PUBLIC TRANSPORT CORPORATION PART C HEAVY RAIL TRACK CONSTRUCTION STANDARDS Prepared by: Track Engineering Department Version 1.3 Date: August 1997TABLE OF CONTENTS Page 4. INTRODUCTION 4 2. PRELIMINARY WORKS .. 4 3, SITE CLEARANCE AND MATERIAL RECOVERY 4 3.4 Description 4 3.2 Length of Work 5 3.3. Widths 5 3.4 Clearance of Trees and Obstructions 5 3.5 Stripping of Topsoil 5 3.6 Track Material Recovery 5 3.6.1 General : 5 36.2 Recovery of Rails and Fastenings from Existing Track 6 Ri : 6 Rail Anchors, Fishplates and Fishbolts 6 Insulated Joints 6 Springspikes, Dogspikes, Rail Clips and Sleeper Plates 6 Sleepers, Concrete Bearers and Crossing Timbers 6 Removal of Turnouts 7 3.7 Survey Marks 7 3.8 Removal and Disposal of Materials 7 3.8.1 General 7 3.8.2 Disposal of Material 7 3.8.3 Disposal of Material on Railway Land 7 EARTHWORKS 8 41 General 8 4.2 Definitions 8 4.3 Earthworks Finish - General 8 43.1 Finish Tolerances - Formation Level 9 2 Finish Tolerances - Formation Width 9 3 Finish Tolerances - Batter Slopes . 9 4.3.4 Finish - Cross Fall . 9 4.4 Management of Earthworks . 3 4.5 Test Rolling ; 9 4.6 Removal of Soft or Unsuitable Material 10 47 Filling - General 10 48 Filling - Approved Material 10 4.9 Sub-ballast - Approved Material 10 4.10 Placing of Filling " 4.11. Filling Around Pipes, Culverts and Structures " 4.42 Benching . ce ceeee 12 4.13 Excavation 12 4.44 Excavation of Rock 12 4.45 Compaction Plant - General 13 4.16 Requirements for Rollers 7 13 4.17 Compaction Procedures... 14 4.48 Compaction Standards : Proof Reling 14 4.19 Compaction Standards : Soil Tests . 14 eSPECOTT4.20 4.24 4.22 4.23 5. DRAINAGE 5.4 5.2 5.3 5.4 5.5 Use pf Geofabrics Disposal of Surplus Material Earthworks on Existing Formation . Levels and Cross Sections Shown on Drawings General Scope of Excavation for Drainage . Installation of Reinforced Concrete Pipes Tolerance of Culverts .. Precautions during Construction 6. BALLAST SUPPLY 7. CONSTRUCTION OF TRACK TA 7.2 iz 7.4 7.5 76 7 78 79 General Preparation of Formation Placement and Compaction of Bottom Ballast Alignment, Level and Cant . Road Crossings Track Geometry Standards 4 General 2 Track Gauge 3 Track Construction Tolerances Interface Between Work Area and Existing Track Marking Tangent Points and Cant Values : Maintenance of Track During Defects Liability Period 8. RAIL WELDING 8.1 8.2 8.3 8.4 General . Fire Prevention Flash Butt Welding Aluminothermic Welding 9. RAILFASTENINGS . 10. | TRACKWORKS 24 9.2 9.3 10.1 10.2 10.3 General Resilient Fastening System 9.2.4 Rail Clips .. 2 Springspikes ... : Serows and Spring Washers. . Pandrol Plates . . Dogspikes ..... Double Shoulder Plates Rail Anchors General *. Materials Rail Bearers 10.3.1 General 10.3.2 Handling and Storage « 10.3.3 Aligning . : 10.3.4 Boring 15, 15 16 16 16 16 16 16 7 7 47 7 7 18 18 18 18 . 18 18 19 19 20 20 20 21 a 2 22 22 22 22 22 22 22 23 23 23 23 24 24 24 24 24 25 25 25 26 26 oral10.4 Rail Fastening System .............-. ener 10.4.1. Spacing ees 10.4.2 Plating ... oe : 10.4.2.1 General | beeen eee 10.4.2.2 Inspection .. 10.5 Rails... 10.5.1 General 10.5.2 Handling Condition . Cutting Drilling . Minimum Length o of Rail in Track Insulated Joints . ; 40.5.8 Laying 5 10.6 Welded Junction Rails 10,7 Welded Joints 5 10.9 Installation of Ballast 10.9.1 Ballast Finish . . 10.1.1 Finish Tolerances - Ballast Widths . 409.1.2 Finish Tolerances - Ballast Depth Under Sleeper 14. TAMPING Peers 11.1 Tamping of Relocated Track 41.2 Stand Sites and Storage Sidings 41.3 Track Occupation and Safeworking ... 41.4 Completion of Trackwork 12, TURNOUTS... 12.1 General 12.2. Gauging 12.4 Points 12.6 Crossings 42.7. Mainline Joints in Turnouts 12.8 Ballast Formation .. 12.9 Removal 3, DESTRESSING .. 44. PEDESTRIAN CROSSOVERS AND SECURITY COMPOUND . 14.1 Fencing oe 14.2. Gates : 143 Pedestrian Crossovers and Compound Surface 14.4 Warning Signs 48. LIST OF DRAWINGS yendix 1 - Public Transport Corporation Standard Drafting Presentation : Microstation Format station Level Record for Existing Features eo Microstation Level Record for Proposed Features Appendix 2 - List of Reference Documents .27 27 27 27 28 28 28 28 28 29 29 30 30 31 231 31 31 32 32 32 32 33 33 33 - 33 33 33 34 34 34 35 35 35 35 35 35 36 38 39 40 4 42 FESPECOT TagaHEAVY RAIL TRACK CONSTRUCTION STANDARDS 2 INTRODUCTION These guidelines have been prepared to facilitate the preparation of the track construction specification. The Contractor will require a sound understanding of track and road construction methods, surveying practice, and of the characteristics of each particular site PRELIMINARY WORKS ‘The Contractor shall conduct a survey of underground services and assets prior tocommencing work to:- ¢ ensure the safety of personnel, e maintain the integrity of existing underground services and assets, © determine if any services or assets need altering or relocating so that the works can proceed, The Contractor shall inform the Superintendent as soon as he becomes aware of the need to alter or relocate any services and shall advise the Superintendent of details of the proposed alteration or relocation. The time of alteration of any such services will be dependent on the requirements of the Authorities concemed and it shall be the Contractor's responsibility organise his works program accordingly. All costs of alteration or relocation of services will be bome by the Principal. The Contractor shall inform the Superintendent when existing services are being proved or before new services are back filled so that a PTC representative, if available, can be present Applications to alter existing services or details of new services shall be submitted to the PTC Property Department, Level 10, 589 Collins Street for referral to the PTC Service Crossing Committee for approval. SITE CLEARANCE AND MATERIAL RECOVERY 3.1 Description Site clearance comprises removal and disposal of: (a) Trees, brush, stumps, logs and other vegetation. (b) Refuse and obstructions such as old foundations, poles, drain, fences and disused structures. (©) Turf and topsoil (4) _Disused overhead structures are not to be removed. (e) _ Recovered track materials. (fy Materials to maintain a clean site for the term of the contract. RESPECTHEAVY RAIL TRACK CONSTRUCTION STANDARDS 3.3 3.4 3.6 3.6 Length of Work Clearing shall be carried out over the entire length of the work as shown on the Drawings. Widths ‘The width to be cleared for the new embankment or cutting comprises the whole width as indicated on the Drawings with a further horizontal distance of 1 metre from the toe of the proposed embankment Where drains are to be constructed, site clearance shall be continued to the outer edge of the drains. Clearance of Trees and Obstructions Alll of the surface within the specified area shall be completely cleared of all obstructions. ‘Trees shall be felled within the area to be cleared in such manner as to avoid damage to any facility and any vegetation outside this area. Where possible, trees which cannot be felled without danger to traffic or damage to other trees, shrubs, structures or property shall be cut in sections from the top down. All trees to be cleared in accordance with P.T.C. Standard Overhead Plan No.F12232 (Rev A), ‘The Contractor shall be responsible for obtaining all permits or authorisations required for the removal of trees or other vegetation. Stripping of Topsoil After removal of all above ground obstructions, the topsoil shall be stripped to a minimum depth of 150 mm, This stripping shall remove all races of grass, weeds, roots and other unacceptable matter. The entire specified area shall be grubbed free of stumps, roots and other perishable matter, to a depth of not less than 300 mm below the stripped surface level. All such grubbed areas shall be refilled with suitable material, compacted to the same extent as the surrounding area. Track Material Recovery 3.6.1 General All surplus materials, unless otherwise specified shall remain the property of the PTC. The Contractor shall return: © any material supplied to the Contractor at no cost for use under the Contract but not included in the finished track, SECO Tra TasHEAVY RAIL TRACK CONSTRUCTION STANDARDS 3.6.2 any reusable material removed from the existing track; and © any material supplied under the terms of the contract. ‘Supplied material shall be kept separate from recovered material. The surplus material shall be handled in a manner which will not be detrimental to the material ‘The Contractor shall be responsible for security of the surplus material ‘All material designated by the Superintendent as capable of being reused shall be delivered by the Contractor to a Perway Depot nominated by the Superintendent. All material designated by the Superintendent as not being capable of being reused shall be disposed of by the Contractor. It shall be the Contractor's responsibilty to locate a site and to arrange with and obtain permission from the Authorities controlling disposal of material at that location Recovery of Rails and Fastenings from Existing Track 3.6.2.4 Rails Rail recovered shall be transported by the Contractor, unloaded and neatly stacked on its foot, off the natural ground as directed by the Superintendent. 