut, T head bolt & nut, square head bolt & nut, crossing bolt & nut, hook bolt & nut, distance bolt & nut, switch heel bolt & nut, stud bolt & nut, and others. We can supply bolts having various types of heads like round, square, hexagonal, 'T' shape, etc. The neck of the bolts can be cylindrical, oval or square. We offer bolts and nuts with UNC, ISO, BSW threads or to customer's specifications.

Channel Steel Sleeper/Bridge Sleepers are used in the track running over bridges where ballast cannot be used to stabilize the track. The channel sleepers are fixed to the girders of bridges. We fabricate using channels of suitable sections and weld together to give required strength. Rails are fastened to the bearing plates which have the cant that is required in the track. The bearing plates are generally riveted to the channel structures.


In addition to channel sleeper we manufacture all the following fittings required with channel sleepers:

• Channels

• Canted Bearing Plates

• Rubber Pad

• Outer Clip

• Inner Clip

• Annular Cap

• T Headed Bolt & Nut

• Tapered Split Pin

• Tapered Washer

• Single Coil Washer

• Packing Plate

• Elastomeric Pad

• Hook Bolt

• Plain Washer

• Square Washer

• Service Bolt

• Flat

Our Dog Spikes are manufactured with reinforced throat, chisel point and square body or to customer’s requirement. They are used on wooden sleepers to fasten down rails on sleepers. It takes the lateral thrust that is coming on the rail to maintain gauge of the track.

Double Shank Spikes are used to fix the rails directly to the wooden sleepers without using bearing or base plates and it acts as an elastic fastener to take the lateral and vertical forces. Added advantage of using double shank spike is that it does not require a base plate and also acts as an elastic fastener thus saving cost to railways.

An ideal rail track assembly is characterized by the ease of its fitment at the time of laying of track, easy and economical maintenance, durability, economical life span and speedy replacement. Our elastic fastenings have serviced indian and international railways over a period of over two decades. They have been successfully used in laying new railroads and in maintenance of existing railroads. They are used in wooden sleepers, concrete sleepers, bridge sleepers and steel sleepers.

royal manufactures elastic fastening systems from traditional pr type clips to more recent elastic fasteners and have proven their value by holding up under ever-increasing pressures. We manufacture elastic fasteners to various specifications namely astm, arema, din, gost, irs, bs, en, rdso, iso, and others. We are one of the very few companies in the world that has manufacturing facilities for manufacturing all types of elastic fasteners.

royal carries all necessary testing facilities to design and develop new fastenings as well as test the regularly produced products. Some of the testing equipments royal carries are toe load tester, fatigue tester, vertical and lateral movement tester, hardness testing machine, utm and others.

the regular produced clips are:

pr type: with flattened toe for greater bearing area, are available in the range of 18 mm diameter to 23 mm diameter, having nominal toe loads varying from 300 kgf to 1250 kgf. The material used is spring steel of different grades. We are manufacturing and supplying all various series such as 400, 600, and others.

e clip: offer greater toe loads than pr clips and are specifically designed for high-speed heavy traffic lines. These clips extend track life by providing a positive and lasting rail alignment under the most severe operating conditions. They are available in the range from 11 mm to 20mm diameter, having nominal toe loads varying from 350 kgf to 1400 kgf. The material used is spring steel of different grades. We are manufacturing and supplying all various series such as 1800, 2000, and others.

others: we are also manufacturing special designed clips for our various customers to suit their needs. These clips include nabla type, clip for fastening where fishplates are used, w type clip (vossloh type), and other special designed metallic fasteners. They are all normally manufactured using spring and alloy steel.

We have in-house rolling, forging and machining capability to manufacture all types of Fish Plates including plain, joggled, angle and combination fishplate to various drawings for various rails. Fishplates are used for joining two rails together of same or different sections, it is also used when welded joints have fractured or which have become defective. Royal not only makes fishplates it also manufactures and supplies fish bolts and nuts.


Qualities:

• Our Fish Plates are made for various rail sections.

• Fishp Plates are manufactured to ensure adequate rail joint strength.

• The bolt holes are either drilled or punched.

• All new design Fish Plates are launched in time to reduce customers cost.

We make all types:

• Plain

• Joggled

• Angles
  

• Combination

Inserts/iron shoulders are cast in the concrete ties for fixation of elastic rail clips. Our iron shoulders are manufactured from pearlitic malleable iron (m. C. I. Inserts) and spheroidal graphite iron (s. G. C. I. Inserts).

we offer two types of iron shoulders :

• single stem iron shoulders mostly used in pre-stressed concrete ties.

• twin stem iron shoulders commonly used in bi-block or twin block concrete ties.

Dowels/Ferrule: They are plastic inserts pre-casted in concrete sleepers, most extensively used in turnings and crossings. They are grouted in concrete sleepers to take in screws to fix the rails to sleepers. Our dowels are molded specifically to suit the sleepers and screws.


Insulators/Liners: Our liners are used as insulators to make the track suitable for electrical circuiting. They are generally made of Nylon-6 or Glass Filled Nylon. They are used with metallic fasteners so that the fasteners and rails do not have direct contact.

Lock Spikes are used to fix base plates to wooden sleepers. We make all different designs including PC3 and L6.

Points and Crossings enable trains to move from one track to another enabling directional changes. They are complex pieces of machinery and in order to keep the service running smoothly require parts changes or occasionally complete replacement.

