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Technical Specification & Scope of Work 02/05/2012

Technical Specification and Scope of Work

DESIGN, MANUFACTURE, DELIVERY &


COMMISSIONING OF ROAD RAIL EQUIPMENT
TO SUIT ISUZU FSS550 DUAL CAB TRUCKS

May 2012
Technical Specification & Scope of Work 02/05/2012

Contents

1. GENERAL......................................................................................................................................... 4
1.1 EXTENT OF WORK .......................................................................................................................... 4
1.2 DEFINITIONS .................................................................................................................................. 4
1.3 SCOPE OF WORKS ........................................................................................................................... 5
1.4 CONTRACTOR’S RESPONSIBILITIES .................................................................................................. 5
1.5 CERTIFICATION .............................................................................................................................. 6
1.6 DRAWINGS...................................................................................................................................... 6
1.7 SUPPLY AND DELIVERY OF MATERIALS .......................................................................................... 6
1.8 MATERIALS - GENERAL................................................................................................................... 6
2. STANDARDS, REFERENCES, POLICIES AND PROCEDURES............................................. 7
2.1 GENERAL........................................................................................................................................ 7
2.2 ARTC STANDARDS ......................................................................................................................... 7
2.3 AUSTRALIAN STANDARDS ............................................................................................................... 8
3. ROAD RAIL EQUIPMENT SPECIFICATIONS.......................................................................... 9
3.1 GENERAL SCOPE ............................................................................................................................ 9
3.2 BASE VEHICLES ......................................................................................................................... 9
3.3 GENERAL TECHNICAL DETAILS ................................................................................................ 10
3.4 SAFETY INTERLOCKS .................................................................................................................... 11
3.5 BRAKE SYSTEM DETAILS............................................................................................................... 12
3.6 RAIL WHEEL DETAILS .................................................................................................................. 12
3.7 ROAD WHEEL DETAILS ................................................................................................................ 13
3.8 ELECTRICAL SYSTEM..................................................................................................................... 13
3.9 EVENT DATA RECORDER ............................................................................................................. 14
3.10 HYDRAULIC & PNEUMATIC SYSTEMS ....................................................................................... 14
3.11 ACCESS & EGRESS .................................................................................................................... 15
3.12 ADR COMPLIANCE .................................................................................................................. 15
3.13 STRUCTURAL WELDING & FABRICATION ................................................................................. 16
3.14 SURFACE PREPARATION & COATINGS ...................................................................................... 16
3.15 SIGNAGE .................................................................................................................................. 17
3.16 EQUIPMENT SUPPORT & SPARE PARTS ..................................................................................... 17
3.17 LIAISON WITH ARTC DISCIPLINES, EXTERNAL AND THIRD PARTIES......................................... 18
4. PROVISIONAL TECHNICAL UPGRADES .............................................................................. 18
4.1 DERAILMENT RESTRAINT SYSTEM ................................................................................................ 18
4.2 TRACK CIRCUIT PROTECTION................................................................................................... 18
4.3 HYDRAULIC TRUCK CRANE RAIL GRABS ................................................................................. 18
5. ACCEPTANCE CRITERIA.......................................................................................................... 18
5.1 REGISTRATION OF EQUIPMENT .................................................................................................... 18
5.2 TYPE TESTS ................................................................................................................................... 19
5.3 COMMISSIONING........................................................................................................................... 19
5.4 CERTIFICATION OF COMPLETED WORK ....................................................................................... 20
5.5 DEFECTS LIABILITY PERIOD ......................................................................................................... 20
5.6 HANDOVER DOCUMENTATION .................................................................................................... 20
5.7 TRAINING ..................................................................................................................................... 21
5.8 COMPONENT MAINTENANCE PROGRAM ...................................................................................... 21
5.9 SAFETY ......................................................................................................................................... 21
6. QUALITY ASSURANCE .............................................................................................................. 22
6.1 QUALITY SYSTEM STANDARD ....................................................................................................... 22
6.2 QUALITY PLAN ............................................................................................................................. 22

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6.3 INSPECTION AND TESTS................................................................................................................ 22


6.4 RECORDS ...................................................................................................................................... 23
6.5 QUALITY AUDIT AND NON-CONFORMANCES ............................................................................... 23
6.6 OCCUPATIONAL HEALTH AND SAFETY ......................................................................................... 23
7. ENVIRONMENTAL ...................................................................................................................... 23
7.1 GENERAL PROTECTION OF THE ENVIRONMENT .......................................................................... 23
7.2 ENVIRONMENTAL CONDITIONS ................................................................................................... 23

Appendices

A Schedule of ARTC Supplied Drawings


B Estimated Vehicle Delivery Schedule
C File Attachments

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1. General
1.1 Extent of Work

This technical specification provides the requirements for the design, manufacture, delivery and
commissioning of up to 12 sets of road rail equipment for use by the Australian Rail Track
Corporation. ARTC may select any number of installations from a variety of suppliers depending
upon the commercial and technical outcomes.
This document should be read in conjunction with any other documents supplied and includes the
construction requirements specified and references to ARTC’s nominated standards for design,
manufacture and installation, maintenance and other works needed in associated with the proposed
scope of work.

1.2 Definitions
Unless defined otherwise in the Contract documents, terms used in this Specification shall have the
following meanings assigned:
‘Approved’ shall mean approved in writing by the Project Manager
‘ARTC’ shall mean Australian Rail Track Corporation
‘Contractor’ shall mean the Contractor engaged for the work to be carried out under this
Specification
‘DIRN’ Defined Interstate Rail Network. Covers all mainline track between capital
cities and other locations operated by interstate freight services.
‘Equipment’ Shall mean the road rail equipmen and all associated installed components
‘FEA’ means Finite Element Analysis, a mathematical technique for analyzing stress,
which breaks down a physical structure into substructures called finite
elements.
‘IP’ shall mean the Ingress Protection rating of the product as per AS1939
‘NDT’ Non-destructive testing
‘Project Manager’ shall mean the ARTC’s nominated Project Manager or representative
‘Project Quality Plan’ shall mean the Contractor’s Project Quality Plan for the Project
‘Rail Corridor’ The area containing the rail tracks, rail junctions, level crossings, station
buildings, platforms, signal boxes, tunnels, bridges and other associated
structures. This area is often defined by railway boundary fencing and in the
absence of such fencing, is defined by a physical boundary (i.e. tunnel, building
or retaining walls).
‘RMS’ shall mean the Roads & Maritime Services NSW, formely known as the Roads
& Traffic Authority
‘Site’ The area of land detailed by the Contractor as the location for the
performance of the specified design, construction and installation works.

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‘TOC’ Shall mean the ARTC Train Operating Conditions manual


‘Track’ The rails, sleepers, pad/plinths and fastenings, associated mechanical and
electrical components and, as appropriate, ballast bed /concrete slab above
formation level including points, crossings and plain track.
‘WOS’ ARTC Wagon Operating Standards

1.3 Scope of Works


Works under this Contract comprises the supply of all facilities, supervision, labour, plant, materials
and consumables as necessary to undertake the design, manufacture, supply and installation of
components required to provide completed and operational road rail equipment in accordance with
the agreed delivery schedule. This includes, but is not limited to the following items that shall be
required to be performed in accordance with the Contract documents, specification and drawings:
1. Project Management and supervision to implement and coordinate the performance of the
work including the preparation of a project management plan and specific OH&S and Quality
Management Plans and work programs, schedules and reports in accordance with the Project
Manager’s requirements.
2. Environmental and Safety management of all construction activities.

3. Provision quality assurance, client liaison, procurement, scheduling and programming services
to the Project Manager and to ensure the avoidance of delays in delivering the equipment to
ARTC.
4. All design work necessary for the equipment structure, integration and operation of the road rail
system components and any necessay controls to the base vehicle supplied.
5. Mobilisation to site of all plant, equipment & personnel necessary to undertake the works.

6. Taking delivery of any ARTC supplied equipment in preparation for their installation as may be
required.
7. Completion of all necessary performance testing and commissioning required to ensure
compliance with ARTC nominated standards.
8. Perform surface preparation, priming, painting and signage of installed equipment in accordance
with ARTC’s Painting and Signage requirements.
9. Where required, demobilisation of plant, labour and establishment facilities from site at the
conclusion of the works.
10. Provision of as built information and drawings, general project documentation and reports
related to the work, including safety, production, QA etc as requested by the Project Manager.

1.4 Contractor’s Responsibilities


The Contractor is responsible for designing, constructing, delivery and installation of the road rail
equipment to ARTC supplied vehicles using a conforming design supplied by the Contractor in
accordance with ARTC’s nominated standards as outlined in Section 2.1 and additional technical
requirements provided in Section 3.

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The Contractor shall provide all qualified and certified personnel, plant, equipment, vehicles, tools,
materials and consumables necessary to perform the work as specified. The Contractor shall
provide all necessary site facilities to complete the specified works.

1.5 Certification
All major materials and manufactured components supplied for the work by the Contractor shall be
accompanied by a certificate from the supplier stating compliance with the Specification and any
relevant ARTC and/or Australian Standards, together with such details and parameters required to
be supplied by those documents and/or the Project Quality Plan.
Additional mandatory certification requirements are detailed in Section 5.

1.6 Drawings
Appendix A contains all drawings issued by ARTC for the performance of the work. Additional
drawings may be included at a later date. These will be issued as an amendment to the specification.

1.7 Supply and Delivery of Materials


The Contractor shall supply to site all necessary materials to complete the works. All materials for
use as part of the Contract must be in accordance with the relevant ARTC and/or Australian
Standards or approved for use by the Project Manager. The Contractor shall also undertake
additional testing at no cost to the Project Manager if the Contractor supplied materials do not
conform to the requirements of this Contract or any other previously approved “non conforming”
specifications.

1.8 Materials - General


The Contractor must in its Quality Plan describe what procedures and tests will be adopted to
ensure that all supplied materials comply with the requirements of the standards outlined in this
Specification. During the performance of this Contract, the Contractor must implement its quality
procedures, verify that the materials comply with the specified standards, and have quality
documentation to verify this has been achieved.
Materials that are damaged or fail compliance after handling, transport and storage must be reported
to the Project Manager.
Materials that do not comply with the specified standards must not be used in the Works. The
Project Manager may carry out independent examination and testing of materials that have been
supplied, stored, handled, transported and or installed. The Contractor must provide any necessary
facilities and assist the Project Manager in such independent examinations and tests. The
independent testing organisation to be used in any such examinations and testing shall be NATA
approved.
Materials that fail to comply with the specified standards are liable to rejection for use in the Works
and where initially supplied by the Contractor are to be replaced at the Contractor’s expense.
The preferred construction material is AS/NZS 3678 – 300 and 350 grade structural steel.