3.6.2.2 Rail Anchors, Fishplates and Fishbolts Surplus rail anchors, fishplates and fishbolts removed from the rail shall be sorted, counted, and transported by the Contractor. 3.6.2.3. Insulated Joints Glued isulated joints shall be cut out so as they can be reused in conformace with Clause 10.5 Rails. Plastic coated fishplate mechnical insulated joints shall be disassemble sorted and transported by the Contractor. 3.6.2.4 Springspikes, Dogspikes, Rail Clips and Sleeper Plates ‘Surplus sleeper plates, dogspikes, rail clips and springspikes removed from the work shall be sorted, counted or weighed and transported by the Contractor. 3.6.2.5 Sleepers, Concrete Bearers and Crossing Timbers Sleepers, concrete bearers and crossing timbers shall be sorted, ‘counted and transported by the Contractor and shall be unloaded and neatly stacked, off the natural ground as directed by the RESPECTHEAVY RAIL TRACK CONSTRUCTION STANDARDS Superintendent. - 3.6.2.6 Removal of Turnouts Turnouts to be removed from the existing track shall be disassembled into individual components sorted and delivered as above for the individual components. 3.7 Survey Marks During site clearance, the Contractor shall take care not to disturb any survey marks. 3.8 Removal and Disposal of Materials 3.8.1 General Note: No burning off shall be permitted. All material recovered from site shall be dealt with as specified in Clause 3.6 Track Material Recovery. ‘All material removed in clearing shall be either: (a) _ removed from the site; (b) disposed of on Railway land All material produced in the initial clearing of the site shall be disposed of before embankment or cutting construction commences. No accumulation of flammable material shall be permitted to remain on the railway reserve. The site shall be maintained at all times and left at the end of the contract in a neat and tidy condition. 3.8.2 Disposal of Material Material removed from the site for disposal shall be moved to a site conforming with all statutory requirements. It shall be the Contractor's responsibilty to locate a site and to arrange with and obtain permission from the Authorities controlling disposal of material at that location, 3.8.3 Disposal of Material on Railway Land Where approved by the Superintendent, debris from site clearance may be disposed of on railway property, under conditions specified by the ‘Superintendent. Fase hee TasHEAVY RAIL TRACK CONSTRUCTION STANDARDS, ~. EARTHWORKS 44 42 43 General ‘All earthworks shall be capable of withstanding the 300-A-12 railway traffic loadings axle group spacings For the whole distance specified, the railway formation shall be formed, compacted, graded, boxed, trimmed and drained as shown on the Drawings and as described in this ‘Specification. The work includes filling and cutting to the required heights and widths, and constructing side drains where existing drains are affected by the new embankment and cuttings, Compaction standards as specified by: (2) defining the required number of roller passes; (b) requiring proof rolling; and (©) soiltests Definitions Formation is the finished surface on which the track is laid after completion of earthworks, including the sub-ballast course but excluding any cut or fill batters. Ballast is the crushed rock supporting the sleepers and forming part of the track. Requirements for ballast are covered in other Parts of this Specification ‘Sub-ballast is the trimmed and graded crushed rock or similar material forming the portion of the formation on which the ballast is laid Batter is the uniform side siope of a cut or fill. Fill is the material used for filling the earthworks up to design surface level as indicated ‘on the Drawings, but not including sub-ballast material. Track consists of rails, sleepers, fastenings and ballast laid on the formation in continuity to line and grade. Earthworks Finish - General All earthworks shall be finished to smooth and uniform surfaces which shall conform to the lines, levels and cross-falls shown on the Drawings, within tolerances specified below. TasrECOTT TT Agar HT TintHEAVY RAIL TRACK CONSTRUCTION STANDARDS 44 45 434 4.3.2 4.3.3 4.3.4 Finish Tolerances - Formation Level The finished surface level of the completed formation shall not vary more than 25 mm above or below the levels shown on the Drawings. No point in the general surface shall vary more than 12 mm either from a 3 metre straight edge laid parallel to the centreline of the formation or from a template placed at right angles to the centreline. Finish Tolerances - Formation Width Finished formation widths shall not vary more than -0 mm, +50 mm from dimensions shown on the Drawings. Finish Tolerances - Batter Slopes For embankments the angle of the batters shall not be steeper than 1.5 horizontal to 1.0 vertical. For excavations, the angle shall not be steeper than 1.0 horizontal to 1.0 vertical unless otherwise approved by the Superintendent. Finish - Cross Fall The cross fall for the surface of the new formation shall be 1 in 60 as shown on the Drawings. Cross fall shall be away from existing tracks Management of Earthworks The earthworks shall be managed in such a way that: (a) __ materials are maintained in a condition suitable for their intended use; (b) __ the earthworks are kept well drained; (©) _ the trimming and final grading of surfaces is completed as work proceeds; and (d) _all work is executed in a safe, neat and workmanlike manner. Test Rolling After site clearance and before commencing any backfilling, the whole of the area on which fill is to be placed shall be test rolled to detect any soft spots. Test rolling shall comprise one pass of a 5 tonne smooth wheel roller. The Contractor shall arrange for the Superintendent to be present at test rolling§ SPECHT Raa TT FaeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 46 47 48 49 Removal of Soft or Unsuitable Material Soft areas identified by the Superintendent shall be removed and replaced with approved fill and compacted in accordance with the Specification. On completion, the areas shall be subject to a further test rolling, Payment for excavation and removal of unsuitable material identified by the ‘Superintendent shall be made at the applicable "Rates for Variations". Payment will be made for the volume certified by the Superintendent, measured as solid volume of excavated and compacted replacement fll. If in the opinion of the Superintendent the material has become unsuitable due to the Contractor's negligence or use of inappropriate methods, no additional payment will be made for this work, Filling - General Embankment construction shall include the preparation of all surfaces upon which the fill is to be placed, the purchase and supply of materials, the placing, spreading and compaction of the fill and the disposal of any unsuitable material. No material shall be borrowed from Railway land unless agreed to by the Superintendent. § Filling - Approved Material Filling shall consist of material free from material exceeding 150mm in the largest dimension, clay lumps, logs, stumps, sod, weeds or other perishable matter. All such filing shall have a liquid limit not greater than 40 and the product of the liquid limit and the percentage passing the 425 micron sieve shall not exceed 1800. Non-cohesive filing with a plasticity index of less than 6 shall only be used with the written approval of the Superintendent, and in accordance with such conditions as may be required to protect the filing from erosion. Prior to placement in fills, and then at intervals of not less than once each five day's production, the Contractor shall submit to the Superintendent for review test results of proposed fill materials. § ‘Sub-ballast - Approved Material ‘Sub-ballast material shall be material from an approved quarry in accordance with this Specification The source quarry for sub-ballast material shall be approved by the Superintendent. 