Royal is one of the premier manufacturers in Points & Crossings. With our international partners who are leaders in this field, we provide Points and Crossings for all types of networks: railways, high speed, metros, light rail and tramways.

The expertise in the railway environment acquired by Royal enables it to perfectly interface its products with all existing equipment and incorporate its products on the track efficiently. We design and manufacture a range of products meeting all the technical and financial requirements of the market. We can propose the best-adapted solution for each network.

We are manufacturing different types of Rail Anchors including “T” type. They are used where the fastenings system requires extra creep resisting arrangement.

There are various shapes of the anchor and the rolled bars which are used to make the anchors have various sections. The anchors when driven in rail feet, grip the rail firmly and when set against sleepers resist longitudinal movement of Rails caused by passing trains.

Our Rail Pads are made of rubber or plastic. They are to dampen the shocks of vibrations of a passing train. Royal rail pads are made from a variety of both natural and synthetic elastomers to meet the precise demands of the operating environment from high-speed track to maintenance bays. Rubber (natural, synthetic or composite) pads are supplied for concrete and wooden sleepers whereas EVA pads are supplied for most steel sleeper applications. Plastic HDPE pads can also be used for isolation of base plate systems.

• Our Rails Pads are made to thickness ranging from 5mm to 25mm.

• Special designed electrometric pads are used to dampen vibrations on the bridges.
  

• We also offer metal bonded pads to reduce extensive vibrations.

Our Rail Pads are made of rubber or plastic. They are to dampen the shocks of vibrations of a passing train. Royal Rail Pads are made from a variety of both natural and synthetic elastomers to meet the precise demands of the operating environment from high-speed track to maintenance bays. Rubber (natural, synthetic or composite) pads are supplied for concrete and wooden sleepers whereas EVA pads are supplied for most steel sleeper applications. Plastic HDPE pads can also be used for isolation of base plate systems.


Advantages:

• Our rails pads are made to thickness ranging from 5mm to 25mm.

• Special designed electrometric pads are used to dampen vibrations on the bridges.
  

• We also offer metal bonded pads to reduce extensive vibrations.

Single Shank Spike are same as double shank but with only one spike. It is generally used in mines and tunnels.

One of the most popular rigid rail fixation items are extensively used to tighten the rail track on to the wooden or concrete tie. Screw Spikes are used for fixing of tie plates on to the wooden ties in pre-bored holes and with plastic inserts pre-cast in concrete sleepers. They are extensively used on high-speed tracks with the extremely popular H.M. fastening.


Features:

• We manufacture screw spikes to various diameters ranging from ¾” to 1 1/8”(19 to 29mm).

• Our flexibility in tooling allows us to produce any type of head design or head top on any type of Screw Spikes we manufacture. We manufacture Screw Spikes having Square or Rectangular Head. These head designs can be varied to suit any type of socket being used by the customer for fixing.

• Our Screw Spikes can be supplied with surface finishes like bitumen dip, linseed oil dip, Hot Dip galvanized etc.

• We also offer heat treated/annealed Screw Spikes which conform to hardness, tensile & bending specifications of our customers.

Royal has a well established track record in supplying product for the development, upgrading and maintenance of indian and other railway infrastructure. Over the last few years this work has principally focussed on the manufacture of steel rail sleepers and associated fasteners and fittings for rail projects. The benefits of the royal rail steel sleeper are, becoming increasingly self-apparent. Investment in design and development has resulted in products to meet modern operational demands and track laying methods. These optimize the combination of sleeper and fastening, for efficient installation and minimum maintenance. All sleepers that are manufactured are chemically and metallurgically tested using the well equipped laboratories.

our steel sleepers are pressed out of rolled profiles in hot or cold conditions to give the required shape. These sleepers are supplied with or without cant, with holes or with welded arrangements of plates. Our rolled steel sleepers can be made in conventional and special profiles to suit a range of rail gauges and axle loads. A range of pad plates and sleeper plates are available to suit the sleepers together with fasteners. If rail insulation is required, royal can provide the insulating pads and liners with a design that will meet the customers’ needs.

steel sleepers are lightweight, dimensionally more accurate than wooden or concrete and regarded as an effective technical solution for modern rail networks. All opportunities have not been explored for further development. Progress with new development and improvement of existing products with the help of our customers has therefore the highest priority at royal.


the benefits of royal steel sleepers are as apparent as the principle sounds:

• time and cost savings at installation

• simple site preparation and installation

• improved stability

• reduced maintenance

• environmental benefits due to reduced ballast requirement

• sleeper finishing options

• lightweight design, leading to ease of handling

• excellent ecologic balance, thanks to numerous recycling possibilities

• long life time

We manufacture different types of Washers (Plain & Spring) in accordance to all International Level specifications including IS, BS, EN, DIN, GOST and others. The spring washers are manufactured from spring steel bars.

Spring Washers have the function of:

• Providing greater bolt tension per unit of applied torque tighter assemblies.
  

• Providing hardened bearing surface to create more uniform torque control

• Providing uniform load distribution through controlled radii section cutoff

• Providing protection against looseness resulting from vibration & corrosion

Spring lock washers are usually supplied in natural black finish unless otherwise specified.

At the request of customer we can offer:

• Phosphate coated

• Zinc plating

• Zinc & yellow dichromatic

• Electro-Galvanised

• Cadmium plated