Permanent Way Manual parti icTha Ballast, Sub-Ballas, Quay Material and cae I< Geotextlos m Chapter 8 Ballast, Sub-Ballast, Quarry Material and Geotextiles Issue Date Description Document History r y 0 May,2018 | First Issue Authorised By: | i Signature: EEPEEEEEEE EEE EEE Date: | General Manager Pommanentway 28 MAY 2015, KFT tap Tarte Metarye Berta Kuala Lumpur KING eo Rev.0 Page 1 of 12Bermanont Way Wanal aor Ballast, Sub-Ballast, Quarry Material and KTM Chapter # Goatees TABLE OF CONTENTS at BALLAST AND SUB-BALLAST 3 a2 TYPE OF BALLAST. 3 83 size 3 a4 BALLAST SPECIFICATION 3 85 SUB-BALLAST. 3 86 BLANKET. 4 87 GEOTEXTILES 4 88 IDENTIFICATION OF LOCATIONS FOR PROVISION OF SUB-BALLAST, BLANKET AND GEOTEXTILE i 4 89 BLOCK METAL, 5 8.10 QUARRY DUST 5 LIST OF FIGURES. 5 LIST OF ANNEXURES 5 Annexure 8.1 - Salient Technical Specification of Ballast for Track Maintenance 9 Annexure 8.2 - Enveloping Curve for Sub-ballast and Blanketing material a SKINS Re Page 2 of 12Permanent Way Manual Part Il KTM Ballast, Sub-Ballast, Quarry Material and Ghisprer 8 Geotextiles 84 BALLAST AND SUB-BALLAST aaa The layer of crushed stone, sand or other suitable material placed between the sleeper and the top of the formation is termed as ballast. It performs the following functions: ‘+ distributes the load from the sleepers to the formation, * provides elasticity and resiliency * offers lateral and longitudinal stability to track, + facilitates easy drainage and ‘+ affords a convenient medium for packing the track to maintain ine and level. 812 Where it is necessary to distribute the track loads on a larger area of formation, a second layer of suitable material, termed sub-ballast is placed between the ballast and the top of the formation. 82 TYPE OF BALLAST Ballast conforming to Specification in Annexure 8.1 is acceptable and shall be machine crushed. 83 SIZE 63mm maximum gauge granite stone ballast is used for all types of track, conforming to the sieve analysis as in Annexure 8.1. 84 BALLAST SPECIFICATION 841 Ballast specification is described in Annexure 8.1. In interpreting the requirements of the specification, reference shall be made to BS EN 13043:2002, “Single Size Road Stone and Chipping’ and BS EN 932-6:1999- Tests for general properties of aggregates. 84.2 Quarry chippings are small sized stone chips used to full up the voids under sleepers to lft the track to pre-determined levels in the system of maintenance of track by measured shovel packing (MSP). This stone chips shall conform to the standard specification (Salient Technical Features of the specifications are given in Annexure 8.1) The stone chips shall pass through 25mm(square mesh) sieve, 98% being retained on 6.3mm sieve. 85 ‘SUB-BALLAST 85.1 This consists of a layer of suitable material (like gravel, quarry dust, and sand) interposed between the stone ballast and the formation to distribute the load more evenly on a larger area of formation soil. It is also used on relatively good formation to improve the maintainability of track on high speed and heavy density lines. 852 The depth of sub-ballast shall not be less than 150 mm (preferably 200 mm) for Class 1 and Class 2 Track. However for Class 1 track the designer shall specify the minimum depth of sub-ballast. 85.3 Figure 8.1 indicates a cross section of Class 2 track with sub-ballast. ‘OKTME Rev. 0 Page 3 of 12Permanent Way Manual Part i Ballast, Sub-Ballast, Quarry Material and KTM Geotextiles cies 85.4 ‘The material shall be well graded and coarse graded. The particle size distribution curve shall fall within the enveloping curves shown in the graph at Annexure 8.2. If the material contains piastic fines (particles passing 75 micron sieve) the percentage of fines shall not exceed 15%. The uniformity coefficient of the material shall not be less than 4 to ensure that its fairly well graded 8.6 BLANKET 861 ‘A blanket is a layer of granular material ike sand or gravel provided on poor formation. The main function of the blanket is to improve the load bearing capacity of the formation and to form a barrier between the ballast/sub-ballast and the formation to prevent fouling of the former. Its thickness usually varies from 800mm to 1000mm and it covers the entire formation width. 862 ‘The material shail be well graded and coarse grained. The particle size distribution curve shall fall within the enveloping curves shown in the graph at Annexure 8.2. If the material contains plastic fines, the percentage of fines (particles passing 75 microns sieve) shall not exceed 5%. If the fines are non-plastic, these can be allowed up to 18% 863 Figure 8.2 gives a cross section of track showing a layer of blanket over the formation 87 GEOTEXTILES ar Geotextiles are layers of synthetic material provided over the formation and they help in solving formation problems by: + Preventing the penetration of ballast into the formation by effectively separating the formation from the ballast. + Acting as a fiter which allows the water through but not the soll fines and, + Facilitating the discharge of water along its plane. ‘+ Provides some element of reinforcement to the embankment * Prevent the process of ‘Mud Pumping’ 872 Specification: The material shall conform to the following technical requirements: + Raw material: Poly propylene. + Minimum weight: 400 grams.m? + Fibre bonding: needle punched. + The minimum grab strength according to ASTM-D4632 should be 1770/1650 N. + 100% polypropylene, continuous filament, non-woven needle punched. 