5 ‘Sub-ballast material shall have a Plasticity Index not greater than 20. No roots, sod or other deleterious matter shall be contained in the sub-ballast. RESPECTHEAVY RAIL TRACK CONSTRUCTION STANDARDS 4.10 444 Grading shall conform to that shown in the following Grading Table. SIEVE SIZE % PASSING 1 AS (mm) (By Mass) 53.0 100 37.5 95 - 100 26.5 75 - 95 19.0 64 - 90 95 42 - 78 4.75 28 - 64 2.36 20 - 50 0.425 7-23 0.075 2-12 ‘The Contractor shall submit a 25 kg sample of the proposed sub-ballast material, together with sieve analysis test results, prior to commencement of the sub-ballast placement, for review by the Superintendent. § The sub-ballast shall be compacted in accordance with the requirements specified for filling ‘Sub-ballast shall be provided to a uniform compacted depth of 150 mm. Placing of Filling ‘The formation shall be constructed in layers of uniform thickness not exceeding 200 mm. loose and each layer shall be compacted as specified. ‘Sub-ballast may be placed in one layer. Fillirig Around Pipes, Culverts and Structures Filling over and around pipes and culverts shall be placed in such a manner that will avoid unbalanced loading and that will not cause movement or place any undue load on the structure. Filing placed adjacent to pipes and culverts shall be compacted:in horizontal layers not exceeding 150 mm loose thickness and shall be thoroughly compacted by hand controlled power driven tampers. The level of filing on either side of such structure shall at no time differ by more than 300 mm. This method of filing shall be carried out for a distance from the structures of at least one and one half times the height of such structures TEREDHEAVY RAIL TRACK CONSTRUCTION STANDARDS - 412 4.13 44 RESPECT Benching ‘Where fil is to be constructed against existing fil or against surfaces which have a slope steeper than 4 horizontally to 1 vertically shall, unless otherwise specified or directed by the Superintendent, be cut progressively in the form of benches over the full area to be covered by new filing - ‘The width of each bench shall be such as to permit safe and effective operation of plant but shall be not less than 1 m. Each bench shall be sloped inwards at a slope not flatter than 10 horizontally to 1 vertically. Each bench shall be filed with compacted material or the bank reinstated at the end of each day so that the distance from the toe of any bench or batter ‘shall not be ing track centre (where H is the height below rail The new filling shall be placed and compacted in layers as specified until the surface reaches the top of the vertical face of each bench, and then a new bench shall be cut; this process shall continue for the full height of the fill Excavation Excavated material which conforms with the Specification for filing material may be stockpiled and used as filling. Excavation operations for the track formation shall be conducted so that material outside the limit of the batters will not be disturbed. Alll slips and falls of insecure masses of material outside the specified batters due to lack of care on the part of the Contractor shall be removed by the Contractor at his own expense. Unless otherwise specified or directed by the Superintendent, the excavation in cut to fill zones shall be continued, in the form of transverse benching, across the cut/fill interface for a distance sufficient to ensure that a minimum thickness of fill of 600 mm is achieved across the full width of the formation. Such distance shall not exceed 30 m on each side of the interface. Excavation of Rock Rock shall be defined as material which cannot be ripped by the ripping attachment¥itted to a D.6 dozer or equivalent. Extra payment for rock excavation shall be made at the applicable rate in the "Rates for Variations". Payment will be made for the volume certified by the Superintendent, measured as solid volume prior to removal. . It shall be the responsibility of the Contractor to make all necessary arrangements for the removal of rock.HEAVY RAIL TRACK CONSTRUCTION STANDARDS 4.15 Compaction Plant - General ‘Sufficient rollers shall be provided of suitable types to compact the stripped surface and the courses of fill material in accordance with this Specification. Drawn type rollers shall be provided with a tractor having sufficient weight and power to pull the roller at a satisfactory speed under actual working conditions. ~~ 416 Requirements for Rollers (a) (b) © (d) (e) Smooth wheel power rollers shall have a mass of not less than 10 tonne and shall provide a load under the rear wheels of not less than 6250 kg per lineal metre of width, ‘Smooth wheel drawn rollers and grid rollers shall provide load not less than 6250 kg per lineal metre of rolling width ‘Tamping Rollers shall consist of metal rollers or drums studded with tamping feet which project not less than 180 mm from the face of the drum. The tamping feet should be arranged in circumferential rows so that the clear distance between the outer ends of adjacent feet is not less than 150 mm nor more than 300 mm in the rows and not more than 300 mm between the rows. ‘The space between circumferential rows shall be properly cleansed by spaced bars. ‘The effective cross sectional areas of each tamping foot measured shall be not less than 4500 mm? and shall be not more than that which will provide a ‘minimum load in each tamping foot of 176 tonne/m? of cross sectional area. This load per tamping foot shall be determined by dividing the total mass of the roller by the maximum number of feet in a row parallel to, or approximately parallel to, the axis of the roller. Rollers with feet which are excessively worn shall not be used. Pneumatic Tyred Rollers tyre pressures shall be not less than 500 kPa and the load per tyre shall be not less than 2270 kg. Double axle type rollers shall have the rear tyres staggered in relation to the front tyres. Vibrating Smooth Drum Rollers shall have a total mass of not less than 4 tonne and shall have a static load on the vibrating roller of not less than 2250 kg per lineal metre of roller width. Also, the ratio of the centrifugal force produced by the rotating mass to the mass of the vibrating roller shall be not less than one. Vibrating Tamping Rollers shall be drawn rollers not less than 4.5 tonne mass and shall comply with the requirements for tamping rollers except that the cross-sectional area of each tamping foot shall be such that the mass of the roller divided by the total cross-sectional area of all of the feet on the roller shall be not less than 4360 kg per m?. RESPECTHEAVY RAIL TRACK CONSTRUCTION STANDARDS 447 418 4.19 ‘Compaction Procedures Compaction of earthworks shall include the compaction of all fill material (including sub-ballast material) to the standards specified. All compaction shall be carried out using rollers approved by the Superintendent. § Construction equipment and traffic shall not be allowed on the formation or sub-ballast while it is in a wet condition, Material which has become excessively wet shall be dried or removed from the site and replaced by material of suitable moisture content Compaction of filing material shall be achieved by a minimum of 10 passes of an approved roller. The speed of all passes of rollers shall not exceed 5 km/h. Compaction of earthworks shall be carried out at a moisture content appropriate to the compacting equipment being used and between 85% - 125% of the optimum moisture content found in the compaction test. Compaction of the filling is not to proceed if the filing is in a wet condition. The filling is not to be watered unless specifically agreed by the Superintendent and then only within the limits of the area defined. § Compaction Standards : Proof Rolling Fill layers and excavated formation shall be compacted so that they are capable of withstanding, without visible deformation or springing, proof rolling with either: (a) __asmooth wheeled roller of mass not less than 12 tonne and with a load intensity on the rear wheels of not less than 6 tonne per metre of width; or (b) a pneumatic tyred roller having tyres inflated to 700 kPa and being loaded to not less than 4.5 tonne per tyre. Proof rolling shall be carried out by the Contractor in the presence of the Superintendent prior to the placing of the next layer of fill material. § The final layer should be proof rolled immediately following completion of compaction. If proof rolled at some later date, the entire surface shall be watered and given not less than eight coverages of the proving roller before the proof rolling commences. Compaction Standards : Soil Tests The Contractor shall carry out soil tests at a minimum frequency of one day's production. The Contractor shall provide the test results to the Superintendent for review immediately on completion of each test. § aSPECOTO4.20 4.24 HEAVY RAIL TRACK CONSTRUCTION STANDARDS All compaction standards shall be measured according to AS 1289 - Methods of Testing Soils for Engineering Purposes, as follows: (a) Standard Compaction AS 1289.£1.1 (b) Modified Compaction AS 1289.