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2. Standards, References, Policies and Procedures


2.1 General
All design, materials, plant, equipment, workmanship and installations must comply with current
revisions of ARTC’s Engineering Standards, Network Rules and Regulations, Policies and
Procedures, National Codes of Practice, Commonwealth OH&S Acts & Regulations 2011,
Workplace & Rail Safety Regulator requirements and Australian Standards relating to the relevant
element or component of the Works unless otherwise noted in this Specification.
Where conflict exists between any statutory requirements, standards, reference documents, and this
specification, the most stringent requirement shall apply. The Contractor must not deviate from the
provisions of the relevant standards and specification without approval.
For items of overseas manufacture that are not in accordance with Australian Standards, relevant
overseas standards must be subject to consent from the Project Manager prior to proceeding with
design or manufacture of equipment.
Latest ARTC Engineering Standards, Policies, Procedures and Network Rules and Regulations are
available from www.artc.com.au
Australian Standards are available from:
http://www.saiglobal.com/shop/Script/Provider.asp?Db=AS

2.2 ARTC Standards


The following Standards listed apply to this specification and are accessible through the ARTC
website. The Contractor is required to make themselves aware of all relevant and current ARTC
standards including those listed.
The work performed under this Contract shall be in accordance with at least the following
standards:

PP139.1 General Plant Requirements

WOS01 Minimum Operating Standards for Rolling Stock

WOS01.010 General

WOS01.100 General Interface Requirements

WOS01.200 Common Interface Requirements

WOS01.700 Track Maintenance Vehicle Specific Interface Requirements

The following links provide direct access to these standards.

http://extranet.artc.com.au/eng_rolling-stock_procedure.html

http://extranet.artc.com.au/eng_plant-equip-ex.html

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2.3 Australian Standards


The Equipment must comply with all requirements of Australian Standard AS4292.3-1997-Part 3
entitled “Railway safety management-Rollingstock” which covers the requirements for safe
operation of rollingstock in Australia.
In addition the following Standards listed are directly applicable to this specification and are
accessible through the RISSB website at http://www.rissb.com.au/linkdev/site/index.php The
Contractor is required to make themselves aware of all relevant and current Australian standards
pertaining to this work.
The work performed under this Contract shall be in accordance with at least the following
standards:
AS1627 Preparation and Pre-treatment of Steel Surfaces

AS2312 Protection of Steel Work against Atmospheric Corrosion

AS4360 Risk Management

Australian Standards pertaining to rolling stock design may also apply and should be reviewed by
the Contractor prior to design and construction. Forward compliance with these draft standards is
preferred.

Draft standards relating to Infrastructure Maintenance Vehicles can be viewed at:

http://www.rissb.com.au/site/products_rollingstock.php

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3. Road Rail Equipment Specifications


3.1 General Scope
This section describes the work associated with the design, supply, manufacture, testing,
commissioning and provisional technical upgrades associated with the road rail equipment which
includes, but is not necessarily limited to the following:
1. Undertake the work to design, construct, test and commission the road rail equipment in
accordance with this Specification.
2. All design and construction activities necessary to provide safe and fit for purpose road rail
equipment
3. Design activities necessary to integrate the road rail equipment into base vehicle operation.

4. Research and design necessary to facilitate any of the provisional upgrades where approved by
ARTC.
5. Procurement of all necessary materials and equipment required to undertake the work.

6. Corrections to defective work or materials attributed to the Contractor at the Contractors


expense.
7. Provision of as built information indicating the work has been completed within the specified
tolerances.
8. Provision of drawings and manuals.

9. Provision of operating instructions including safety checklists for each type of activity.

10. Provision of all training requirements for operators and maintenance crews.

3.2 Base Vehicles

The road rail equipment supplied under this agreement shall be compatible for installation on the
following vehicle class:
Model Description Configuration GVM (Tonne)
Isuzu FSS550 CREW PTO 4x4 10.0

These vehicles shall have the bodies and any ancilliary equipment including cranes & suspension
upgrades fitted prior to supply & installation of the road rail equipment. Refer to Appendix A for
the base vehicle chassis drawings and specifications.

The vehicles shall be supplied and bodies fitted by a Newcastle based dealer.

In order to minimise vehicle transport & inspection costs, ARTC’s preferred build location is on
the Eastern seaboard of Australia. The Contractor shall nominate the anticipated installation
location for the road rail equipment.

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Alternate locations may be considered if deemed cost neutral to ARTC.

The proposed vehicle supply schedule is included in Appendix B.

The Contractor shall nominate their proposed build schedule to match the delivery of each
vehicle.

3.3 General Technical Details


The road rail equipment shall be capable of performing the following functions:
1. All equipment shall be designed and manufactured to suit the Australian Standard Gauge
railway network with a 1435mm operating gauge.
2. All completed road rail vehicles shall be compliant with standards detailed in WOS 01.700.
3. Whilst on track the road rail vehicle shall be fully compliant with the Narrow Non-Electric
Rolling Stock Gauge at all times during transit, whilst empty or loaded. Refer Appendix A –
Figure 1 for the operating clearance dimensions.
4. All road rail equipment manufactured from new shall be constructed from new materials only.
5. The road rail equipment shall be securely bolted to the vehicle chassis and shall not create stress
concentration areas resulting in early life failures of the chassis components.
6. The road rail equipment shall not be welded to the vehicle chassis in any location.
7. Where required, suitable chassis strengthening plates must be supplied and fitted to eliminate
potential fatigue related failures.
8. The Contractor shall provide FEA results prior to commissioning for both the road rail
equipment and the vehicle chassis incorporating typical loads to be applied to and by the road
rail equipment both when stored & in use.
9. The road rail equipment shall be readily transferable between vehicles of identical make &
model.
10. The road rail equipment shall incorporate an over-centre design to ensure the weight of the
vehicle assists in retaining the rail equipment in the on-track position.
11. The system used to deploy the road rail equipment shall be suitably sized to ensure it can readily
overcome the full laden weight of the selected vehicle to reach the over centre position.
12. The road rail equipment shall be adjustable to enable correct alignment between the rail wheels,
the vehicle chassis and the rail head, including:
a. Parallel alignment of the rail kit and wheels to the road wheels
b. Alignment of the rail kit to the vehicle centre line
c. Adjustment of the rail wheel back to back gauge to between 1358 & 1360mm
d. Adjustment of front rail wheel toe-in for stable operation on track

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13. The road rail equipment shall incorporate a suspension system to provide a smooth ride on rail
and enable appropriate wheel loading for all conditions of operation.
14. The road rail equipment suspension shall be adjustable to enable correct balancing of rail wheel
loading to ensure safe operation on track, minimise rail equipment fatigue and achieve no
greater than 50% wheel unloading when subjected to a static vehicle twist test as described in
WOS 01.283.
15. All suspension units must be suitably sized for the intended applied load under al l operating
conditions.
16. The road rail vehicle shall be capable of minimum safe operating speeds on track of 50km/hr.
Any proposed deviation from this rated speed shall be clearly stated by the Contractor in the
offer document.
17. The road rail vehicle shall be capable of operating safely at its rated speed on the DIRN through
all degrees of track curvature from tangent track to 180m radius curves and reverse curves with
no transition.
18. The road rail vehicle shall also be required to negotiate 70 metres radius curves and turn-outs in
yards.
19. The road rail vehicles must be capable of achieving the base ride performance requirements
specified in WOS 01.288
20. The road rail equipment shall be designed to prevent pooling of water in any structural areas
which may otherwise accumulate through rain periods or travel through ground water.
21. All supplied road rail equipment shall be permanently labelled with the manufacturer’s unique
serial number for ongoing asset identification purposes.

3.4 Safety Interlocks


The system shall incorporate coordination rules, lockouts &/or warning systems to avoid
unintentional movement of road rail equipment while in use or stored. As a minimum the
following shall be provided:
1. An in cabin audible warning alarm shall indicate when the road rail equipment is not in one of
it’s designated operational or stored positions.
2. When in the stored position, the rail equipment must be automatically restrained to prevent
creep down when the vehicle is in use on road. The use of manually applied chains, shackles or
locking pins is not preferred.
3. Separate provisions must be made for the installation of a proximity detection switch(as per
item 3.8.13) to identify when the rail equipment is in the fully deployed position. This indication
will be used as an input to the event data recorder to be supplied by ARTC as detailed in
Section 3.9.
4. Front axle locks must be suitably designed and installed to fully restrain and support the front
road axle when on rail. The front axle locks must be integrated into the road rail engagement
system to automatically restrain & release the front axle in the appropriate sequence without
further input from the operator.

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3.5 Brake System Details


The general technical requirements for brake system design and installation on road rail equipment
covered by this Contract include the following:

1. All brake systems & brake performance shall be in compliance with WOS 01.722

2. All brake componentry must be new and not used or reconditioned.

3. Details of all proposed brake componentry must be included in the offer document.

4. All brake system componentry must be readily available from Australian suppliers.

5. All brake componentry must remain within the Narrow Non-Electric Rollingstock outline at all
times.

6. Vehicles with front elevated steer axles must incorporate suitable braking systems to achieve the
brake performance outcomes stated in WOS01.722.

7. The Contractor shall ensure that proper storage, handling and installation techniques are
employed to maintain internal cleanliness of all brake system componentry.

8. Provisions for independent emergency rail wheel brake applications will be required where
vigilance systems are fitted to road rail vehicles. The Contractor is to advise how this would be
achieved.

3.6 Rail Wheel Details


The general technical requirements for wheels covered by this Contract must comply with the
requirements of WOS 01-200 and include the following:

1. All wheels shall be new and of low stress design.

2. All wheels are to be non-insulated.

3. All wheels shall conform to the ANZR1 wheel profile as shown in Appendix A – Figure 2.

4. Wheels conforming to the WPR2000 or other wheel profiles will not be accepted.

5. Wheels shall be manufactured to comply with AAR Class B material or equivalent.

6. Wheels shall not be painted, however they may be coated with a rust preventative solution
which is to be removed prior to commissioning.

7. Wheel sizes are to be uniform across the vehicle unless specifically approved by the ARTC
Project Manager.

8. The Contractor shall provide a detailed, dimensioned diagram of the wheel construction with
the tender response including details of materials used for manufacture and any material
hardness specifications.

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9. Wheels with visible surface defects may be rejected by the Project Manager and must be
replaced by the Contractor at no cost to ARTC.

10. Axle bearings shall have no in-field lubrication requirements between scheduled servicing.
Bearing service life shall be calculated and must exceed the minimum service interval of 6
months without deterioration or failure.

