PT.

WASKITA KARYA (PERSERO) Tbk

Corporate Office/ Business Unit : Infrastructure 2 Division

Project : Railway Electrification and Double-Double Tracking of Java Mainland Project (I), Package A

NO KEBERTERIMAAN
ITEM PEKERJAAN DAN SUB ITEM
ITEM
PEKERJAAN
PEK. BAHAN PRO

SECTION 4 : TRACK WORKS

4.00 GENERAL FOR TRACK WORKS

(4) Design 1)

4.02 RAIL WELDING

(2) Scope of Work
 (4) Construction

4.03 RAIL JOINTS

(2) Materials 1)
a)

b)
 (4) Construction 1)
a)

b)

c)

d)

4.04 SLEEPER AND FASTENING

(2) Concrete Sleepers a)

b)
 c)
-
-

4.05 TRACK PANEL ASSEMBLY

(2) Materials 1)
a)

b)

c)

d)
 e)

f)

g)

h)

2)

3)

4)

(3) Construction
4.06 RAILWAY SWITCHES
(2) Materials 1)

a)

b)

2)
 3)
-
-

(4) Construction

4.08 BALLAST SUPPLY

(2) Materials 1) Material shall be crushed basalt, granite or andesite
that is durable, angular and hard and does not
contain any organic materials, soils and debris and
shall conform to the following grading
requirements.

Ballast shall be tested at the authorized laboratory

approved by the Engineer whenever directed by the
 Ballast shall be tested at the authorized laboratory
approved by the Engineer whenever directed by the
Engineer to examine grading requirements,
resistance to abrasion, gravity and soundness etc.
Coefficient of abrasion of the sampled ballast shall
not exceed 30% in accordance with AASHTO-T-96.

4.09 TRACK TAMPING, RAISING AND

SHIFTING
(2) Materials
Ballast, as required for changing of track alignment,
shall be supplied and furnished by the Contractor in
accordance with Clause 4.08 “BALLAST SUPPLY” of
this Specification. Quantity of ballast supply
shall be calculated by the Contractor in
accordance with the lines and grades from Shop
Drawings approved by the Engineer and shall be
the responsibility of the Contractor for satisfactory
completion of work as required by this Clause.

(3) Construction

4.11 BUFFER STOPS

 (2) Materials

a)

b)
c)

(4) Construction

4.12 TRACK SIGN AND POST

(2) Materials

a)
b)
c)
d)
e)
f)
g)
 (4) Construction

4.13 LEVEL CROSSING PAVEMENT

(2) Materials Materials to be applied for level crossing pavement
shall be as listed below and in accordance with
SECTION 2 “CIVIL WORKS” of this Specification.
Quantity necessary and required for level crossing
pavement works shall be the responsibility of the
Contractor.
a) Asphalt Concrete Surface Course
b) Asphalt Concrete Binder Course
c) Asphalt Treated Base Course
d) Sub Base Course
e) PVC Pipe for Fastening Cover
f) Rubble Stone Foundation
g) Concrete
h) Reinforcing Bar
i) Steel Structure Works for U-Ditch Cover

(3) Construction 1)
 2)
a)
b)

4.14 TRACK FACILITY TEMPORARY

WORK
(2) Materials

a)
b)
c)
d)
e)
f)

(4) Construction

4.15 TRACK FACILITY REMOVAL WORK

 (2) Construction 1)

2)
a)
b)
c)
d)

Diperiksa oleh:

NO BAGIAN PARAF

1 SOM/GSP

2 SPLEM

3 SCARM

4 SQHSEM

5 QHSE MANAGER BU
oject (I), Package A

RENCANA INSPEKSI DAN TES

KEBERTERIMAAN RINCIAN DOKUMEN

SUMBER TOLERANSI KEBERTERIMAAN BAHAN
PRODUK PERSYARATAN MUTU

Specification and Indonesian Railway Standards,

including the following major design standards:
 Tolerance of finished rail head top and
inner side surface shall be as follows:

Ordinary Rail Joint

Chemical composition shall be as follows:

Mechanical properties shall be as follows:

Manufacture of washers shall be in accordance with

UIC Code 684 - 3/0. Spring steel washers shall be
hardened in oil at a temperature between 20 to
40°C and mechanical properties after heat
treatment shall conform to Rockwell Hardness HRC
UIC Code 684 - 3/0. Spring steel washers shall be
hardened in oil at a temperature between 20 to
40°C and mechanical properties after heat
treatment shall conform to Rockwell Hardness HRC
40 to 46. Preliminary loading shall be with a 1,500
kgf load.