€2.1 The following compaction standards shall be achieved (a) Embankments more than 3. m high, remainder of formation and stripped area - 95% modified. (b) Formation within 600 mm of finished surface 95% modified. (c) _ Sub-ballast. - 95% modified (4) Embankments less than 3 m high, remainder of formation and stripped surface 195% standard. Use pf Geofabrics ‘The use of geofabric under compacted fill or sub-ballast shall be installed: . Where extremely poor subgrade conditions prevail, that is where the CBR value is 10 or less . Under Road/Rail level crossings. . For the full length of passenger platforms. The Superintendent shall approve the locations, types and amounts of geofabrics to be used. § Where it is evident that proper compaction and/or drainage of the stripped area cannot be achieved or where excavation of soft or unsuitable material cannot be effected, a suitable geofabric is to be used. For record purposes an “as constructed" plan of any area where Geofabric is used showing the extent and type of Geofabric is to be prepared by the Contractor and submitted to the Superintendent. Disposal of Surplus Material Any excavated material, not required or acceptable for use as fill, and all other waste material shall be removed to a site of disposal conforming with all statutory requirements. It shall be the Contractor's responsibility to locate a site and to arrange with and obtain permission from the Authorities controlling disposal of spoil material at that location. ‘When approved by the Superintendent, surplus excavated material may by disposed of on Railway land by widening embankments, or as otherwise directed, AESPECOTT4.22 4.23 HEAVY RAIL TRACK CONSTRUCTION STANDARDS Earthworks on Existing Formation Where new track is to be constructed on existing formation, excavation shall be carried ‘out down to the new formation level. The Contractor shall carry out all work necessary to ensure that this formation meets all the standards specified for formation construction Levels and Cross Sections Shown on Drawings ‘The Contractor, prior to tendering, shall ensure that all levels and cross sections shown on the drawings are a true representation of actual ground conditions. ‘The Corporation will not consider claims based on alleged variations between indicated and actual ground levels, DRAINAGE 4 5.4 5.2 5.3 General This section covers the drainage works including the construction of table drains, catch drains, drainage channels, sub-soil drains, reinforced concrete pipe and box drains and end walls, trench drains, dish drains and pits. All drainage works shall be in accordance with the drawings. ‘Throughout the entire period of works the Contractor shall provide a drainage system ‘such that at all the times water is drained directly off and kept away from all formations, roads and work areas to the satisfaction of the Superintendent Scope of Excavation for Drainage The scope of excavation for drainage includes excavation for culverts and open drains and regrading of existing open drains. All excavation for drainage shall be made to the lines, grades and forms shown on the drawings and plans or as given by the Superintendent. Precautions shall be,taken by the Contractor to ensure that all excavations are rendered secure and safe and comply with all statutory regulations. Installat n of Reinforced Concrete Pipes The bedding of all pipes shall be in accordance with AS.3500.3-1990 and be sand complying with the following :~ (a) Max. particle size of 5 mm. (b) Not more than 5% by weight passing the 75 micron AS 1152 sieve. (©) _ Free from organic impurities (4) Consisting of hard durable particle. 7 (©) Well graded. TesrECTTE Tepe FAT aHEAVY RAIL TRACK CONSTRUCTION STANDARDS & 'A.15 kg sample and the results of a grading analysis shall be given to the Superintendent for approval prior to use. Allreinforced concrete pipes shall be flush jointed class 4 and, unless shown otherwise on the Drawings, shall conform to the requirements of the current edition of the Australian Standard AS 1342. ° Reinforced concrete pipes shall be laid true to line and grade with the female end (where it exists) upstream. Joints between pipes shall be kept tightly closed. Mortared joints shall be caulked with ‘a compound of two parts fine sand and one part cement well tamped into the joints. All surrounding back fill material shall be crushed rock and be progressively compacted in layers. 5.4 Tolerance of Culverts ‘The alignment of all pipes shall not vary more than 25 mm from the design alignment. The invert level of culverts shall be subject to the following tolerances :~ Invert level +0 to -25 tolerance, 5.5 Precautions during Construction Construction equipment shall not be driven over a pipe until at least 600 mm thickness of fling has been placed over pipe culverts unless approved by the Superintendent. For heavy equipment the thickness of filings shall be such that the induced stresses in the pipe are less than the allowable design stress. The Contractor shall satisfy the ‘Superintendent with calculations if requested, that such stresses are not being exceeded with the Contractors proposed equipment and construction methods. BALLAST SUPPLY Procedures to be followed shall comply with the Public Transport Corporation's “Ballast Supply Specification’, see Appendix 2. Second hand ballast material shall not be used unless the Contractor demonstrates that it conforms with the above specification. CONSTRUCTION OF TRACK TA General This Part specifies requirements for construction of.track. It shall be read in conjunction with the Parts on Construction of Turnouts, and on Tamping RESPECTSHEAVY RAIL TRACK CONSTRUCTION STANDARDS 7.2 73 7.4 75 76 Preparation of Formation Track construction shall not be carried out over any length of formation until the formation has been checked by the Superintendent. § Placement and Compaction of Bottom Ballast Following acceptance of the completed formation and prior to laying sleepers, the Contractor shall place, grade and compact one or more layers of bottom ballast. ‘Compaction shall be by a smooth wheeled vibrating roller as specified for earthworks. ‘The Contractor shall establish vertical control points to enable the depth of ballast to be measured. The compaction plant shall be subject to approval by the Superintendent. § Completed work shall be inspected by the Superintendent prior to placement of sleepers. § ‘The depth of bottom ballast following compaction shall be: (a) 200 mm where the finished depth of ballast below sleeper level is required to be 300 mm. () 4100 mm where the finished depth of ballast below sleeper level is required to be 150 mm. Alignment, Level and Cant ‘The track shall conform to the alignment, levels and cant shown on the Drawings. Road Crossings Where the track is required to be constructed through a roadway, the Contractor shall excavate the road surface, construct the track in accordance with the Drawings and this ‘Specification, and reinstate the road surface with full depth asphalt as shown on the Drawings. Any road markings destroyed or damaged by the Contractor's operations shall be reinstated by the Contractor. The Contractor shall make all arrangements with Road and other Authorities for all work required at road crossings. Track Geometry Standards 7.6.1 General All work undertaken by the Contractor shall conform with the requirements of the ‘specification prior to handing over the Works for train operations and for practical completion. RaSPECHT Tae = aHEAVY RAIL TRACK CONSTRUCTION STANDARDS 7.6.2 7.6.3 Track Gauge Track Construction Tolerances Track gauge shall be measured between the two running edges of the rail at a point 16mm below the running surface. In concrete sleepers the location of ‘Pandro!’ shoulders will determine the track ‘gauge and the Contractor shall not be responsible for the accuracy of the gauge. However, the Contractor shall advise the Superintendent when the gauge varies beyond the specified tolerances Track shall be constructed to the tolerances shown in the following table. PARAMETER TOLERANCE Centreline location 4 5mm Level + 5mm Gauge Using Timber Sleepers +3,-0 mm Using Concrete Sleepers +2,-4mm For Turnouts +3,-Omm Line measured over a 10 m chord + 5mm Twist Over 3.5 m chord + 2mm Cant + 3mm Top on 10 m chord + 5mm . Cant is to be applied uniformly over the full length of transitions. RESPECT Shae ATHEAVY RAIL TRACK CONSTRUCTION STANDARDS WT 78 73 Interface Between Work Area and Existing Track “The point of interface between the new trackwork and for 10m into the existing trackwork shall be smoothly transitioned. Under no circumstances shall the following tolerances be exceeded in this 10m interface zone: Gauge on curves + = 16mm wide Gauge on straights ~ 8mm wide Line on 10m chord = 18mm Twist is 3.5m chord = 15mm ‘Twist in 10m chord - 30mm Top in 10m chord = 20mm Care shall be exercised to ensure that welds do not occur over sleepers. Where this occurs the Contractor shall respace sleepers at each weld site to achieve an arrangement which is satisfactory to the Superintendent. Care shall be exercised when cutting mainline rails particularly adjacent to turnouts. If the rail is be continuously welded, suitable rail anchoring shall be in place before rail is cut. ‘All mainline curves on the work site shall have transitions. The Contractor shall undertake smoothing of curves aided by the use of survey pegs. Marking Tangent Points and Cant Values ‘Tangent Points are to be stencilled in white paint on the outside of the low leg rail web reading from the Melbourne end of a curve as follows:- T.S. (tangent-spiral) at the beginning of the transition, S.C. (spiral-curve) at the end of the transition/start of the circular curve. C.S. (curve-spiral) at the end of the circular curve/beginning of the transition. S.T. (spiral-tangent) atthe end of the transition. Cant values are to be stencilled on the inside of the high leg rail web at each 10. mm increment through the transitions. Maintenance of Track During Defects Liability Period During the Defects Liability Period, the Contractor shall maintain, to the satisfaction of the ‘Superintendent, all track and