11. Bearing seals must be carefully selected to minimise water and dust ingress during service.

12. Stub axle shafts must be suitably designed and manufactured to minimise stress raising areas.

3.7 Road Wheel Details


The general technical requirements for wheels covered by this Contract must comply with the
requirements of WOS 01.723.

Where dual rear wheels are fitted to heavy vehicles by the OEM, the Contractor shall identify and
supply suitable single replacement wheels & tyres to ensure compliance for both on road and on rail
use.

Consideration of this must include allowable wheel point loads, axle loads, GVM rating, rail head
coverage, lateral centering of road wheels and rail wheels, operating speed and appropriate tyre
construction.

Consideration must also be given to spare wheels and the available space for spare wheel transport.

3.8 Electrical System

Where electrical equipment is installed, the following items are mandatory and compliance shall be
achieved by the Contractor’s proposed equipment.

1. The electrical control system shall be 12 or 24 volt DC to match that of the base vehicle.
2. A complete electrical schematic diagram detailing all standard electrical wiring is to be supplied
with the equipment.
3. An electrical component parts listing shall be provided with the equipment service manuals.
4. All wiring external to control cabinets must be fully insulated and housed in non-split protective
flex conduit.
5. All wiring must comply with AS3000 and be suitably sized for the current carrying capacity
required.
6. Electrical wiring must not be attached to hydraulic hosing.
7. Scotch locks must not be used to join wires.
8. Use of standard or glue based heat shrink materials is encouraged to insulate and seal exposed
wiring joints and connections.
9. Electrical wiring and componentry must not be in contact with high temperature sources.
10. Cable lugs must be used for wiring terminations.
11. All earth point connections must contact with bare metal.
12. The ‘IP’ rating of cabinets & enclosures intended for use on the project shall be minimum IP66.

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13. Inductive proximity switches are preferred for sensing the location of stored or deployed
equipment. The preferred sensor type is Turk Uprox part no: Ni12U-EG18SK-AP6X. Flexible
rod or spring type limit switches will not be accepted.

3.9 Event Data Recorder

All new road rail vehicles are required to be fitted with an operational event data recorder
(Circuitlink black box) in order to comply with rail safety regulations. The event data recorder shall
be supplied by ARTC and installed by the Contractor in accordance with the manufacturer’s
instructions.

The event data recorder will typically record factors such as:
• Operational speed
• Engine RPM
• Engagement of road rail equipment
• Amber beacon operation
• Air horn operation
• Headlight operation
• Service brake application
• Reverse gear engagement
• Park brake application

3.10 Hydraulic & Pneumatic Systems


Where hydraulic and pneumatic equipment is installed the following items are mandatory and
compliance shall be achieved by the Contractor’s proposed equipment.

1. The hydraulic circuit must be designed to prevent component failure as a result of high
hydraulic fluid temperatures. Hydraulic oil temperatures must not exceed OEM recommended
temperatures during normal operation at ambient operating conditions.
2. Due to extreme weather conditions in Australia it is a requirement that an appropriately sized oil
cooler be employed in the hydraulic system to maintain system temperatures when ambient
temperatures exceed 40 degrees Celsius.
3. The hydraulic system shall be compatible with SAE 68 hydraulic oil.
4. The specification of all hydraulic/pneumatic pumps and motors used on the equipment or as
accessories must be provided. All parts used are to be readily available from well known
hydraulic distributors e.g. Parker, Rexroth.
5. A suitably designed emergency manual pump system must be included to raise and lower the hi-
rail equipment in the event of primary system failure. The circuit design for the emergency
system must ensure that it is effectively isolated from the primary hydraulic system when not in
use.
6. Clear diagrammatic instructions must be provided for operation of the manual pump system.
7. The vehicles to be supplied will be fitted with PTO output facilities. Any intention to utilise this
power source for operation of the hi-rail system shall be nominated by the Contractor in the
tender response.

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8. All circuits must incorporate adequate system filtration. Filter type, bypass pressure (if
applicable) and absolute rating specifications must be clearly stated by the Contractor.
9. All hydraulic components must be capable of withstanding maximum static and surge pressures
generated within the system.
10. All hydraulic hoses must conform to S.A.E. standards with double braid non-skive hydraulic
hose with swaged ends.
11. Permanent steel piping must be used wherever hydraulic line passes through the chassis.
12. Hydraulic hoses must not be located in areas or positions where they are subjected to excessive
abrasion or wear. The use of ‘tough cover’ hosing and or spiral wrap is recommended in areas
of susceptibility.
13. All hydraulic cylinders shall have chrome plated piston rods.
14. Hydraulic cylinders subject to damage from flying rocks must have the piston rods adequately
protected to prevent pitting of the surface.
15. All hydraulic hoses located near the operator must be shielded to minimise the risk of injury
resulting from hydraulic hose failures.
16. All hydraulic tanks must:
a. Have the tank contents clearly labelled including grade of hydraulic oil used
b. Be fitted with an easily accessible drain point
c. Be fitted with visual features for readily determining tank content level

3.11 Access & Egress


Operation of road rail vehicles on track often leads to reduced access and egress to the base vehicle
as a result of increased body lift and restricted access from the sloping track shoulder. Contractors
must address this issue by installing appropriate additional steps (and where required grab handles)
to ensure appropriate front and rear cabin access is maintained when the vehicle is in use on track.
A typical track construction diagram is included in Appendix A.

Tread surfaces for all additional steps shall be slip resistant and no more than 500mm above rail
head to the lowest access point.

Installation of the additional access points must not interfere with normal on-road use and
operational underbody clearances.

Additional steps may be retractable but shall not be removable. Any retractable steps must include a
warning system to the operator if not fully retracted when transferring to road use.

3.12 ADR Compliance


All modifications undertaken to the base vehicle during the installation of the road rail equipment
must ensure compliance can still be maintained to the Australia Design Rules for motor vehicles.

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Changes to the body outline, lighting position, exhaust system and other vehicle systems affected
must be addressed in order to ensure an engineering certificate for a modified production vehicle
can be issued by an RMS authorised signatory.

Where the front rail equipment protrudes beyond the original bumper outline, suitable protection
must be put in place to minmise pedestrian injury potential. Fully enclosed designs are preferred.

3.13 Structural Welding & Fabrication

All welding shall be in accordance with the Australian Standards including but not limited to:
• AS 1554.1:2000 - Structural steel welding - Welding of steel structures,
• AS 1554.4:1995 - Structural steel welding - Welding of high strength quenched and
tempered steels
• AS1554.5:1995 - Structural steel welding - Welding of steel structures subject to high levels
of fatigue loading.
All welding shall be pre-qualified with tradespersons qualified in accordance with AS 1554.

All structural sections shall be continuous and where applicable seal welded to prevent entry of
moisture. Single sided fillet welds are not permitted on main structural members.

NDT inspection shall be carried out on all critical welds as specified on manufacturing drawings.
Test reports must be provided for all NDT.

Welding may be subject to further close inspection before acceptance and other non-destructive
testing methods may be employed at the discretion of the Project Manager.

The cost of rectification and recertification of any defective welds shall be to the Contractors
account.

High resistance welding return circuits are detrimental to good welding under any circumstances
and should avoided.

All completed welds are to be cleaned of slag and weld spatter and suitably primed to prevent the
onset of corrosion.

3.14 Surface Preparation & Coatings

All external steel surfaces of new structural installations & repairs including welded surfaces shall be
prepared in accordance with the requirements of AS1627 and painted to prevent corrosion in
accordance with the requirements of AS2312.

The Contractor shall prepare the surface, prime and apply appropriate surface coatings to all new
structural & mechanical equipment. All surfaces shall be prepared, primed and painted to provide a
protective coating with a minimum film thickness of 160 microns and to give a 10 year service life.

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Rail wheels are not to be painted but may be supplied with surface coating protection to prevent the
onset of corrosion prior to commissioning.

3.15 Signage

Operating instructions & safety signage complying with AS1319 shall be installed to indicate
hazards where appropriate following full curing of the paintwork. This shall include supply and
installation of in-cabin warning and instruction labels.

Installation of ARTC supplied logos and reflective delineators shall also undertaken by the
Contractor prior to commissioning.

3.16 Equipment Support & Spare Parts

The Contractor shall advise in their offer document the locations & contact details of approved
service agents for the proposed equipment.

The successful Contractor shall provide one complete parts lists (bill of materials) specifying all
items in electronic format. Items of a repairable/rotable nature need to be identified as such.

Based upon the knowledge of the proposed equipment and its intended use within the ARTC
operations, the Contractor shall apply one of the following usage categories to each item in the
electronic schedule:

Category Description
A Stock turnover greater than 4 per year per unit
B Stock turnover between 1 and 3 per year per unit
C Slow moving stock (less than 1 per year per unit)
D Long lead time item either capital or insurance spare

For items not manufactured by the Contractor, the original manufacturer’s name and reference
number is required against each item on the electronic bill of materials.

Items that have a shelf life or require special storage conditions are to be highlighted on the
electronic bill of materials.

The Contractor must bring to the notice of ARTC, any hazardous or dangerous goods by notating
on the electronic bill of materials, the applicable UN hazardous goods code, dangerous goods
rating, including material safety data sheets for products considered to be hazardous and or
dangerous.

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3.17 Liaison with ARTC disciplines, external and third parties


The Contractor shall be required to liaise with relevant third parties and ARTC personnel as may be
required or where directed by the Project Manager to ensure the effective completion of the works.

4. Provisional Technical Upgrades


The following items are deemed provisional and all upgrades offered are subject to review by ARTC
prior to inclusion. These provisional items include:

4.1 Derailment Restraint System


If not provided in the base tender, the Contractor may tender options for additional restraint
systems to limit transverse movement and assist the road rail vehicle to remain on the track
structure in the event of a derailment

4.2 Track Circuit Protection


The Contractor may provide options for the supply of equipment to prevent track circuit activation
through insulation of rail to rail contact via the road rail equipment. The supplied base equipment is
to be non-insulated.

4.3 Hydraulic Truck Crane Rail Grabs


The Contractor may provide options for the supply of hydraulic rail grabs to provide effective
stability to the vehicle whilst stationary on track when the truck mounted crane is in use (where
fitted). The Contractor shall coordinate all necessary information with the crane supplier to ensure
the appropriate vehicle stability calculations are performed to ensure the crane is safe to use when
on track in rail mode without the OEM supplied stabilisers being used.