Ordinary Rail Joint

All joints shall have six (6) bolts per joint and shall
be fully bolted and fitted with spring washers.
Before fastening rail joints, grease coating shall be
applied to the web of rails where fishplates contact
and bolt holes of fishplates shall be coated with
lubricating oil.

All joints shall be tightened to provide a flat and

smooth rail surface.
Joints in parallel rails shall be squared or within
100mm tolerance and in curves care shall be taken
to insert shorter rails in the inner curve to maintain
square joints.

Concrete Sleepers

Concrete sleepers shall conform to Indonesian

Railway Standards and from local factories
approved by DGR with specified marking of month
and year of manufacturing as instructed by the
Engineer. The Contractor shall test the quality of
concrete sleepers and submit test results as
instructed by the Engineer for his approval. Age of
concrete bearings is estimated at 60 years.

Fastenings

Fastenings shall be double elastic type and conform

to Indonesian Railway Standards and shall include
all parts and fittings for the various types of
Fastenings shall be double elastic type and conform
to Indonesian Railway Standards and shall include
all parts and fittings for the various types of
sleepers as shown on the Drawings and instructed
by the Engineer. The Contractor shall submit
technical data from the manufacturer for approval
of the Engineer.

Item Name
Concrete Sleeper R 54
Fastening for Concrete Sleeper

Rail R54
New rail shall be manufactured from steel ingots or
continuous casting blooms (hereinafter referred to
as C.C. blooms) made either by basic open hearth,
electric, or basic Bessemer process or basic oxygen
converter.
Chemical composition shall be as follows:

Ends of blooms and ingots shall be sufficiently

cropped so as to ensure that rails are free from
internal defects and slag.
Rails shall be uniform in shape throughout the
entire length and be free from flaws, twists and
other defects.
All rail shall have their ends sawn or machined and
the sawn section of rail shall show no pipes or
other internal defects.
Both ends of rail shall be rectangular to longitudinal
axis, all burrs shall be removed and rail ends shall
be chamfered 1.5mm.
Camber of rails after cooling shall not exceed
100mm per 10m length and shall be straightened
by applying
Both ends ofgradual
R54 railpressure.
in length of 25 meters shall
not be drilled at ends, necessary holes at end for
rail joint shall be drilled at site in accordance with
UIC or this Specification.

Mechanical properties shall be as follows:

Rail Joint

Rail Joint shall be furnished by the Contractor under

Clause 4.03 “RAIL JOINT” of this Specification.

Sleeper and Fastening

Sleeper and Fastening shall be furnished by the
Contractor under Clause 4.04 “SLEEPER AND
FASTENING” of this Specification.
Ballast
Ballast shall be furnished by the Contractor under
Clause 4.08 “BALLAST SUPPLY” of this
Specification.

The work shall be executed by staking out the new

track center, spreading the lower ballast over the
prepared sub-ballast layer and compacting the
ballast from the required depth as shown on the
Drawings below the bottom level of the sleepers.
The track panel, including sleepers, rail and
fastenings, is assembled on the above prepared
Drawings below the bottom level of the sleepers.
The track panel, including sleepers, rail and
fastenings, is assembled on the above prepared
lower ballast. The work shall be further executed by
making up the upper ballast cross section, tamping
and setting the track panel such that the track
horizontal and vertical alignment is in accordance
with the final design alignment and the track
condition suitable for train operation.

Materials to be used for frogs, including nose and

wing rails, shall be high manganese cast steel
conforming to the requirements specified below.
Mechanical Requirement

Chemical Composition

Except for frogs as described below, all materials to

be used for railway switches shall be in accordance
with requirements given in Clause 4.01 "RAIL R
54", Clause 4.03 "RAIL JOINTS" and Clause 4.04
"SLEEPER AND FASTENING" of this Specification.
"SLEEPER AND FASTENING" of this Specification.
Item name
Simple Turnout R 54 # 10
Scissors Crossing R 54 # 10

1) Assembly and Inspection

All switches shall be pre-assembled in the

mill and checked to confirm that the
permissible variations specified below are
met after which they shall be knocked
down and packed. Permissible variations
shall be as follows:

AASHTO-T-96
 Any track irregularities at unloaded
Horizontal and vertical alignment of track shall be conditions shall be within the following
as shown on the Contractor's track layout drawings tolerances:
as approved by the Engineer. All tamping work and
track realignment by raising and shifting works shall
be based on the staking marks established by this
Specification. Ballast shall be well packed with
Multiple Tie Tamper (MTT) or equipment
approved by the Engineer as final tamping works
after regular train operation. The Contractor shall
trim the ballast to conform to the standard ballast
section shown on the Drawings or instructed by the
Engineer.
Rail shall be used rails salvaged from the site and
arranged by the Contractor. Concrete and wooden
sleepers, together with fastening and rail joints,
shall be used sleepers salvaged from the site and
arranged by the Contractor. Quantity necessary and
required for buffer stock works shall be the
responsibility of the Contractor. Assembling parts
shall be fabricated from locally available materials.
Type of buffer stops shall be as follows:

Buffer Stop Type A by concrete and ballast stopper

Buffer Stop Type B by rail and ballast stopper

Buffer Stop Type C by rail stopper

Area for buffer stop installation shall be cleared,

grubbed and compacted. Buffer stops shall be
assembled and installed in accordance with Shop
Drawings approved by the Engineer.

Rail shall be used rail salvaged from the site and

arranged by the Contractor. Assembling parts shall
be fabricated from locally available materials. Track
signs and posts shall include as follows:
Gradient Sign
Curve Sign
Andrews Cross Sign
Kilometer Post
Meter Post
Clearance Post
Curve Datum Post
All track signs and posts shall be anchored in place
as indicated on the Drawings. Anchoring of sign
post shall be done by a method suitable for each
site. The Contractor shall perform excavation of
installation ground to the lines, grades and
elevations indicated on the Drawings. Backfill of
signs and posts shall be accomplished by using
excavated soil and shall be compacted.
Installation of signs and posts shall not interfere
with the existing train operation.

After completion of final tamping works and

confirmation of final track alignment by the
Contractor, level crossing pavement work shall
be executed by the Contractor to cover the track
ballast and to interface with the existing public road
surface as shown on the Drawings. Existing
be executed by the Contractor to cover the track
ballast and to interface with the existing public road
surface as shown on the Drawings. Existing
asphalted and concrete roads shall be interfaced by
an overlay of asphalt concrete on the existing
surface. Existing surface will be left intact but
cleaned and trimed to accept the new surface for
asphalt overlay works.

Item Name
Level Crossing Ballast Supporter
Temporary Level crossing

Materials to be applied for the temporary work will

be utilized from the procured or salvaged ones
under execution of this Project and the Contractor
shall be responsible for arrangement of the
necessary quantity of all materials.
Rail R54
Compromised Rail R54/42
Rail Joint
Sleepers and Fastening R54
Railway Switches R54 and R42
Ballast

Temporary track facility shall be installed with

ballast on trackbed to the lines, levels and grades
approved by the Engineer. Salvaged materials
derived from other works, which shall be arranged
by the Contractor under the permission of PT. KAI,
shall be returned to PT. KAI when removed from
the temporary track.
Removal work of the existing track facility
shall be executed at the same time of track or
switch installation according to the work schedule
approved by the Engineer. Cutting of rails, when
necessary, shall be carried out by sawing and the
end surfaces of rails shall be right-angled to the
longitudinal axis of rail. The Contractor shall make
an inventory of designated track materials to
be removed and submit to the Engineer. All
removed rails shall be disassembled and
transported to the location instructed by the
Engineer.

Item name
Track Panel Removal
Scissor Crossing Removal
Double Slip Switch Removal
Ballast Removal

Disetujui oleh,

Project Manager
 Fo
R

N TES
Halaman

INSPEKSI & TES KEBERTERIMAAN KODE INSPEKSI & TES

DOKU
BAHAN PRODUK I T W H D

Before welding work, the Contractor shall perform a

hardness test.
a) Bending test and break surface inspection for
pieces of test specimens welded two rails of 0.75m
length. The Contractor shall repeat the tests as
required by the Engineer if the results are
unsatisfactory.
 length. The Contractor shall repeat the tests as
required by the Engineer if the results are
unsatisfactory.
b) Hardness test shall comply with Brinell Hardness
test more than HB 270 at the welded section and
HB 210 at the base metal affected by the heat of
welding within 15cm of the welded section.
 Keterangan
Inspeksi (I) = Bila produ
dipastikan
Dibuat oleh, secara vis

Tes (T) = Bila produ

dipastikan
terlebih d

Witness (W) = Bila peke

keberterim
SEM pengama

Hold (H) = Bila peke

terhenti a
 Bila peke
terhenti a
sesuai ke
Documentation (D) = Bukti info
pekerjaan
 Form PW-QHSE-01-03
Rev. 00, Mei 2019