turnouts laid or relocated as part of this Contract. RESPECHTT oy = TaeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 8. ‘As part of this requirement the Contractor shall, on request from the Superintendent, arrange for the PTC to correct any track defect which exceeds the tolerances given in the following table at the contractors expense. PARAMETER TOLERANCE Line (variation on 10 m chord) 18 mm Wide Gauge 15 mm Top (variation on 10 m chord) 20 mm Cant 25 mm Twist (over 10 m base) 30 mm Twist (over 3.5 m base) 45 mm Tolerance specified will be audited on a regular basis by the PTC's Track Recorder. RAIL WELDING 8.4 8.2 General Rail welding shall be by the Aluminothermic and/or flashbutt welding processes. All welding materials and equipment shall be supplied by the Contractor and may be reviewed by the Superintendent prior to use. Welding teams shall be equipped with safety equipment appropriate to the activity. The Contractor shall submit to the Superintendent for review and approval, the proposed procedures, method of rail welding and testing, qualification of welders and ultrasonic testers, prior to the Works commencing. § Fire Prevention The Contractor shall comply with all Statutory requirements and prepare a management plan for the prevention of fires during welding operations The fire prevention management plan shall be approved by the Superintendent prior to the commencement of welding operations. ‘aesPECOTeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 8.3 8.4 ‘The Contractor shall take all necessary precautions to prevent fires being started by hot metal, slag, waste products, and grinding, and shall be solely responsible for meeting the cost of such damage should any occur. Each welding team shall be equipped with suitable fire fighting equipment. Flash Butt Welding Procedures to be followed shall comply with TM36 Public Transport Corporation, Technical Specification, Joining of Rail by Flash Butt Welding and TM37 Public Transport Corporation, Technical Specification, Control Cooling of Flash Butt Welds for 60kg A.S. Head Hardened Rails, see Appendix 2. Aluminothermic Welding Procedures to be followed shall comply with TM35 Public Transport Corporation, Technical Specification, Joining of Rails by Aluminothermic Welding, see Appendix 2 ‘Material and equipment used shall conform to the requirements of TM31 - Manufacture and Supply of Aluminothermic Rail Welding Material and Equipment. RAIL FASTENINGS 94 9.2 General The type of existing fastenings is to be confirmed by the Contractor. Rall fastening to bearers shall be by resilient fastening system for all mainline tracks unless otherwise approved by the Superintendent. Resilient Fastening System 9.2.4 — Rail Clips Rail clips shall be driven into the baseplate assembly or cast-in shoulder in accordance with the manufacturer's recommendations, Rail clips shall be installed so that they do not interfere with any other component at rail joints. At insulated joints rail clips shall not permit currents to cross the insulation area. 9.2.2 Springspikes The Contractor shall supply new springspikes to replace unserviceable springspikes for use with timber sleepers. Springspikes shall be used to tie the sleeper plates to timber sleepers where resilient fastenings are used except in 47 and 53kg turnouts. ESCO Saga TT coalHEAVY RAIL TRACK CONSTRUCTION STANDARDS 9.2.3 9.2.4 Springspikes shall be driven vertically until the head stands between 28 and 34mm above the sleeper plate conforming to the requirements of CEC 2/91. ‘The number of springspikes shall be installed as specified in CEC 2/91 and in 60kg turnouts as shown on the turnout design drawing. Screws and Spring Washers ‘The Contractor shall supply new screws and spring washers (Drawing No.338/70 Rev.D) conforming to the requirements of TM18. ‘Screws shall be screwed vertically down until the sleeper plate is firmly held and the spring washer is fully compressed. The number and type of screws in 47 and 53kg turnouts shall conform to relevant tumout design drawings. Pandrol Plates Rolled steel or cast clip fastening sleeper plates, conforming to AS. 1085.9 and the requirement of TM29 shall be used. ‘The Pandrol plates for use in the plain line sections of the track shall be canted at 1:20. 9.3 Dogspike Fastening System 9.3.4 Dogspikes Standard dogspikes shall be used to fasten all track where resilient fastenings are not used or specified, Dogspikes shall for general use be 19mm x 150mm long and for bridge transoms 19mm x 125mm long and shall conform to TM19. Dogspikes shall be installed in conjunction with double shoulder sleeper plates. Serviceable dogspikes shall be reused, where the dogspike is not deformed, ‘excessively corroded and has a minimum diagonal dimension of 23mm. Two dogspikes shall be driven in each sleeper plate, one field side and one” gauge side, staggered where possible, Refer to Standard Plan F474C. ‘On curves of 500 m radius or less, two dogspikes shall be provided on the field side of the rail. The second dogspike shall permit a spike against the foot of the rail wherever possible. At rail joints, dogspikes shall be installed in accordance with Standard Plan F474C and Plan 940-58. No dogspike shall be driven into a hole from which a dogspike has been removed, TEREHEAVY RAIL TRACK CONSTRUCTION STANDARDS 9.3.2 Double Shoulder Plates Double shoulder taper and level base sleeper plates which conform with AS 1085.3 shall be used. All plates are to be spiked to standard as per Standard Plan F474C. The sleeper plates for use in the plain line sections of the track shall be canted at 1:20. 9.3.3 Rail Anchors Rail Anchors conforming to AS. 1085.10 and the requirements of TM13 shall be used. The Contractor shall re-anchor all timber sleepered rail which is to be welded with existing and additional rail anchors, as required, at the Contractors expense. Rail anchors which are not ‘sprung’ shall be reused. Rail anchors shall be installed to bear hard-up against the edge of the sleeper and shall be reinstated in accordance with the required anchor pattern. Anchors which are more than 10mm from the face of the sleeper must be removed and reapplied. Anchor Patterns shall conform to CEC 3/87 and Standard Plans MF523C and MF524C. 10. TRACKWORKS 10.1 General This specification covers general trackwork associated with the Works of this contract Prior to any Works commencing, the Contractor shall submit details of his proposed methods of work to be reviewed by the Superintendent. § 10.2. Materials Prior to commencing any works the contractor shall have all necessary materials available on site to complete those works proposed and any foreseeable consequence to ensure scheduled train operations at completion of the scheduled works. Material will be delivered to nominated sites. ‘The Contractor shall be responsible for security and any damage caused to the material by subsequent storage and handling, aSPECT RTT TaHEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.3 Rail Bearers Rail bearers include sleepers, timbers, concrete bearers and areas of direct fixation. 10.3.1 10.3.2 General Concrete sleepers shall comply with the “Technical Specification for Design, Manufacture, Supply and Delivery of Railway Prestressed Concrete Sleepers”, see Appendix 2 Direct fixation shall use a pandrol clip based resilient fastening system. The direct fixation fastening system and bearer design shall be submitted to the Superintendent for approval. Timber sleepers and timbers shall comply with AS 097, Rail Track Sleepers, Lead or Crossing Timbers and Bridge Transoms from Eastern Australian Hardwoods. ‘Timber sleepers for open track shall be - = Broad Gauge 10"x 5" x 9, +2", -1" long (250mm x 125mm x 2.750m) - Standard Gauge 10" x 5 * x 86", +2”, -1" long (250mm x 125mm x 2.590m) made from the following species - grey box, red ironbark, red box or red gum. Timbers for turnouts shall be 10" x 7" (250 mm x 175 mm) or 12" x 6" (300 mm x 150 mm) as specified on layout drawings and to specified lengths. Turnout timbers shall be either forest red gum or river red gum. ‘All new bearers will be inspected by the Superintendent, Serviceable sleepers and timbers may also be utilised unless otherwise stated. Bearers to be renewed shall be marked by the Principle. Replacement bearers shall be inserted into existing bays. Timber bearers shall be laid heart side down. All sleepers shall be lifted, lined and tamped after installation and fastening of rails. Handling and Storage Replacement sleepers shall be handled and moved into position in such a way as to avoid damage or bruising. Sleepers shall not be subjected to blows from a hammer or any other tool or appliance. The use of picks or hoe tines to pull sleepers into position is not permitted. RESPECT TapaTESCO HEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.3.3 10.3.4 Timber bearers shall be stored and stacked in a manner which will prevent warping and twisting. Contractor claims for condition of bearers supplied by the Principle will not be accepted unless notified within 48 hours of receipt. Aligning Bearers shall be