5. Acceptance Criteria
5.1 Registration of Equipment
All completed road rail equipment when in travel or work mode shall conform to the Narrow Non
Electric Rolling Stock Profile and provide the equivalent swept path as per the ARTC standard
WOS01.100 General Interface Requirements.
Prior to completion and on track commissioning, the Contractor must provide all relevant
information to enable the application for a TOC waiver for testing purposes. The general period of
time required to permit listing of a TOC Waiver for equipment is approximately 8 weeks from
submission of the required information. The ARTC TOC waiver website address is
http://www.artc.com.au/nsw/toc-waivers.htm.

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5.2 Type tests

Prototype vehicles of each type are to be tested independent of the remainder of the fleet to ensure
all operational requirements are met prior to the completion and commissioning of the entire fleet.
Any defects or operational deficiencies noted in the testing of the first completed road rail vehicle
shall be addressed by the Contractor in the following equipment builds.

ARTC shall arrange the ride performance & brake performance testing of the type test vehicle. The
Tender shall rectify any deficiencies found and may be responsible for re-testing costs if necessary.

5.3 Commissioning

A detailed final commissioning program must be provided with the tender. The final
commissioning program will specify the milestones that will be used to indicate that the equipment
is attaining the expected levels of performance. The Contractor will not receive final documented
acceptance of the equipment until the Project Manager is satisfied that all expected performance
criteria have been achieved.

Any item which fails to be commissioned successfully in the first instance shall be subjected to a
repeat performance assessment in accordance with the above process once the identified defects
have been rectified. The duration and timing for completion of the repeat commissioning period
shall recommence once the equipment is deemed fit for service.

The final commissioning and testing of the equipment will be carried out at an ARTC provided
proving area in conjunction with the Project Manager and or other representatives of ARTC.

A comprehensive commissioning report will be provided by the Contractor at the completion of the
equipment commissioning period.

The commissioning report must include but is not limited to the following:-

1. The equipment shall be checked to ensure that all specification criteria are satisfied.
2. A thorough check of all essential fluid levels and lubrication points must be conducted before
testing.
3. Testing will involve equipment operation through all normal operating cycles.
4. Completion and documentation of rail equipment alignment and twist test results to the
satisfaction of the Project Manager
5. Testing of the rail equipment over centre activation under full GVM conditions
6. Testing of the emergency hand pump system
7. Ontrack acceptance testing for general ride, stability & handling
8. Details of testing procedures and test equipment will be recorded and included in the report.
9. Completion of the ARTC’s Vehicle Information Pack – WOS 01.A5 for the purposes of
achieving a final TOC waiver

The report must be signed by the Project Manager to the effect that all tests were undertaken and
the results were correct.

Final documented acceptance of the Equipment will be provided by the Project Manager only.

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5.4 Certification of Completed Work


Before the Project Manager accepts any completed equipment, the equipment must be made
available to be inspected by the Project Manager and any adjustments and corrections are to be
completed by the Contractor.

The Contractor will be responsible for providing engineering signoff for all design, construction &
modifications performed. The engineering signatory must be competent to perform such
authorisation.

5.5 Defects Liability Period


Subject to ARTC’s rights at law the Contractor shall maintain the road rail equipment free from
defects for a period of 12 months from the date of commissioning. Defect items shall include, but
shall not be limited to:
• Faults in any materials supplied and or installation work by the Contractor (excludes any
ARTC supplied material);

5.6 Handover Documentation


Prior to commissioning the Contractor shall provide a handover package containing, but not limited
to, the following documentation:
1. Two (2) sets of as-built hardware schematics including full electrical wiring diagrams.

2. Two (2) sets of as-built PLC program documentation where applicable.

3. Two (2) sets of full maintenance and spare parts manuals (including settings, service and
maintenance schedules).

4. One (1) copies of fully priced spare parts listings. The spare parts listings are to contain tender
and original parts manufacturer part numbers. These listings must be received in time to allow
the order and delivery of maintenance and insurance spare parts. See Section 3.19 for further
detail.

5. One (1) electronic copy on CD of the operational Risk Assessment.

6. Two (2) Copies of the Operational instruction manual plus One (1) copy of operational
instruction manual per vehicle

7. Two (2) copies per vehicle of the completed twist compliance and road rail equipment
alignment results as per ARTC standard PP139.2F-02 and PP139.2F-03.

All literature must be written in English.

One set of digital drawings (to Australian Standards) are to be provided with the equipment. These
drawings must show sufficient detail and dimensions to ensure that the equipment may be fully
maintained by ARTC’s workshops or designated Contractors.

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The Contractor shall produce all final as built drawing according to ARTC Drawing Management
Procedure PP117.4. A copy of the requirements of this standard and drawing sheet templates will
be made available to the Contractor by the Project Manager.

In the event that ARTC requires access to detailed technical information due to statutory or legal
requirements, the Contractor must make available the following items upon request:

• Detailed mechanical and structural drawings.


• Design calculations and material specifications.

5.7 Training

An appropriate competency based training program will be tendered with the proposed equipment.

The Contractor shall be required to co-ordinate all training into a single training package.

This training shall be carried out prior to the final commissioning of the equipment.

Provision shall be included for twelve (12) operating and three (3) maintenance personnel to attend
the initial training program.

5.8 Component Maintenance Program

The Contractor must provide a detailed component maintenance schedule for the effective
maintenance of all the individual equipment components. This schedule must be supplied on CD
and must be suitable for use in current Microsoft software packages.

The Contractor must supply safe working procedures for all maintenance tasks. The safe working
procedures must be supplied on CD and must be suitable for use in current Microsoft software
packages.

All of the “safe working procedures”, “operational risk assessment” and “component maintenance
schedules”, as specified must be supplied prior to the delivery and commissioning of the equipment.

5.9 Safety

An Operational Risk Assessment shall be facilitated by the Contractor and shall be provided prior
to final commissioning of the equipment and should be to the AS4360-2004. This risk assessment
should at minimum cover:
• Pre-start checks
• Set up and de-rigging
• Maintenance
• Operations
• Other risks

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6. Quality Assurance
6.1 Quality System Standard
The Contractor shall maintain a documented Quality System in accordance with this document and
with an Australian Standard for Quality System in accordance with AS/NZ ISO 9001/2. The
quality system shall cover the whole of the work under this Contract.

6.2 Quality Plan


The Quality Plan shall detail how the Contractor will manage and control the quality of the work
under the Contract. The plan is to be submitted to the Project Manager. Works are not to proceed
until the Quality Plan is approved by the Project Manager.
The Quality Plan shall include:-
1. Management responsibilities specific to the Contract including the responsibility and authority
for quality.
2. Organisation(s) proposed for the Contract.
3. Qualifications and competencies, including currency, of all staff proposed to be used on the
Contract.
4. Contractor’s method of control of sub-Contract work.
5. All work processes and equipment including equipment, methods and process proposed to be
used:
a. for structural fabrication works
b. for vehicle body works
c. for surface preparation & coatings
6. Site management and supervision.
7. All witness and hold points, and
8. Inspection and test plans.

6.3 Inspection and Tests


During the course of the work the Contractor shall arrange for all relevant testing required by the
Project Quality Plan to be carried out by suitably qualified personnel approved by the Project
Manager. Inspection and Test Plans shall be submitted to the Project Manager for approval prior to
any work commencing. Inspection and test plans shall:-
1. Identify tests/inspections against Contract requirements;
2. Identify hold points;
3. Identify records to be maintained for particular tests and/or inspections; and
4. Detail test equipment to be used for specified tests and/or inspections.

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6.4 Records
The Contractor shall establish and maintain a system of records that provides objective evidence
that the requirements of the Contract have been satisfied.
The Contractor shall make all records pertaining to the Contract available to the Project Manager at
all reasonable times and, where requested by the Project Manager, provide the Project Manager with
a copy of the records.
The Contractor shall as a minimum provide weekly reports on the following:
• Details of progress for the completion of works currently in progress
• All delays, causes and remedial actions taken

6.5 Quality Audit and Non-Conformances


The Contractor shall give the Project Manager access to its or its sub-Contractor’s premises /
working area and to documentation for audit purposes.
The Contractor shall make or arrange to be available all facilities, documentation, records and
personnel, including those of sub Contractors, that are reasonably required for any audits or
surveillance to be undertaken by the Project Manager to ensure specified requirements are being
met.
All non-conformances shall be promptly reported to the Project Manager via non conformance
reports.

6.6 Occupational Health and Safety


The Contractor shall provide and, for the duration of the Contract comply with, a safety
management plan covering the management of occupational health and safety in accordance with
the relevant Statutory Occupational Health and Safety Acts & Regulations for their State or
Territory.

7. Environmental
7.1 General Protection of The Environment
The equipment once completed must comply with ARTC’s Environmental Protection License No
3142 with respect to maintenance of plant and equipment.
http://www.epa.nsw.gov.au/prpoeo/licences/L3142.pdf

7.2 Environmental Conditions

All equipment supplied must be capable of operating under the following range of ambient
conditions which are encountered in the ARTC operations:-

• Dry Bulb Temperature -10 to 50° Celsius.


• Relative Humidity up to 95%

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• Operating Altitude 1370m above to 100m below sea level.

The following points regarding environmental conditions encountered should also be noted when
considering the design and IP rating of exposed and or sealed componentry:

• Periods of torrential rain.