: 1 dari 1

DOKUMEN YANG DIGUNAKAN

Bila produk atau pekerjaan cukup
dipastikan keberterimaan dengan
secara visual

Bila produk atau pekerjaan harus

dipastikan keberterimaan dengan tes
terlebih dahulu

Bila pekerjaan harus dipastikan

keberterimaan dengan melakukan
pengamatan selama proses pekerjaan

Bila pekerjaan terjadi kemungkinan

terhenti akibat hasil tes yang tidak
Bila pekerjaan terjadi kemungkinan
terhenti akibat hasil tes yang tidak
sesuai keberterimaan

Bukti informasi terdokumentasi suatu

pekerjaan sudah sesuai keberterimaan
 PT. WASKITA KARYA (Persero) Tbk
V DIVISI =
V PROYEK =

RENCANA INSPEKSI DAN TES

Halaman : 1 dari 1

NO KEBERTERIMAAN RINCIAN DOKUMEN INSPEKSI & TES KEBERTERIMAAN KODE INSPEKSI & TES
ITEM PEKERJAAN DAN SUB ITEM TOLERANSI KEBERTERIMAAN
ITEM SUMBER DOKUMEN YANG DIGUNAKAN
PEKERJAAN BAHAN
PEK. PERSYARATAN MUTU
BAHAN PRODUK BAHAN PRODUK I T W H D
A PEKERJAAN STRUKTUR
1 Pekerjaan wash boring a. Beton a. Dimensi pengeboran : Ø 80 cm a. Beton a. Trial mix dan jobmix design beton a. Cek dimensi pengeboran v v v v v a. Berita acara trialmix beton
1) Mutu Beton : fc’ 30 MPa (K-350) b. Kedalaman bor : ± 23 m dibawah peil ± - Slump beton 14-16 cm b. Cek mutu & slump beton b. Cek kedalaman pengeboran b. Berita acara tes besi beton
0.00
2) Portland cement : type I b. Besi Beton (uk mm) c. Kuat tekan benda uji beton c. Pencatatan bor log c. Form approval material
3) Pengambilan sample tiap 40 m3 Berdasarkan SNI 07-2052-2002 d. Cek type bentonite sesuai approval d. Cor beton sesuai level yang d. Form bor log
ditentukan
4) Tiap 1 set diambil 4 bh - Dia 6 → ± 0,3 mm e. Tes kuat tarik dan tekuk besi beton e. IMTP beton-01 sd 04
RKS Struktur Pasal 2
5) Tes kuat tekan umur 7 hr = 1bh, 14 hr = 1bh dan 28 hal 9 s/d 28
- Dia 8 ≤ d ≤ 14 → ± 0,4 mm f. Cek diameter besi dengan stigmate e. Tes axial load f. Form inspeksi & tes PROD-51
hr = 2 bh Cek jumlah besi sesuai surat jalan
- Dia 16 ≤ d ≤ 25 → ± 0,5 mm g. g. Berita acara tes axial load
b. Bentonite ex SIKA, FOSROC, setara - Dia 28 ≤ d ≤ 34 → ± 0,6 mm h. Cek nama suplier sesuai approval i. Instruksi Kerja (metode kerja)
c. Besi beton - Dia d > 36 → ± 0,8 mm j. Shop drawing yang sudah disetujui
1) Besi ulir BJTD 40 untuk diameter ≥ 10 mm
2) Besi polos BJTP 24 untuk diameter < 10 mm

2 Pemadatan tanah a. Tanah urug

1) Tanah merah dan kering a. Penghamparan tiap lapisan tanah
2) Bebas dari batu atau kerikil yang lebih besar dari 50 setiap 40 cm
mm dalam semua dimensi b. Pemadatan tiap lapisan 6 kali spacing
3) Bebas dari sampah, material beku, tanaman, dan (lintasan)
bahan yang merugikan c. Tinggi urugan 2 m dari elv 0.00
d. Hasil tes pemadatan CBR = 95%
a. Cek jenis tanah urug
b. Cek gradasi tanah urug
RKS Struktur Pasal 3 c. Cek kebersihan tanah urug
hal 12 s/d 17
a. Cek tebal hamparan tiap lapis
b. Jumlah spacing tiap lapisan
c. Elv tanah padat sesuai level
d. Tes CBR
v v v v v a. Berita acara tes trial embankmnet
b. Form approval material
c. Form inspeksi & tes PROD-51
d. Instruksi Kerja (metode kerja)
e. Shop drawing yang sudah disetujui