laid central to the track + 50mm and at right angles to the track, unless otherwise specified. (On curves where spiking is required through the slots of angle fishplates, the sleeper may be slightly skewed, In turnouts, the allowable overhang of timber bearers shall be within the range of 400 mm to 550 mm from the rail running edge. Turnout timbers and bearers shall be aligned on one end as specified on drawings. Boring Holes for dogspikes and screws shall be bored with a 19 mm auger or drill at right angles to the bearing face of the sleeper and through the full depth of the sleeper. Holes for springspike shall be bored in accordance with CEC 2/91 Holes may be pre-bored utilising suitable templates which ensure a final track gauge +3 mm - 0 mm for open track. Bridge transoms should be prebored for dogspikes before placement. In existing track situations where dogspikes are loose in spike holes or regauging is required new holes may be cross bored otherwise sleeper plates or sleepers shall be relocated and new holes bored. New holes shall be bored in serviceable sleepers. The minimum width of sound wood shall be 25 mm between spike holes and 40 mm between a spike hole and edge of sleeper. ‘Spike holes from which a spike has been removed shall not be reused. Existing holes in sleepers and timbers shall be plugged if under plates or rail or at the minimum separating distance for spike holes. Pegs shall be 20 mm square KD hardwood of similar length to sleeper and timber depth. Aap TaeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.4 Rail Fastening System 10.4.1 10.4.2 Spacing Rail fastening system attached to slab, concrete bearers, sleepers or timbers shall be spaced at the following centres:- Open track - 685 mm + 25 mm (Minimum 1460 rail fastening systems per rail per km), Mechanical joints utilising bar type fishplates - 460 mm #5 mm Mechanical joints utilising angle fishplates - 510 mm + 5 mm Mechanical insulated joints on timbers - 510 mm + 5 mm (40/47 and 53kg) Refer to Standard Plan F578 Glued Insulated and Plastic Coated Fishplate Insulated Joints = ontimber bearers with dogspikes or resilient fastening = 510mm (except for 50kg rail) = 870mm (for 50kg rail) = onconcrete bearers or slab - 640mm (Refer Plan No. 2095193) Turnouts - as specified on relevant drawings. General tolerance £10 mm, Tolerance for position of fixed rail fastening systems + 5 mm. Rail fastening system spacing shall be adjusted to ensure that welds in the rails are kept well clear of rail fastening plates and generally within 50 mm of the centre of the bay between the rail fastening systems. Joints shall be placed centrally between rail fastening systems Plating 10.4.2.1 General Plates for plain line sections of track shall be positioned so that the rail, when laid, will be inclined towards the track centre line at 1:20, Level base sleeper plates shall be used at turnouts in accordance with relevant layout drawings. Sleeper plates shall be placed centrally about the longitudinal axis of the sleepers and squared so that the shoulder of the plate sits firmly and parallel with the rail foot. The entire sleeper plate must be seated on the sleeper. Existing plates in a serviceable condition may be reused unless otherwise stated. RESPECTHEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.5 Rails 10.6.1 10.5.2 10.5.3 10.4.2.2 Inspection In track sleeper plates shall be visually inspected, without removal from track, for obvious defects such as breaks, wor spike holes, cracks, mechanical damage and flatness. Existing sleeper plates in serviceable condition shall be reused. Replacement sleeper plates shall not be used if in a damaged condition. General All 53 and 60kg rail shall be new and installed in an undamaged condition. Rail supplied shall conform with AS 1085.1 and the certificate of compliance shall be submitted to the Superintendent. Handling Rail shall not be handled in any manner which is detrimental to the rail, trackwork, trackwork components or structures. Damage caused by improper handling shall be rectified at the Contractor's expense. Condition Rails shall conform to detailed specifications for rail end condition (cutting), proximity of welds (minimum closure lengths), head matching (joint alignment) and requirement for square or staggered joints (position of joints) All rails shall be straight and true prior to laying. Any crippled, deformed or damaged rail shall not be used. The bottom of the rail, the sleeper plate and the bearing surface of the sleeper shall be clean before the rail is laid. ‘Any obvious defects in the rail, e.g. cracks, cripples or serious deformations as determined by the Superintendent shall be cut out. Welds shall be cut out if proximity does not comply with minimum closure lengthyequirements. ‘An inspection shall be carried out of the rail end for horizontal and vertical splits and pipes. Bolt holes shall be inspected for cracks and excessive ovality. If any cracks or splits are detected or if bolt hole ovality exceeds 1 mm the rail end shall be cut out. Rese Taga TT TeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.5.4 10.5.5 Cutting The Contractor shall avoid any unnecessary cutting of rails except where otherwise specified. Both ends of each completed length of long welded rail shall be inspected and measured to ensure compliance with AS.1085.1 for rail end squareness and condition. Rails shall be cut using a Rail Saw which can be shown by the Contractor to accurately provide square rail cuts. Flame cutting of running rail is prohibited except where otherwise specified in TM35 and TM36. Cutting compound should be used for cooling and lubrication when a rail saw is used. Cutting compound shall not be used with friction saws. The Contractor shall adopt work methods which minimise the necessity for cutting of rails. Drilling When necessary to provide holes in the rail web, such holes shall be made only by driling. Drils shall be sharp and cutting compound should be used for cooling and lubrication. All holes shall be drilled utilising a suitable template for the relevant rail section. Holes shall be parallel throughout their depth, clean and square with the web. No burrs or projections shall be left and the rails shall not be damaged. Holes shall be 32 mm diameter for 1" fishbolts and 30 mm diameter for M24 fishbolts. All holes on the same rail end shall be the same diameter. Hole diameter tolerances shall be + 1.0 mm. Where 6 hole fishplates are used, three holes shall be drilled in each rail end unless otherwise specified. For 4 hole fishplates, two holes shall be drilled in each rail end No two holes shall be closer than 127 mm centres. Incorrectly drilled holes shall be cut out. ‘The number of holes shall be governed by: © the work associated with turnout installation; and ‘® the work methods adopted by the Contractor when connecting into existing trackwork. RESPECT T Raa TT TBHEAVY RAIL TRACK CONSTRUCTION STANDARDS Hole positions at rail ends and turnouts shall conform to dimensions specified and shall be within horizontal and vertical tolerances of + 1.0 mm:- as ae RAIL | A 8 c D kt D Tr 40 kg 58 185 312 58.7 4A j}-—B- 47 kg 62 189 316 619 Lc 50kg } 88 | 218 | 348} 67 53kg | 62 | 189 | 316 | 67.9 ' 60kg | 88 | 218 | 348 | 74.5 All dimensions in millimetres 10.5.6 Minimum Length of Rail in Track The minimum length of primary rail to be used shall be 13.72m welded into 82m lengths. ‘The minimum length of closure rail in plated track is 6.0 metres, In CWR closure rails of 3.0m may be used in event of a broken weld or rail and when the rail is to be re-welded to continuous. Closure rails in mainline track shall be welded as soon as possible after installation and under no circumstances shall closure rail be permitted to remain unless appropriate arrangements are made with the Superintendent. If an emergency arises and a train is required to run over a mainline closure which is not welded, then the Superintendent shall be notified in advance so that appropriate arrangements can be instituted. 