• Salt laden atmosphere.
• Dust containing high silica content may be present in some areas.
• Occasional travel through low lying ground water may be required.
• Harsh ground conditions may be encountered including loose or falling ballast & vibration

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Appendix A
Schedule of drawings supplied by ARTC:

Drawing/ Ref Drawing Title No of


Number Pages
Figure 1 Narrow Non-Electric Rolling Stock Profile 1
Figure 2 ANZR1 Wheel Profile 1
Figure 3 Typical Shoulder Design 1
Figure 4 Isuzu FSS550 CREW PTO specifications 5

TOTAL PAGES 2

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Figure 1 – Narrow Non-Electric Rolling Stock Profile

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Figure 2 – ANZR1 Wheel Profile

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Figure 3
Typical Shoulder Design

Figh

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Appendix B
Estimated Schedule of Vehicle Delivery:

Vehicle Vehicle Available for Rail


Number Equipment Installation
1 1/5/2012
2 1/5/2012
3 1/6/2012
4 1/6/2012
5 1/7/2012
6 1/7/2012
7 1/8/2012
8 1/8/2012
9 1/9/2012
10 1/9/2012
11 1/10/2012
12 1/10/2012

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Appendix C
File Attachments:

Document No Description
WOS 01.700 Track Maintenance Vehicle Specific Interface Requirements
PP139.2F-02 Rail Guidance System Maintenance Inspection
PP139.2F-03 Road Rail Vehicle Twist Compliance Inspection

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Technical Specification and Scope of Work

DESIGN, MANUFACTURE, DELIVERY &


COMMISSIONING OF ROAD RAIL EQUIPMENT
TO SUIT ISUZU FSS550 DUAL CAB TRUCKS

May 2012
Technical Specification & Scope of Work 02/05/2012

Contents

1. GENERAL......................................................................................................................................... 4
1.1 EXTENT OF WORK .......................................................................................................................... 4
1.2 DEFINITIONS .................................................................................................................................. 4
1.3 SCOPE OF WORKS ........................................................................................................................... 5
1.4 CONTRACTOR’S RESPONSIBILITIES .................................................................................................. 5
1.5 CERTIFICATION .............................................................................................................................. 6
1.6 DRAWINGS...................................................................................................................................... 6
1.7 SUPPLY AND DELIVERY OF MATERIALS .......................................................................................... 6
1.8 MATERIALS - GENERAL................................................................................................................... 6
2. STANDARDS, REFERENCES, POLICIES AND PROCEDURES............................................. 7
2.1 GENERAL........................................................................................................................................ 7
2.2 ARTC STANDARDS ......................................................................................................................... 7
2.3 AUSTRALIAN STANDARDS ............................................................................................................... 8
3. ROAD RAIL EQUIPMENT SPECIFICATIONS.......................................................................... 9
3.1 GENERAL SCOPE ............................................................................................................................ 9
3.2 BASE VEHICLES ......................................................................................................................... 9
3.3 GENERAL TECHNICAL DETAILS ................................................................................................ 10
3.4 SAFETY INTERLOCKS .................................................................................................................... 11
3.5 BRAKE SYSTEM DETAILS............................................................................................................... 12
3.6 RAIL WHEEL DETAILS .................................................................................................................. 12
3.7 ROAD WHEEL DETAILS ................................................................................................................ 13
3.8 ELECTRICAL SYSTEM..................................................................................................................... 13
3.9 EVENT DATA RECORDER ............................................................................................................. 14
3.10 HYDRAULIC & PNEUMATIC SYSTEMS ....................................................................................... 14
3.11 ACCESS & EGRESS .................................................................................................................... 15
3.12 ADR COMPLIANCE .................................................................................................................. 15
3.13 STRUCTURAL WELDING & FABRICATION ................................................................................. 16
3.14 SURFACE PREPARATION & COATINGS ...................................................................................... 16
3.15 SIGNAGE .................................................................................................................................. 17
3.16 EQUIPMENT SUPPORT & SPARE PARTS ..................................................................................... 17
3.17 LIAISON WITH ARTC DISCIPLINES, EXTERNAL AND THIRD PARTIES......................................... 18
4. PROVISIONAL TECHNICAL UPGRADES .............................................................................. 18
4.1 DERAILMENT RESTRAINT SYSTEM ................................................................................................ 18
4.2 TRACK CIRCUIT PROTECTION................................................................................................... 18
4.3 HYDRAULIC TRUCK CRANE RAIL GRABS ................................................................................. 18
5. ACCEPTANCE CRITERIA.......................................................................................................... 18
5.1 REGISTRATION OF EQUIPMENT .................................................................................................... 18
5.2 TYPE TESTS ................................................................................................................................... 19
5.3 COMMISSIONING........................................................................................................................... 19
5.4 CERTIFICATION OF COMPLETED WORK ....................................................................................... 20
5.5 DEFECTS LIABILITY PERIOD ......................................................................................................... 20
5.6 HANDOVER DOCUMENTATION .................................................................................................... 20
5.7 TRAINING ..................................................................................................................................... 21
5.8 COMPONENT MAINTENANCE PROGRAM ...................................................................................... 21
5.9 SAFETY ......................................................................................................................................... 21
6. QUALITY ASSURANCE .............................................................................................................. 22
6.1 QUALITY SYSTEM STANDARD ....................................................................................................... 22
6.2 QUALITY PLAN ............................................................................................................................. 22

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6.3 INSPECTION AND TESTS................................................................................................................ 22


6.4 RECORDS ...................................................................................................................................... 23
6.5 QUALITY AUDIT AND NON-CONFORMANCES ............................................................................... 23
6.6 OCCUPATIONAL HEALTH AND SAFETY ......................................................................................... 23
7. ENVIRONMENTAL ...................................................................................................................... 23
7.1 GENERAL PROTECTION OF THE ENVIRONMENT .......................................................................... 23
7.2 ENVIRONMENTAL CONDITIONS ................................................................................................... 23

Appendices

A Schedule of ARTC Supplied Drawings


B Estimated Vehicle Delivery Schedule
C File Attachments

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1. General
1.1 Extent of Work

This technical specification provides the requirements for the design, manufacture, delivery and
commissioning of up to 12 sets of road rail equipment for use by the Australian Rail Track
Corporation. ARTC may select any number of installations from a variety of suppliers depending
upon the commercial and technical outcomes.
This document should be read in conjunction with any other documents supplied and includes the
construction requirements specified and references to ARTC’s nominated standards for design,
manufacture and installation, maintenance and other works needed in associated with the proposed
scope of work.

1.2 Definitions
Unless defined otherwise in the Contract documents, terms used in this Specification shall have the
following meanings assigned:
‘Approved’ shall mean approved in writing by the Project Manager
‘ARTC’ shall mean Australian Rail Track Corporation
‘Contractor’ shall mean the Contractor engaged for the work to be carried out under this
Specification
‘DIRN’ Defined Interstate Rail Network. Covers all mainline track between capital
cities and other locations operated by interstate freight services.
‘Equipment’ Shall mean the road rail equipmen and all associated installed components
‘FEA’ means Finite Element Analysis, a mathematical technique for analyzing stress,
which breaks down a physical structure into substructures called finite
elements.
‘IP’ shall mean the Ingress Protection rating of the product as per AS1939
‘NDT’ Non-destructive testing
‘Project Manager’ shall mean the ARTC’s nominated Project Manager or representative
‘Project Quality Plan’ shall mean the Contractor’s Project Quality Plan for the Project
‘Rail Corridor’ The area containing the rail tracks, rail junctions, level crossings, station
buildings, platforms, signal boxes, tunnels, bridges and other associated
structures. This area is often defined by railway boundary fencing and in the
absence of such fencing, is defined by a physical boundary (i.e. tunnel, building
or retaining walls).
‘RMS’ shall mean the Roads & Maritime Services NSW, formely known as the Roads
& Traffic Authority
‘Site’ The area of land detailed by the Contractor as the location for the
performance of the specified design, construction and installation works.

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‘TOC’ Shall mean the ARTC Train Operating Conditions manual


‘Track’ The rails, sleepers, pad/plinths and fastenings, associated mechanical and
electrical components and, as appropriate, ballast bed /concrete slab above
formation level including points, crossings and plain track.
‘WOS’ ARTC Wagon Operating Standards

1.3 Scope of Works


Works under this Contract comprises the supply of all facilities, supervision, labour, plant, materials
and consumables as necessary to undertake the design, manufacture, supply and installation of
components required to provide completed and operational road rail equipment in accordance with
the agreed delivery schedule. This includes, but is not limited to the following items that shall be
required to be performed in accordance with the Contract documents, specification and drawings:
1. Project Management and supervision to implement and coordinate the performance of the
work including the preparation of a project management plan and specific OH&S and Quality
Management Plans and work programs, schedules and reports in accordance with the Project
Manager’s requirements.
2. Environmental and Safety management of all construction activities.

3. Provision quality assurance, client liaison, procurement, scheduling and programming services
to the Project Manager and to ensure the avoidance of delays in delivering the equipment to
ARTC.
4. All design work necessary for the equipment structure, integration and operation of the road rail
system components and any necessay controls to the base vehicle supplied.
5. Mobilisation to site of all plant, equipment & personnel necessary to undertake the works.

6. Taking delivery of any ARTC supplied equipment in preparation for their installation as may be
required.
7. Completion of all necessary performance testing and commissioning required to ensure
compliance with ARTC nominated standards.
8. Perform surface preparation, priming, painting and signage of installed equipment in accordance
with ARTC’s Painting and Signage requirements.
9. Where required, demobilisation of plant, labour and establishment facilities from site at the
conclusion of the works.
10. Provision of as built information and drawings, general project documentation and reports
related to the work, including safety, production, QA etc as requested by the Project Manager.

1.4 Contractor’s Responsibilities


The Contractor is responsible for designing, constructing, delivery and installation of the road rail
equipment to ARTC supplied vehicles using a conforming design supplied by the Contractor in
accordance with ARTC’s nominated standards as outlined in Section 2.1 and additional technical
requirements provided in Section 3.

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The Contractor shall provide all qualified and certified personnel, plant, equipment, vehicles, tools,
materials and consumables necessary to perform the work as specified. The Contractor shall
provide all necessary site facilities to complete the specified works.

1.5 Certification
All major materials and manufactured components supplied for the work by the Contractor shall be
accompanied by a certificate from the supplier stating compliance with the Specification and any
relevant ARTC and/or Australian Standards, together with such details and parameters required to
be supplied by those documents and/or the Project Quality Plan.
Additional mandatory certification requirements are detailed in Section 5.

1.6 Drawings
Appendix A contains all drawings issued by ARTC for the performance of the work. Additional
drawings may be included at a later date. These will be issued as an amendment to the specification.

1.7 Supply and Delivery of Materials


The Contractor shall supply to site all necessary materials to complete the works. All materials for
use as part of the Contract must be in accordance with the relevant ARTC and/or Australian
Standards or approved for use by the Project Manager. The Contractor shall also undertake
additional testing at no cost to the Project Manager if the Contractor supplied materials do not
conform to the requirements of this Contract or any other previously approved “non conforming”
specifications.

1.8 Materials - General


The Contractor must in its Quality Plan describe what procedures and tests will be adopted to
ensure that all supplied materials comply with the requirements of the standards outlined in this
Specification. During the performance of this Contract, the Contractor must implement its quality
procedures, verify that the materials comply with the specified standards, and have quality
documentation to verify this has been achieved.
Materials that are damaged or fail compliance after handling, transport and storage must be reported
to the Project Manager.
Materials that do not comply with the specified standards must not be used in the Works. The
Project Manager may carry out independent examination and testing of materials that have been
supplied, stored, handled, transported and or installed. The Contractor must provide any necessary
facilities and assist the Project Manager in such independent examinations and tests. The
independent testing organisation to be used in any such examinations and testing shall be NATA
approved.
Materials that fail to comply with the specified standards are liable to rejection for use in the Works
and where initially supplied by the Contractor are to be replaced at the Contractor’s expense.
The preferred construction material is AS/NZS 3678 – 300 and 350 grade structural steel.