B PEKERJAAN ARSITEKTUR
1 Pasangan dinding
a. Bata ringan uk 60x10x20 cm ex hebel, primacon atau a. Ketinggian pemasangan bata ringan a. Bata ringan a. Cek ukuran bata ringan & jumlahnya a. Cek ketinggian pemasangan v v a. Form approval material
setara dalam 1 hari = 1,5 m - Ukuran dimensi → 2-3 mm b. Cek nama bahan sesuai approval b. Cek pengecoran kolom praktis b. Form inspeksi & tes PROD-51
b. Perekat bata ringan ex MU, drymix atau setara b. Kolom praktis harus sudah dicor c. Cek kondisi mortar belum mengeras c. Cek kondisi plesteran c. Instruksi Kerja (metode kerja)
c. Plesteran ex MU, drymix atau setara sebelum dilanjutkan penambahan d. Cek kerataan vertikality d. Shop drawing yang sudah disetujui
pemasangan bata ringan RKS Struktur Pasal 7
d. Acian ex MU, drymix atau setara hal 21 s/d 27 e. Cek adanya retak rambut acian
c. Ring balk dan kolom praktis dipasang
dengan luasan dinding tiap 25 m²
d. Pasangan dinding bata harus tegak lurus
setelah diplester
e. Acian dilakukan setelah plesteran kering
sehingga tidak terjadi retak rambu
setelah selesai diaci

Disetujui oleh, Dibuat oleh, Keterangan

Inspeksi (I) =
Bila produk atau pekerjaan cukup
dipastikan keberterimaan dengan secara
Proejc Manager SEM visual
Tes (T) =
Bila produk atau pekerjaan harus dipastikan
keberterimaan dengan tes terlebih dahulu
Witness (W) =
Bila pekerjaan harus dipastikan
keberterimaan dengan melakukan
pengamatan selama proses pekerjaan
Hold (H) =
Bila pekerjaan terjadi kemungkinan terhenti
akibat hasil tes yang tidak sesuai
keberterimaan
Documentation (D) = Bukti informasi terdokumentasi suatu
pekerjaan sudah sesuai keberterimaan
 ± 0.5 mm in 1m at weld
Individual Horizontal
Camber
± 0.5 - 0.1 mm in 1m, at weld
Individual Vertical
Camber

Component Fishplate Fishbolt

Carbon 0.40% - 0.55% 0.38% - 0.43%
Silicon Max. 0.40% 0.15% - 0.35%
Manganese 0.55% - 1.00% 0.60% - 0.85%
Phosphorus Max. 0.04% Max. 0.03%
Sulphur Max. 0.045% Max. 0.03%

Carbon 0.70 – 0.80%

Silicon 0.90 – 1.10%
Manganese 0.15 – 0.35%
Phosphorus Max. 0.035%
Sulphur Max. 0.025%
 Nut Spring Washer Property Fishplate Fishbolt
0.37% - 0.53% 0.59% - 0.86% Tensile Strength Min. 70 Kgf/mm2 Min. 110 Kgf/mm2
0.15% - 0.35% 0.15% - 0.35% Elongation Min. 12% Min. 10%
0.60% - 0.90% 0.30% - 0.90% Hardness HB 262 - 331 HB 262 - 341
Max. 0.03% Max. 0.04%
Max. 0.035% Max. 0.04%
 Nut Tensile strength 80 Kgf / mm²
Min. 85 Kgf/mm2 Elongation Min. 10%
Min. 13% Hardness Min. HB 270
HB 262 – 341
Tensile Strength
Elongation
Bending Property
Brinell Hardness
Min. 80 Kg/mm2 Carbon 0.90 – 1.20% Item
Min. 40% Manganese 11.0 – 14.0% Gauge
180 degrees (inside radius 25 mm) Silicon 0.3 – 1.8 % Alignment
170 – 223 HB (after casting) Phosphorus Max. 0.05% Cross Level
Sulphur Max. 0.035% Longitudinal Level
Main Track Depot Track Remarks Sieve (mm) Size (inch)
+ 2 mm to – 2 mm + 3 mm to – 3 mm 63.5 2½“
+ 2 mm to – 2 mm + 3 mm to – 3 mm Per 10 m length 50.8 2”
+ 3 mm to – 3 mm + 3 mm to – 3 mm 38.1 1½“
+ 3 mm to – 3 mm + 3 mm to – 3 mm Per 10 m length 25.4 1”
19.1 3/4 “
Percentage passing by weight Gauge Difference
100 Alignment Deviation
80-100 Longitudinal Level Deviation
35-75 Cross Level Deviation
0-40
0-5
+ 5 mm to – 2 mm (on straight)
+ 5 mm to – 5 mm (for 10 m span)
+ 7 mm to – 7 mm (for 10 m span)
+ 6 mm to – 6 mm (at spot)