10.8.7 Insulated Joints Mainline insulated rail joints shall be the glued type and shall comply with CEC 8/91, AS 1085.12 and requirements of TM21 unless otherwise approved by the Superintendent. ‘A certificate of compliance shall be submitted to the Superintendent. All glued insulation joint assemblies shall be welded into the track. nase Tap Tae10.6 10.7 10.8 10.9 HEAVY RAIL TRACK CONSTRUCTION STANDARDS 10.5.8 Laying All rail shall be supported on sleeper plates. Turnouts plating shall conform to relevant drawings. All rail through roadways shall be coated with black bituminous sealing ‘compound as per Standard Plan F558A and shall conform to the requirements of CEC 3/87. Welded Junction Rails Aluminothermic Welded Junctions shall be field welded at locations where rail weight changes are directed by the Superintendent. Welded Joints Except at insulated rail joints or where fish plated joints are required rails shall be welded by either flash butt welding or an aluminothermic welding process in accordance with Clause 8 of this specification. No welded joints shall be situated less than 3 m from another welded joint and not less than 3 m from the edge of a level crossing, unless approved by the Superintendent. Welded rail joints shall not be seated on or be foul of sleeper plates. Bolted Fish Plated Joints Fishplated rail joints shall be bolted using six hole fishplates with heat treated bolts unless directed otherwise by the Superintendent. Heat treated fish bolts shall be tightened to a torque between 450 Nm and 500 Nm in conformance with CEC 3/87 Appendix F. Installation of Ballast ‘Approved 63mm ballast shall be supplied, placed and compacted by the Contractor to achieve the required standard profile at the completion of the Works. Ballast shoulder profile shall be at least level with the top of the bearer after compaction and extend beyond the end of the bearer as follows: @ At least 400mm wide for straight track and curves of radius 800m and over, (i) For tracks with curves of radius under 800m: (a) High Leg At least 450mm wide and heaped 150mm above top of sleeper level (b) Low Leg As per (i) above. FERC41. RGSrECOTS HEAVY RAIL TRACK CONSTRUCTION STANDARDS The top surface of all sleepers and fastenings shall be swept clear of all ballast after tamping and regulating is completed In loop lines and at loop extensions the ballast thickness provided shall account for the required 1 in 60 cross fall required to drain the formation and the approved vertical profile design, 10.9.1 Ballast Finish 10.9.1.1 Finish Tolerances - Ballast Widths Finished ballast widths shall not vary more than -Omm, +50mm from dimensions shown on the Drawings. 10.9.1.2 Finish Tolerances - Ballast Depth Under Sleeper Finished ballast depth under sleepers shall not vary more than -Omm, +25mm from dimensions shown on the Drawings. TAMPING Associated with the work of adjustment of cross level and running top, the ballast underneath and adjacent to all sleepers shall be properly tamped. All new sleepers inserted shall be tamped through the full closing cycle with unworn machine tamping heads. The tamping shall be carried out under each rail seat in the four quadrants of each rail seat “Tamping of the track shall be carried out so as to give a firm support to the sleepers over their full width and such lengths as specified Tamping shall only be carried out with an approved heavy duty mechanical tamper with minimum of two liftipasses. Around crossings and elsewhere where standard tamping tools will not fit between rails, special equipment is to be used to hand pack the ballast. The Contractor shall ensure that the tamping undertaken provides support to the sleepers and correct rail geometry. Bearers in plain track shall be packed for 250mm either side of the rail seat. Bearers in turnouts shall be packed for their full length. Final tamping cycle shall include stabilisation/compaction of ballast between sleepers and shoulders at the end of sleepers. The Contractor shall be responsible for all additional setting out as necessary to achieve proper alignment of the new track. The Contractor shall be responsible for the protection, preservation and if necessary re- establishment of all reference pegs and other setting out. The loss, disturbance or damage to any such mark or peg shall be the Contractor's responsi aaa TT TaeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 44.1 Tamping of Relocated Track Track which has been relocated, and track replacing relocated turnouts, shall be thoroughly tamped to the required levels. 41.2 Stand Sites and Storage Sidings ‘The provision of off-racking stand sites and storage sidings for track machinery shall be the responsibility of the Contractor. ‘The Superintendent shall approve the location of stand sites and temporary storage sidings. § ‘On completion of Contract work, all stand sites and temporary sidings shall be removed by the Contractor and the sites made good to the satisfaction of the Superintendent. 44.3 Track Occupation and Safeworking ‘The operation of track machines on or foul of tracks in use, or the travel of machines on tracks between work sites, will require special operating arrangements to be made by the Superintendent. Requirements for such arrangements are specified in Part G : Procedure for Working on Public Transport Corporation's Property and Facilities. 14.4 Completion of Trackwork On completion, the Contractor shall leave the trackwork neat and tidy and ballasted correctly to profile, The tops of sleepers shall be swept clean of ballast. All surfaces and drains shall be clear and to the correct section and all damage shall be made good All surplus ballast is to be removed from the formation surface and the site. Where approved by the Superintendent, surplus ballast may be utilised to increase the shoulder width or height on completed work. 12. TURNOUTS: 12.1 General The turnout shall be set out, aligned and laid in accordance with drawings. Flex turnouts shall be set out, aligned and laid in accordance with the design prepared. All turnouts shall be fully plated. Welded junction rails and graduated cant plates shall be installed as specified in turnout drawings. Turnouts shall be laid with zero cross level. TeRCOT Rapa TTHEAVY RAIL TRACK CONSTRUCTION STANDARDS 12.2 12.3 12.4 12.5 12.6 12.7 Gauging Track gauge shall be 1600 mm Broad Gauge or 1435 mm Standard Gauge, +2 mm - 0 mm at the following positions:- points - stock rails ahead of set at the toe and at heel crossings -_ at ends of running rails closure rails - at centres of closures Guard rail gauge shall be 1555 mm Broad Gauge or 1390 mm Standard Gauge, + 1 mm - 2mm. Existing turnouts must be regauged if tolerance does not comply. Adjustment Closure rails shall be cut and laid in such a manner that 3 mm gaps are provided at joints. Points Points shall be assembled such that toes are square. Switch blades shall bear evenly on all slide chairs and shall fit properly against stock rails before spreader bars are fitted. ‘Spreader bars shall be fitted such that the switches open to the extent specified on relevant drawings. Point slide chair pads shall be thoroughly cleaned and lubricated in accordance with CEC 2196. Hand Points Operation Hand worked point operation equipment shalll be fitted and adjusted in accordance with Standard Plan F564B. Crossings Crossings shall be fixed with one leg in true alignment with the running line. Mainline Joints in Turnouts Al joints in mainline 60kg turnouts shall be welded unless otherwise directed by the ‘Superintendent. All joints in mainline 47kg and 53kg turnouts shall be Huck bolted unless otherwise directed by the Superintendent. ESTES Taga13. 14, 12.8 12.9 HEAVY RAIL TRACK CONSTRUCTION STANDARDS Ballast Formation Ensure that ballast formation (width and height) from the timber in front of the toe to the timber beyond the V crossing conforms to CEC 3/87, Section A 22 (li) (refer Appendix 2 and Standard Plan F598) and that width of ballast at each end of timbers on each side of operating spreaders is 800mm Ballast shall be profiled so it remains clear of the turnout operationing equipment. Removal Turnouts and other trackwork requiring removal from track shall be unfastened from timbers and dismantled into half sets of points, crossings, guard rails, closure rails etc. Unnecessary cutting of rail shall be avoided. Platework shall be unfastened and removed from timbers. Bolts and screws shall be unscrewed wherever possible. Material shall be unfastened and handled in a manner which is not detrimental to components, rail, trackwork or structures. DESTRESSING All mainline track, new or reinstated, shall be destressed by the Contractor to accord a stress free rail temperature of 38°C. Destressing for new or existing track shall comply with P.T.C. CEC 3/87 Rall tensing gaps shall be in accordance with Rail Stress Adjustment Table shown in CEC 3/87. The weld gap shall be added to the tensing gap. PEDESTRIAN CROSSOVERS AND SECURITY COMPOUND 14.4 14.2 Fencing A three metre high galvanised weld mesh fence with steel posts, topped with a self ‘supporting single coil tiger tape wire shall be provided around the stabling compound. ‘Typical Drawing No. 2181/90 indicates the type of fencing to be provided. The fence shall be clear of overhead structures. Gates ‘The security fence shall to include manual double gates for road access and single gates for pedestrian entry/emergency escape. The number and location of pedestrian gates is to be determined under this contract. Motor operated train access gates, including gate post uprights, interlocked with the signalling shall be provided by the signalling Contractor where the fence crosses the entry tracks. ESPECHTT14.3 14.4 HEAVY RAIL TRACK CONSTRUCTION STANDARDS Pedestrian Crossovers and Compound Surface A\l pedestrian pathways that are required to cross tracks shall be asphalted to rail level. ‘Screenings (20mm) shall be spread to a depth of 40mm over the entire compound and spread to form an even surface. The screenings shall extend to the sleeper edge. Warning Signs Provision of security signs warning against trespass, shall be positioned inside the