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2. Standards, References, Policies and Procedures


2.1 General
All design, materials, plant, equipment, workmanship and installations must comply with current
revisions of ARTC’s Engineering Standards, Network Rules and Regulations, Policies and
Procedures, National Codes of Practice, Commonwealth OH&S Acts & Regulations 2011,
Workplace & Rail Safety Regulator requirements and Australian Standards relating to the relevant
element or component of the Works unless otherwise noted in this Specification.
Where conflict exists between any statutory requirements, standards, reference documents, and this
specification, the most stringent requirement shall apply. The Contractor must not deviate from the
provisions of the relevant standards and specification without approval.
For items of overseas manufacture that are not in accordance with Australian Standards, relevant
overseas standards must be subject to consent from the Project Manager prior to proceeding with
design or manufacture of equipment.
Latest ARTC Engineering Standards, Policies, Procedures and Network Rules and Regulations are
available from www.artc.com.au
Australian Standards are available from:
http://www.saiglobal.com/shop/Script/Provider.asp?Db=AS

2.2 ARTC Standards


The following Standards listed apply to this specification and are accessible through the ARTC
website. The Contractor is required to make themselves aware of all relevant and current ARTC
standards including those listed.
The work performed under this Contract shall be in accordance with at least the following
standards:

PP139.1 General Plant Requirements

WOS01 Minimum Operating Standards for Rolling Stock

WOS01.010 General

WOS01.100 General Interface Requirements

WOS01.200 Common Interface Requirements

WOS01.700 Track Maintenance Vehicle Specific Interface Requirements

The following links provide direct access to these standards.

http://extranet.artc.com.au/eng_rolling-stock_procedure.html

http://extranet.artc.com.au/eng_plant-equip-ex.html

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2.3 Australian Standards


The Equipment must comply with all requirements of Australian Standard AS4292.3-1997-Part 3
entitled “Railway safety management-Rollingstock” which covers the requirements for safe
operation of rollingstock in Australia.
In addition the following Standards listed are directly applicable to this specification and are
accessible through the RISSB website at http://www.rissb.com.au/linkdev/site/index.php The
Contractor is required to make themselves aware of all relevant and current Australian standards
pertaining to this work.
The work performed under this Contract shall be in accordance with at least the following
standards:
AS1627 Preparation and Pre-treatment of Steel Surfaces

AS2312 Protection of Steel Work against Atmospheric Corrosion

AS4360 Risk Management

Australian Standards pertaining to rolling stock design may also apply and should be reviewed by
the Contractor prior to design and construction. Forward compliance with these draft standards is
preferred.

Draft standards relating to Infrastructure Maintenance Vehicles can be viewed at:

http://www.rissb.com.au/site/products_rollingstock.php

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Technical Specification & Scope of Work 02/05/2012

3. Road Rail Equipment Specifications


3.1 General Scope
This section describes the work associated with the design, supply, manufacture, testing,
commissioning and provisional technical upgrades associated with the road rail equipment which
includes, but is not necessarily limited to the following:
1. Undertake the work to design, construct, test and commission the road rail equipment in
accordance with this Specification.
2. All design and construction activities necessary to provide safe and fit for purpose road rail
equipment
3. Design activities necessary to integrate the road rail equipment into base vehicle operation.

4. Research and design necessary to facilitate any of the provisional upgrades where approved by
ARTC.
5. Procurement of all necessary materials and equipment required to undertake the work.

6. Corrections to defective work or materials attributed to the Contractor at the Contractors


expense.
7. Provision of as built information indicating the work has been completed within the specified
tolerances.
8. Provision of drawings and manuals.

9. Provision of operating instructions including safety checklists for each type of activity.

10. Provision of all training requirements for operators and maintenance crews.

3.2 Base Vehicles

The road rail equipment supplied under this agreement shall be compatible for installation on the
following vehicle class:
Model Description Configuration GVM (Tonne)
Isuzu FSS550 CREW PTO 4x4 10.0

These vehicles shall have the bodies and any ancilliary equipment including cranes & suspension
upgrades fitted prior to supply & installation of the road rail equipment. Refer to Appendix A for
the base vehicle chassis drawings and specifications.

The vehicles shall be supplied and bodies fitted by a Newcastle based dealer.

In order to minimise vehicle transport & inspection costs, ARTC’s preferred build location is on
the Eastern seaboard of Australia. The Contractor shall nominate the anticipated installation
location for the road rail equipment.

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Alternate locations may be considered if deemed cost neutral to ARTC.

The proposed vehicle supply schedule is included in Appendix B.

The Contractor shall nominate their proposed build schedule to match the delivery of each
vehicle.

3.3 General Technical Details


The road rail equipment shall be capable of performing the following functions:
1. All equipment shall be designed and manufactured to suit the Australian Standard Gauge
railway network with a 1435mm operating gauge.
2. All completed road rail vehicles shall be compliant with standards detailed in WOS 01.700.
3. Whilst on track the road rail vehicle shall be fully compliant with the Narrow Non-Electric
Rolling Stock Gauge at all times during transit, whilst empty or loaded. Refer Appendix A –
Figure 1 for the operating clearance dimensions.
4. All road rail equipment manufactured from new shall be constructed from new materials only.
5. The road rail equipment shall be securely bolted to the vehicle chassis and shall not create stress
concentration areas resulting in early life failures of the chassis components.
6. The road rail equipment shall not be welded to the vehicle chassis in any location.
7. Where required, suitable chassis strengthening plates must be supplied and fitted to eliminate
potential fatigue related failures.
8. The Contractor shall provide FEA results prior to commissioning for both the road rail
equipment and the vehicle chassis incorporating typical loads to be applied to and by the road
rail equipment both when stored & in use.
9. The road rail equipment shall be readily transferable between vehicles of identical make &
model.
10. The road rail equipment shall incorporate an over-centre design to ensure the weight of the
vehicle assists in retaining the rail equipment in the on-track position.
11. The system used to deploy the road rail equipment shall be suitably sized to ensure it can readily
overcome the full laden weight of the selected vehicle to reach the over centre position.
12. The road rail equipment shall be adjustable to enable correct alignment between the rail wheels,
the vehicle chassis and the rail head, including:
a. Parallel alignment of the rail kit and wheels to the road wheels
b. Alignment of the rail kit to the vehicle centre line
c. Adjustment of the rail wheel back to back gauge to between 1358 & 1360mm
d. Adjustment of front rail wheel toe-in for stable operation on track

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13. The road rail equipment shall incorporate a suspension system to provide a smooth ride on rail
and enable appropriate wheel loading for all conditions of operation.
14. The road rail equipment suspension shall be adjustable to enable correct balancing of rail wheel
loading to ensure safe operation on track, minimise rail equipment fatigue and achieve no
greater than 50% wheel unloading when subjected to a static vehicle twist test as described in
WOS 01.283.
15. All suspension units must be suitably sized for the intended applied load under al l operating
conditions.
16. The road rail vehicle shall be capable of minimum safe operating speeds on track of 50km/hr.
Any proposed deviation from this rated speed shall be clearly stated by the Contractor in the
offer document.
17. The road rail vehicle shall be capable of operating safely at its rated speed on the DIRN through
all degrees of track curvature from tangent track to 180m radius curves and reverse curves with
no transition.
18. The road rail vehicle shall also be required to negotiate 70 metres radius curves and turn-outs in
yards.
19. The road rail vehicles must be capable of achieving the base ride performance requirements
specified in WOS 01.288
20. The road rail equipment shall be designed to prevent pooling of water in any structural areas
which may otherwise accumulate through rain periods or travel through ground water.
21. All supplied road rail equipment shall be permanently labelled with the manufacturer’s unique
serial number for ongoing asset identification purposes.

3.4 Safety Interlocks


The system shall incorporate coordination rules, lockouts &/or warning systems to avoid
unintentional movement of road rail equipment while in use or stored. As a minimum the
following shall be provided:
1. An in cabin audible warning alarm shall indicate when the road rail equipment is not in one of
it’s designated operational or stored positions.
2. When in the stored position, the rail equipment must be automatically restrained to prevent
creep down when the vehicle is in use on road. The use of manually applied chains, shackles or
locking pins is not preferred.
3. Separate provisions must be made for the installation of a proximity detection switch(as per
item 3.8.13) to identify when the rail equipment is in the fully deployed position. This indication
will be used as an input to the event data recorder to be supplied by ARTC as detailed in
Section 3.9.
4. Front axle locks must be suitably designed and installed to fully restrain and support the front
road axle when on rail. The front axle locks must be integrated into the road rail engagement
system to automatically restrain & release the front axle in the appropriate sequence without
further input from the operator.

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3.5 Brake System Details


The general technical requirements for brake system design and installation on road rail equipment
covered by this Contract include the following:

1. All brake systems & brake performance shall be in compliance with WOS 01.722

2. All brake componentry must be new and not used or reconditioned.

3. Details of all proposed brake componentry must be included in the offer document.

4. All brake system componentry must be readily available from Australian suppliers.

5. All brake componentry must remain within the Narrow Non-Electric Rollingstock outline at all
times.

6. Vehicles with front elevated steer axles must incorporate suitable braking systems to achieve the
brake performance outcomes stated in WOS01.722.

7. The Contractor shall ensure that proper storage, handling and installation techniques are
employed to maintain internal cleanliness of all brake system componentry.

8. Provisions for independent emergency rail wheel brake applications will be required where
vigilance systems are fitted to road rail vehicles. The Contractor is to advise how this would be
achieved.

3.6 Rail Wheel Details


The general technical requirements for wheels covered by this Contract must comply with the
requirements of WOS 01-200 and include the following:

1. All wheels shall be new and of low stress design.

2. All wheels are to be non-insulated.

3. All wheels shall conform to the ANZR1 wheel profile as shown in Appendix A – Figure 2.

4. Wheels conforming to the WPR2000 or other wheel profiles will not be accepted.

5. Wheels shall be manufactured to comply with AAR Class B material or equivalent.

6. Wheels shall not be painted, however they may be coated with a rust preventative solution
which is to be removed prior to commissioning.

7. Wheel sizes are to be uniform across the vehicle unless specifically approved by the ARTC
Project Manager.

8. The Contractor shall provide a detailed, dimensioned diagram of the wheel construction with
the tender response including details of materials used for manufacture and any material
hardness specifications.

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9. Wheels with visible surface defects may be rejected by the Project Manager and must be
replaced by the Contractor at no cost to ARTC.

10. Axle bearings shall have no in-field lubrication requirements between scheduled servicing.
Bearing service life shall be calculated and must exceed the minimum service interval of 6
months without deterioration or failure.

11. Bearing seals must be carefully selected to minimise water and dust ingress during service.

12. Stub axle shafts must be suitably designed and manufactured to minimise stress raising areas.

3.7 Road Wheel Details


The general technical requirements for wheels covered by this Contract must comply with the
requirements of WOS 01.723.

Where dual rear wheels are fitted to heavy vehicles by the OEM, the Contractor shall identify and
supply suitable single replacement wheels & tyres to ensure compliance for both on road and on rail
use.

Consideration of this must include allowable wheel point loads, axle loads, GVM rating, rail head
coverage, lateral centering of road wheels and rail wheels, operating speed and appropriate tyre
construction.

Consideration must also be given to spare wheels and the available space for spare wheel transport.

3.8 Electrical System

Where electrical equipment is installed, the following items are mandatory and compliance shall be
achieved by the Contractor’s proposed equipment.

1. The electrical control system shall be 12 or 24 volt DC to match that of the base vehicle.
2. A complete electrical schematic diagram detailing all standard electrical wiring is to be supplied
with the equipment.
3. An electrical component parts listing shall be provided with the equipment service manuals.
4. All wiring external to control cabinets must be fully insulated and housed in non-split protective
flex conduit.
5. All wiring must comply with AS3000 and be suitably sized for the current carrying capacity
required.
6. Electrical wiring must not be attached to hydraulic hosing.
7. Scotch locks must not be used to join wires.
8. Use of standard or glue based heat shrink materials is encouraged to insulate and seal exposed
wiring joints and connections.
9. Electrical wiring and componentry must not be in contact with high temperature sources.
10. Cable lugs must be used for wiring terminations.
11. All earth point connections must contact with bare metal.
12. The ‘IP’ rating of cabinets & enclosures intended for use on the project shall be minimum IP66.

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13. Inductive proximity switches are preferred for sensing the location of stored or deployed
equipment. The preferred sensor type is Turk Uprox part no: Ni12U-EG18SK-AP6X. Flexible
rod or spring type limit switches will not be accepted.

3.9 Event Data Recorder

All new road rail vehicles are required to be fitted with an operational event data recorder
(Circuitlink black box) in order to comply with rail safety regulations. The event data recorder shall
be supplied by ARTC and installed by the Contractor in accordance with the manufacturer’s
instructions.

The event data recorder will typically record factors such as:
• Operational speed
• Engine RPM
• Engagement of road rail equipment
• Amber beacon operation
• Air horn operation
• Headlight operation
• Service brake application
• Reverse gear engagement
• Park brake application

3.10 Hydraulic & Pneumatic Systems


Where hydraulic and pneumatic equipment is installed the following items are mandatory and
compliance shall be achieved by the Contractor’s proposed equipment.

1. The hydraulic circuit must be designed to prevent component failure as a result of high
hydraulic fluid temperatures. Hydraulic oil temperatures must not exceed OEM recommended
temperatures during normal operation at ambient operating conditions.
2. Due to extreme weather conditions in Australia it is a requirement that an appropriately sized oil
cooler be employed in the hydraulic system to maintain system temperatures when ambient
temperatures exceed 40 degrees Celsius.
3. The hydraulic system shall be compatible with SAE 68 hydraulic oil.
4. The specification of all hydraulic/pneumatic pumps and motors used on the equipment or as
accessories must be provided. All parts used are to be readily available from well known
hydraulic distributors e.g. Parker, Rexroth.
5. A suitably designed emergency manual pump system must be included to raise and lower the hi-
rail equipment in the event of primary system failure. The circuit design for the emergency
system must ensure that it is effectively isolated from the primary hydraulic system when not in
use.
6. Clear diagrammatic instructions must be provided for operation of the manual pump system.
7. The vehicles to be supplied will be fitted with PTO output facilities. Any intention to utilise this
power source for operation of the hi-rail system shall be nominated by the Contractor in the
tender response.

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8. All circuits must incorporate adequate system filtration. Filter type, bypass pressure (if
applicable) and absolute rating specifications must be clearly stated by the Contractor.
9. All hydraulic components must be capable of withstanding maximum static and surge pressures
generated within the system.
10. All hydraulic hoses must conform to S.A.E. standards with double braid non-skive hydraulic
hose with swaged ends.
11. Permanent steel piping must be used wherever hydraulic line passes through the chassis.
12. Hydraulic hoses must not be located in areas or positions where they are subjected to excessive
abrasion or wear. The use of ‘tough cover’ hosing and or spiral wrap is recommended in areas
of susceptibility.
13. All hydraulic cylinders shall have chrome plated piston rods.
14. Hydraulic cylinders subject to damage from flying rocks must have the piston rods adequately
protected to prevent pitting of the surface.
15. All hydraulic hoses located near the operator must be shielded to minimise the risk of injury
resulting from hydraulic hose failures.
16. All hydraulic tanks must:
a. Have the tank contents clearly labelled including grade of hydraulic oil used
b. Be fitted with an easily accessible drain point
c. Be fitted with visual features for readily determining tank content level

3.11 Access & Egress


Operation of road rail vehicles on track often leads to reduced access and egress to the base vehicle
as a result of increased body lift and restricted access from the sloping track shoulder. Contractors
must address this issue by installing appropriate additional steps (and where required grab handles)
to ensure appropriate front and rear cabin access is maintained when the vehicle is in use on track.
A typical track construction diagram is included in Appendix A.

Tread surfaces for all additional steps shall be slip resistant and no more than 500mm above rail
head to the lowest access point.

Installation of the additional access points must not interfere with normal on-road use and
operational underbody clearances.

Additional steps may be retractable but shall not be removable. Any retractable steps must include a
warning system to the operator if not fully retracted when transferring to road use.

3.12 ADR Compliance


All modifications undertaken to the base vehicle during the installation of the road rail equipment
must ensure compliance can still be maintained to the Australia Design Rules for motor vehicles.

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Changes to the body outline, lighting position, exhaust system and other vehicle systems affected
must be addressed in order to ensure an engineering certificate for a modified production vehicle
can be issued by an RMS authorised signatory.

Where the front rail equipment protrudes beyond the original bumper outline, suitable protection
must be put in place to minmise pedestrian injury potential. Fully enclosed designs are preferred.

3.13 Structural Welding & Fabrication

All welding shall be in accordance with the Australian Standards including but not limited to:
• AS 1554.1:2000 - Structural steel welding - Welding of steel structures,
• AS 1554.4:1995 - Structural steel welding - Welding of high strength quenched and
tempered steels
• AS1554.5:1995 - Structural steel welding - Welding of steel structures subject to high levels
of fatigue loading.
All welding shall be pre-qualified with tradespersons qualified in accordance with AS 1554.

All structural sections shall be continuous and where applicable seal welded to prevent entry of
moisture. Single sided fillet welds are not permitted on main structural members.

NDT inspection shall be carried out on all critical welds as specified on manufacturing drawings.
Test reports must be provided for all NDT.

Welding may be subject to further close inspection before acceptance and other non-destructive
testing methods may be employed at the discretion of the Project Manager.

The cost of rectification and recertification of any defective welds shall be to the Contractors
account.

High resistance welding return circuits are detrimental to good welding under any circumstances
and should avoided.

All completed welds are to be cleaned of slag and weld spatter and suitably primed to prevent the
onset of corrosion.

3.14 Surface Preparation & Coatings

All external steel surfaces of new structural installations & repairs including welded surfaces shall be
prepared in accordance with the requirements of AS1627 and painted to prevent corrosion in
accordance with the requirements of AS2312.

The Contractor shall prepare the surface, prime and apply appropriate surface coatings to all new
structural & mechanical equipment. All surfaces shall be prepared, primed and painted to provide a
protective coating with a minimum film thickness of 160 microns and to give a 10 year service life.

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Rail wheels are not to be painted but may be supplied with surface coating protection to prevent the
onset of corrosion prior to commissioning.

3.15 Signage

Operating instructions & safety signage complying with AS1319 shall be installed to indicate
hazards where appropriate following full curing of the paintwork. This shall include supply and
installation of in-cabin warning and instruction labels.

Installation of ARTC supplied logos and reflective delineators shall also undertaken by the
Contractor prior to commissioning.

3.16 Equipment Support & Spare Parts

The Contractor shall advise in their offer document the locations & contact details of approved
service agents for the proposed equipment.

The successful Contractor shall provide one complete parts lists (bill of materials) specifying all
items in electronic format. Items of a repairable/rotable nature need to be identified as such.

Based upon the knowledge of the proposed equipment and its intended use within the ARTC
operations, the Contractor shall apply one of the following usage categories to each item in the
electronic schedule:

Category Description
A Stock turnover greater than 4 per year per unit
B Stock turnover between 1 and 3 per year per unit
C Slow moving stock (less than 1 per year per unit)
D Long lead time item either capital or insurance spare

For items not manufactured by the Contractor, the original manufacturer’s name and reference
number is required against each item on the electronic bill of materials.

Items that have a shelf life or require special storage conditions are to be highlighted on the
electronic bill of materials.

The Contractor must bring to the notice of ARTC, any hazardous or dangerous goods by notating
on the electronic bill of materials, the applicable UN hazardous goods code, dangerous goods
rating, including material safety data sheets for products considered to be hazardous and or
dangerous.

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3.17 Liaison with ARTC disciplines, external and third parties


The Contractor shall be required to liaise with relevant third parties and ARTC personnel as may be
required or where directed by the Project Manager to ensure the effective completion of the works.

4. Provisional Technical Upgrades


The following items are deemed provisional and all upgrades offered are subject to review by ARTC
prior to inclusion. These provisional items include:

4.1 Derailment Restraint System


If not provided in the base tender, the Contractor may tender options for additional restraint
systems to limit transverse movement and assist the road rail vehicle to remain on the track
structure in the event of a derailment

4.2 Track Circuit Protection


The Contractor may provide options for the supply of equipment to prevent track circuit activation
through insulation of rail to rail contact via the road rail equipment. The supplied base equipment is
to be non-insulated.

4.3 Hydraulic Truck Crane Rail Grabs


The Contractor may provide options for the supply of hydraulic rail grabs to provide effective
stability to the vehicle whilst stationary on track when the truck mounted crane is in use (where
fitted). The Contractor shall coordinate all necessary information with the crane supplier to ensure
the appropriate vehicle stability calculations are performed to ensure the crane is safe to use when
on track in rail mode without the OEM supplied stabilisers being used.