fence at not more than 50m intervals. Fig. 1 shows a typical warning sign message. TeTECT Taga TT aeHEAVY RAIL TRACK CONSTRUCTION STANDARDS 15. LIST OF DRAWINGS 3 F598 Track Formation and Ballast for Open Single Track Construction F564 B Point Levers : End Pull Arrangement F474C Arrangement of Dog Spikes with Sleeper Plates F12232 Tree Clearances 1500V Caty. & Cont. Only Clearance for % of Span F12233 Tree Clearances 1500V Caty. & Cont. with Side or Electrolysis Feeder at Structure Plan No, 338-70 Stee! Spring Washer for M24 Fishbolt! Plan No. 133-95 Clearance Diagram for New Construction of Bridges, Walls, Signal and Electrification Structures oaHEAVY RAIL TRACK CONSTRUCTION STANDARDS APPENDIX 1 Public Transport Corporation Standard Drafting Presentation: Microstation Format Plans forwarded to the PTC shall conform to the following configuration requirements Presentation of elements to conforming to: # PTC Microstation element attributes setup. List attached # PTC text font library # PTC colour table The Microstation environment as follows: # Working Units - Units Names Master Units "m" Sub Units "" - Resolution "4000" per m "1" Pos Units Per # Data Readout (Coordinates Readout) - Coordinates Format "Master Units" Accuracy "0.123" - Angle Format "DD MM SS" Mode "Conventional" Accuracy "0.1234" aesrECOTT Wage 1907HEAVY RAIL TRACK CONSTRUCTION STANDARDS APPENDIX 2 List of Reference Documents “Note: Unless state otherwise design, materials and construction shall be to Australian Standards. Railways of Australia (R.O.A) - Manual of Engineering Standards and Practices, Volume 1. = Code for the installation of other parties services and pipelines within railway boundaries. Australian Standards - AS O97 - AS 1289 - AS 4058 - AS 1085 AS 1289.E1.1 AS 1289.E2.1 AS 3500.3 Rail Track Sleepers, Lead or Crossing Timbers and Bridge Transoms from Eastern Australian Hardwoods. Methods of Testing Soils for Engineering Purposes. Method E1.1 : Soil Compaction and Density Tests - Determination of the Dry Density/Moisture Content - Relation of a Soil using Standard Compaction (Standard Method) Method E2.1 : Soil Compaction and Density Tests - Determination of the Dry Density/Moisture Content - Relation of a Soil using Standard Compaction (Subsidiary Method). Stormwater Drainage. Precast Concrete Pipes, Pressure and Non Pressure. Railway Permanent Way Material Stee! Rails. Fishplates. Sleeper Plates. Fishbolts and Nuts. Spring Washers. Material, Dogspikes Clip Fastenings Sleeper Plates. Rail Anchors. Part I! : Head-hardened Rails. Glued Insulation Joints. Spring Fastening Spikes. Concrete Sleepers. Part 15 : Aluminothermic Rail Welding.PUBLIC TRANSPORT CORPORATION (VICTORIA) TRACK GROUP CIRCULAR: CEC 6/91 . TAB NO: 3/16 DATE: NOVEMBER 1991 Distribution: All Track Engineers, Roadmasters, Road Foreman, a) Special Gangers, Gangers and Track Welders. RAIL JUNCTIONS NTRODUCTION This circular describes the policy for joining rails of different classes i.e. different rail weights or cross section. RAIL JUNCTION TYPES The heads of different classes of rail may be brought to the same gauge and level by one of the following methods * Aluminothermic Junction Welds Junction welds are now standard practice in the P.T.C. and are described in CEC ‘Aluminothermic Rail Welds: Types and Uses’. * Junction Fishplates The supply of junction fishplates from the Perway Materials Depot is being phased out. * Flash Butt Welded Junction Rails Flash butt welded junction rails are no longer manufactured at the Perway Materials Depot and their use is being phased out. RAIL JUNCTIONS IN MAINLINE TRACK Existing junction fishplates in mainline track must be replaced with flash butt welded junction rails (while:stocks last) or junction welds as the opportunity arises. Rail. junctions occuring in programmed new work or alteration in mainline track must be formed using flash butt welded junction rails (while stocks last) or junction welds. Junctions fishplates may be installed in mainline track during emergency or temporary repairs. : (cxcs-sijceci) pace 1600 900 Public Transport Corporation WARNING TRESPASSING FORBIDDEN THESE PREMISES ARE PROTECTED BY SECURITY SYSTEMS AND SECURITY PATROLS TRESPASSERS PROSECUTED nN uw w ro) w ww w w w w wn wi wn oS ULE LLP LT w wn roy |BALLASTED TO LEVEL OF TOP OF SLEEPER Now Ess ORS. 1000 CEE fsibe ron 1000 RTT SOLID SIDE DITGH ak 4 aS 2 250 MIN RO ” pene Tt CUTTING F TROL NOTES: 1. ‘Track formation to be compacted to 96% modified (tefer AS1289,621-19771 of moma dy dens Fn uate BROAD GAUGE G=1600 a approximately can = soe Kpe fr Commonly ned ate aoa TYPE OF TRACK AlB]c{D]E] P| ,graauacy, | mesure 2. Shoulder of ballast to be increased on Sulaie of curve for eurves is Pines oer [ano] ann| vo] n |amo| ow | 0 — aa ae eae tc 8/81 [tinbereepere T°" | 4000}8500 | s100 asco |2760| «os 300 pie" 3, Crossfall should be waitorm over ESET eel om sea | Reine isins Bue re || on |aeo [ro] wo | _so cs Saeco by Engines! 5 All dimensions tn limetes | STANDARD GAUGE 0.1435 Clee noted there DEP Tan ERT 6 Ballast volumes tte azo not to rypgor track = [a|B|c|p|e| F| eatietes | ‘Shia Bethe to elclat bolle guanttien aitne RATES 6 Tose" Iona [aioe [aso] as | 20, 24a" 1. Concrete Sloper: Value pected ae based jini Bw oT i tn the dimenaions of tho following sleepers timber | 3920 | 3420 | 4940) 2400 | 2590] 405 we itn! SG. AUSTRAK NRC Drg No 1314-0037 A [issiongat ora SSC ay BG. AUSTRAK Drg No 601-011 [Sidings ‘ ‘ * | 3620 | 3120 | 4240 | 2890 | 2590] 150 150 094m" CADD FILENAME SVR4\MISC\F598D.DGN 20.1296 romaaS evan] eet REVOLT] omaww [er] nome mart cowouron | goyep ay x0" 26098 . Px heat Pcan- urDaTeD, sas] | reemeat senwces omsion | 5 'B_|21293|SIDE DRAIN ADDED. | MANAGER ENGINEERING Se neces Dpremexaealxcr] —| ome |_| STANDARD DRAWING Tove] anape . ‘D [ie nad Dinas New Ce Sees ACHL| | CORRES ACK FORMATION & DALLAST Jscatsl NOT TO SCALE ConsTiUETION RAG He T T 5 7 3 T a Ss $ign, eB cox mos eed Ee i TmCALLEWTIONS POINT LEVERS END PULL ARRANGEMENT= i= INTERMEDIATE ‘SLEEPERS: Biel eal CHAIAT RAIL JOINT ANGLE FISHPLATES (7) RAIL JOINT fop__ANGLE FiSHPLATES ai = lg —t 16 ae ate G : } 3s Lipa RAIL JOINT GAR FISHPLATES SECTION B-B APPLICATION OF DOUBLE SHOULDER SLEEPER PLATES SECTION A-A pat sort DES ED BAR FISHPLATES tr i HH 4 SECTION C-C APPLICATION OF SINGLE SHOULDER SLEEPER PLATES UT RAIL JOINT F BAR FISHPLATES iu J } Hh SECTION EE APPLICATION OF FLAT SLEEPER PLATES This Plan supersedes Plan NOFAT4® . |O-35H) Sagan mance we EAS © 8 A Reta One ‘Anendment “VICTORIAN RAILWAYS — WAY ANC WORKS BRANCH “Adopted STANDARD DRAWING 1956 ARRANGEMENT OF DOS SPIKES {eet | PLAN | WITH SLEEPER PLATE AIGER |B a7ac Cae}*—FOR 3 YEARS REGROWTH "ARNG ACE ADOTTIONAL CLEARANCE TO ALLOW TREE TO BE TRIMMED. * TO BE LEFT AESTHETALLY PLEASHO] NOTE :- {, ALL DIMENSIONS TH METERS 2. FOR DEFINITIONS & EXPLANATIONS. ‘REQURING CUTTING, sreb RENN tiOn 30 SEE ORG. 0 Nominal Ls USIP T SS EA TO BE CLEARED TO —-—> GROURO LEVEL TRA & CVEDEAD DUARTE & GUS ‘TREE CLEARANCES . ~ 1500 V, CATY, & CONT. ONLY DESION | DATE SCALE KTS _|ADOITIONA INSPECTION space RANCE TO ALLOW CLEARING i FOR 3 YEARS REGROWTH SPACE Naty. 4 a ‘TREE TO BE TRIMMED - (TO BE LEFT AESTHETICALLY PLEASING) — 15 —+ ( Leb AUL DIMENSIONS TN METERS 2, FOR DEFINITIONS & EXPLANATIONS SEE ORG. D aa 3.0 the 4, > Nominal ' oa ¢ SIANIASYIR TRIS s TREE OR UMD ABLE THIS |AREA TO BE TO BREAK ‘OR FALL REQUIRING CUTTING. CLEARED TO GROUND LEVEL, VICTORIAN RAILWAYS, ELECTRICAL_ENGINEERING BRANCH TRACK & OVERNEAD CHARTS © GPRS, TREE CLEARANCES 1800 V. CATY. & CONT. WITH SIDE OR DESIGN pram £i ID * J cuecKen DESCRIPTION revo | cuxo | pass | aprro | PASSED T - zMax 3 Min. DIMENSIONS J [2] Inside Size Pitch Diameter of of of Washer } Material | Washer + 1), -O | Nominal D A Bic ral Ritch changed. woke 27 12 12 Go. Th 45.1085 added; Pitch 1900] waa 9:5; Toleranea wa D c B_ | 70} Dimensions convert to metric dimenstor A gp] Tolerances on size how] & pitch removed NOTES: 1: FOR OTHER, REQUIREMENTS "SPRING: WASHER TO CONFORM ‘Tos :AS, 1085"- PART 7 - 1978. — [C]" 2. REMOVE ALL. SHARP CORNERS | FROMTHE INSIDE OF THE’.SPRING WASHER, 3. THE. 12 SQUARE SECTIONED WASHER IS PREFERRED, BUT A SIMILAR SIZED HELICAL WASHER OF EITHER SQUARE, RECTANGULAR,OR OVAL SECTION CONFORMIN TO THE SPECIFICATION WOULD BE CONSIDERED. 4, ALL DIMENSIONS IN mm UNLESS OTHERWISE SPECIFIED. VR. STEEL SPRING WASHER for M24 Fishbolt ° Pd) t7.70 Scale. Full Size. the? Engineer [revision “| Amendment ro rales eq areS80, aaa ronirensTATE RAL TIUFFIC 200 (ELECTRIFIED) (REFER NOTE 4) ‘G0 (NOT ELECTRIFIED) rRNOEMENT FORTRAN STOPS OMY. REFER, DRAWN 175 — {OER HAN PLATFORNS, ELECTRIFICATION STRUCTURES, overncaD cine stRUCTURES ‘SIONAL STRUCTURES, VERANDAH EAVES. SIONAL STRUCTURES, VEANDAN EAVES ONNTERSTATE UNES. PASSENGER AND GOODS} ROERS PLATFORMS RALERIDGE' fONAL TRONENG 1) 4500 MIN. FORINTERSTATE RAL TRAFF {h Ss00 MIN WINERE STANDARD OVERHEAD HuASTS ARE LOCATED BETWEEN TRACKS aa 7 asrmcesuensunnscunerorms | 2 ce ces ro cmacrneonermcTon ret | > mvc cence Tm 1 et TA ener ace coer «Poms eran oe sma ena eae sea nee 4 PIERS BETWEEN TRACKS SHALL HAVE