5. Acceptance Criteria
5.1 Registration of Equipment
All completed road rail equipment when in travel or work mode shall conform to the Narrow Non
Electric Rolling Stock Profile and provide the equivalent swept path as per the ARTC standard
WOS01.100 General Interface Requirements.
Prior to completion and on track commissioning, the Contractor must provide all relevant
information to enable the application for a TOC waiver for testing purposes. The general period of
time required to permit listing of a TOC Waiver for equipment is approximately 8 weeks from
submission of the required information. The ARTC TOC waiver website address is
http://www.artc.com.au/nsw/toc-waivers.htm.

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5.2 Type tests

Prototype vehicles of each type are to be tested independent of the remainder of the fleet to ensure
all operational requirements are met prior to the completion and commissioning of the entire fleet.
Any defects or operational deficiencies noted in the testing of the first completed road rail vehicle
shall be addressed by the Contractor in the following equipment builds.

ARTC shall arrange the ride performance & brake performance testing of the type test vehicle. The
Tender shall rectify any deficiencies found and may be responsible for re-testing costs if necessary.

5.3 Commissioning

A detailed final commissioning program must be provided with the tender. The final
commissioning program will specify the milestones that will be used to indicate that the equipment
is attaining the expected levels of performance. The Contractor will not receive final documented
acceptance of the equipment until the Project Manager is satisfied that all expected performance
criteria have been achieved.

Any item which fails to be commissioned successfully in the first instance shall be subjected to a
repeat performance assessment in accordance with the above process once the identified defects
have been rectified. The duration and timing for completion of the repeat commissioning period
shall recommence once the equipment is deemed fit for service.

The final commissioning and testing of the equipment will be carried out at an ARTC provided
proving area in conjunction with the Project Manager and or other representatives of ARTC.

A comprehensive commissioning report will be provided by the Contractor at the completion of the
equipment commissioning period.

The commissioning report must include but is not limited to the following:-

1. The equipment shall be checked to ensure that all specification criteria are satisfied.
2. A thorough check of all essential fluid levels and lubrication points must be conducted before
testing.
3. Testing will involve equipment operation through all normal operating cycles.
4. Completion and documentation of rail equipment alignment and twist test results to the
satisfaction of the Project Manager
5. Testing of the rail equipment over centre activation under full GVM conditions
6. Testing of the emergency hand pump system
7. Ontrack acceptance testing for general ride, stability & handling
8. Details of testing procedures and test equipment will be recorded and included in the report.
9. Completion of the ARTC’s Vehicle Information Pack – WOS 01.A5 for the purposes of
achieving a final TOC waiver

The report must be signed by the Project Manager to the effect that all tests were undertaken and
the results were correct.

Final documented acceptance of the Equipment will be provided by the Project Manager only.

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5.4 Certification of Completed Work


Before the Project Manager accepts any completed equipment, the equipment must be made
available to be inspected by the Project Manager and any adjustments and corrections are to be
completed by the Contractor.

The Contractor will be responsible for providing engineering signoff for all design, construction &
modifications performed. The engineering signatory must be competent to perform such
authorisation.

5.5 Defects Liability Period


Subject to ARTC’s rights at law the Contractor shall maintain the road rail equipment free from
defects for a period of 12 months from the date of commissioning. Defect items shall include, but
shall not be limited to:
• Faults in any materials supplied and or installation work by the Contractor (excludes any
ARTC supplied material);

5.6 Handover Documentation


Prior to commissioning the Contractor shall provide a handover package containing, but not limited
to, the following documentation:
1. Two (2) sets of as-built hardware schematics including full electrical wiring diagrams.

2. Two (2) sets of as-built PLC program documentation where applicable.

3. Two (2) sets of full maintenance and spare parts manuals (including settings, service and
maintenance schedules).

4. One (1) copies of fully priced spare parts listings. The spare parts listings are to contain tender
and original parts manufacturer part numbers. These listings must be received in time to allow
the order and delivery of maintenance and insurance spare parts. See Section 3.19 for further
detail.

5. One (1) electronic copy on CD of the operational Risk Assessment.

6. Two (2) Copies of the Operational instruction manual plus One (1) copy of operational
instruction manual per vehicle

7. Two (2) copies per vehicle of the completed twist compliance and road rail equipment
alignment results as per ARTC standard PP139.2F-02 and PP139.2F-03.

All literature must be written in English.

One set of digital drawings (to Australian Standards) are to be provided with the equipment. These
drawings must show sufficient detail and dimensions to ensure that the equipment may be fully
maintained by ARTC’s workshops or designated Contractors.

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The Contractor shall produce all final as built drawing according to ARTC Drawing Management
Procedure PP117.4. A copy of the requirements of this standard and drawing sheet templates will
be made available to the Contractor by the Project Manager.

In the event that ARTC requires access to detailed technical information due to statutory or legal
requirements, the Contractor must make available the following items upon request:

• Detailed mechanical and structural drawings.


• Design calculations and material specifications.

5.7 Training

An appropriate competency based training program will be tendered with the proposed equipment.

The Contractor shall be required to co-ordinate all training into a single training package.

This training shall be carried out prior to the final commissioning of the equipment.

Provision shall be included for twelve (12) operating and three (3) maintenance personnel to attend
the initial training program.

5.8 Component Maintenance Program

The Contractor must provide a detailed component maintenance schedule for the effective
maintenance of all the individual equipment components. This schedule must be supplied on CD
and must be suitable for use in current Microsoft software packages.

The Contractor must supply safe working procedures for all maintenance tasks. The safe working
procedures must be supplied on CD and must be suitable for use in current Microsoft software
packages.

All of the “safe working procedures”, “operational risk assessment” and “component maintenance
schedules”, as specified must be supplied prior to the delivery and commissioning of the equipment.

5.9 Safety

An Operational Risk Assessment shall be facilitated by the Contractor and shall be provided prior
to final commissioning of the equipment and should be to the AS4360-2004. This risk assessment
should at minimum cover:
• Pre-start checks
• Set up and de-rigging
• Maintenance
• Operations
• Other risks

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6. Quality Assurance
6.1 Quality System Standard
The Contractor shall maintain a documented Quality System in accordance with this document and
with an Australian Standard for Quality System in accordance with AS/NZ ISO 9001/2. The
quality system shall cover the whole of the work under this Contract.

6.2 Quality Plan


The Quality Plan shall detail how the Contractor will manage and control the quality of the work
under the Contract. The plan is to be submitted to the Project Manager. Works are not to proceed
until the Quality Plan is approved by the Project Manager.
The Quality Plan shall include:-
1. Management responsibilities specific to the Contract including the responsibility and authority
for quality.
2. Organisation(s) proposed for the Contract.
3. Qualifications and competencies, including currency, of all staff proposed to be used on the
Contract.
4. Contractor’s method of control of sub-Contract work.
5. All work processes and equipment including equipment, methods and process proposed to be
used:
a. for structural fabrication works
b. for vehicle body works
c. for surface preparation & coatings
6. Site management and supervision.
7. All witness and hold points, and
8. Inspection and test plans.

6.3 Inspection and Tests


During the course of the work the Contractor shall arrange for all relevant testing required by the
Project Quality Plan to be carried out by suitably qualified personnel approved by the Project
Manager. Inspection and Test Plans shall be submitted to the Project Manager for approval prior to
any work commencing. Inspection and test plans shall:-
1. Identify tests/inspections against Contract requirements;
2. Identify hold points;
3. Identify records to be maintained for particular tests and/or inspections; and
4. Detail test equipment to be used for specified tests and/or inspections.

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6.4 Records
The Contractor shall establish and maintain a system of records that provides objective evidence
that the requirements of the Contract have been satisfied.
The Contractor shall make all records pertaining to the Contract available to the Project Manager at
all reasonable times and, where requested by the Project Manager, provide the Project Manager with
a copy of the records.
The Contractor shall as a minimum provide weekly reports on the following:
• Details of progress for the completion of works currently in progress
• All delays, causes and remedial actions taken

6.5 Quality Audit and Non-Conformances


The Contractor shall give the Project Manager access to its or its sub-Contractor’s premises /
working area and to documentation for audit purposes.
The Contractor shall make or arrange to be available all facilities, documentation, records and
personnel, including those of sub Contractors, that are reasonably required for any audits or
surveillance to be undertaken by the Project Manager to ensure specified requirements are being
met.
All non-conformances shall be promptly reported to the Project Manager via non conformance
reports.

6.6 Occupational Health and Safety


The Contractor shall provide and, for the duration of the Contract comply with, a safety
management plan covering the management of occupational health and safety in accordance with
the relevant Statutory Occupational Health and Safety Acts & Regulations for their State or
Territory.

7. Environmental
7.1 General Protection of The Environment
The equipment once completed must comply with ARTC’s Environmental Protection License No
3142 with respect to maintenance of plant and equipment.
http://www.epa.nsw.gov.au/prpoeo/licences/L3142.pdf

7.2 Environmental Conditions

All equipment supplied must be capable of operating under the following range of ambient
conditions which are encountered in the ARTC operations:-

• Dry Bulb Temperature -10 to 50° Celsius.


• Relative Humidity up to 95%

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• Operating Altitude 1370m above to 100m below sea level.

The following points regarding environmental conditions encountered should also be noted when
considering the design and IP rating of exposed and or sealed componentry:

• Periods of torrential rain.


• Salt laden atmosphere.
• Dust containing high silica content may be present in some areas.
• Occasional travel through low lying ground water may be required.
• Harsh ground conditions may be encountered including loose or falling ballast & vibration

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Appendix A
Schedule of drawings supplied by ARTC:

Drawing/ Ref Drawing Title No of


Number Pages
Figure 1 Narrow Non-Electric Rolling Stock Profile 1
Figure 2 ANZR1 Wheel Profile 1
Figure 3 Typical Shoulder Design 1
Figure 4 Isuzu FSS550 CREW PTO specifications 5

TOTAL PAGES 2

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Figure 1 – Narrow Non-Electric Rolling Stock Profile

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Figure 2 – ANZR1 Wheel Profile

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Figure 3
Typical Shoulder Design

Figh

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Appendix B
Estimated Schedule of Vehicle Delivery:

Vehicle Vehicle Available for Rail


Number Equipment Installation
1 1/5/2012
2 1/5/2012
3 1/6/2012
4 1/6/2012
5 1/7/2012
6 1/7/2012
7 1/8/2012
8 1/8/2012
9 1/9/2012
10 1/9/2012
11 1/10/2012
12 1/10/2012

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Appendix C
File Attachments:

Document No Description
WOS 01.700 Track Maintenance Vehicle Specific Interface Requirements
PP139.2F-02 Rail Guidance System Maintenance Inspection
PP139.2F-03 Road Rail Vehicle Twist Compliance Inspection

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