87.3 Geotextiles are placed sandwiched between two layers of sand blanket. A typical cross section of track showing the use of geo-textiles is shown in Figure 8.3, where the sand layer thickness indicated is @ minimum of 50-75mm, The sand layer thickness for Class 1 Tracks shall be 2 minimum of 150mm up to 200mm: 88 IDENTIFICATION OF LOCATIONS FOR PROVISION OF SUB-BALLAST, ‘©OKT™MB BLANKET AND GEOTEXTILE ‘The Regional Engineer, with the approval of the General Manager Permanent Way, shall decide the location and other technical details about the provision of sub-ballast, blanket and geotextile In track. Rev. 0 Page 4 of 12SS a KTM Ballast, Sub-Ballast, Quarry Material and Chapa & Geotextiles 2 8.9 BLOCK METAL 89.4 Block metal is usually used to protect toe of slopes to prevent slope failure. They are also Used for the protection of river embankment against erosion from water and to prevent ‘embankment wash-outs. a92 The block metal must be clean, angular in shape in all dimensions and free from deleterious matter. The size of the block metal supplied shall be approximately 152 mm x 229 mm x 100mm (6" x 9° x 4") 8.9.3 The block metal supplied shall be granite or other approved igneous rocks. Before commencing the Supply, the Supplier shall submit the sample for KTMB Representative’s approval. The block metal shall be supplied in accordance to the sample submitted. 8.10 QUARRY DUST 8.10.1 Quarry dust is @ by-product of the crushing of granite stone or other approved igneous rock during the production of ballast materials. They are usually used in the field for the filing of slopes in cases of embankment slope failure. They may also be used for the purpose of filing up of cess. 8.10.2 The quarry dust must be clean and free from deleterious matter. LIST OF FIGURES Figure 8.1 Cross Section of Class 2 track with Sub-ballast Figure 8.2 Cross Section of Class 1 or Class 2 track with a Blanket Figure 8.3 Geotextiles to prevent Mud Pumping LIST OF ANNEXURES Annexure 8.1 Specification for Ballast. Annexure 8.2 Enveloping Curve for Sub-ballast and Blanketing material OKTMB Rev. 0 Page 5 of 12Permanent Way Manual Part il KTM Ballast, Sub-Bellast, Quarry Material and Chapter 8 Geotexilles 7 Fig. 8.1 _—SUB BALLAST 150 mm 7200 mm PREFERRED * NOTE : THE TOP WDTH OF THE BANK SHALL BE ADEQUATE TO ACCOMMODATE THE STANDARD TRACK PROFILE DULY ENSURING A MINIMUM 500mm CESS ON EITHER SIDE. Figure 8.1 - Cross Section of Class 2 track with Sub-ballast ‘©KTMB : ~ Rev.0 Page 6 of 12,Permanent Way Manual Part Il KTM Ballast, Sub-Ballst, Query Material and Chapter 8 eotextiles Fig. 8.2 | 7 MLAS _—BLANKET 800 mm (MIN) 7 T0-1000 mm Figure 8.2 - Cross Section of Class 1 or Class 2 track with a Blanket. eKTNB Rev. 0 Page 7 of 12Permanent Way Manual ee KTM Ballast, Sub-Ballast, Quarry Material and Part il Geotextiles Chapter 8 Fig. 8.3 = 180mm — 200mm THICKNESS! NOTES 1. SAND LAYER THICKNESS vaRiS. {We TOP WIM OF THE GANK SHALL BE ADEQUATE TO ACCOMMODATE THE STANOARD TRACK PROFLE DULY ENSURING A WINIMUM OF 500mm CESS. ON Figure 8.3 - Geotextiles to prevent Mud Pumping ‘©KTNB Rev.0 Page 8 of 12Permanent Way Manual Part I KTM Ballast, Sub-Bellest, Quarry Material and Chapter 8 Geotextiles Annexure 8.1 - Salient Technical Specification of Ballast for Track Maintenance The technical specifications for the ballast are as follows: 1. Ballast supplied shall be produced from the crushing of granite or other approved igneous rock. Before commencing the supply, the contractor shall submit the sample for the KTMB Representative’s approval. 2. The sample shall be taken at the quarry site in the presence of KTMB's Representative. The ballast shall be supplied in accordance with the approved sample. 3. The ballast shall be clean, angular in shape in all dimensions, with all dimensions nearly equal and free from deleterious matter. 4. The ballast shall be subjected to the following tests in authorised testing laboratory and the results shall be submitted for KTMB's Representative's inspection and approval: () The Wet Attrition Value shall not be more than 6% as per test carried in accordance with EN standard (BS EN 932-6:1999- Tests for general properties of aggregates), or the Los Angeles Value by Abrasion shall not be greater than twenty five percent (25%) (ASTM C-131-1981): (i) The Crushing Value (ACV) shall not exceed thirty percent (30%) (BS 812, Part 110/1990); (i) The Impact Value (AIV) shall not exceed twenty five percent (25%) (BS 812, Part 112/190); (iv) The maximum permissible Flakiness Index shall not exceed fifty percent (50%)(BS 812, Part 105.1/1989); (v) The maximum permissible Elongation Index shall not exceed fifty percent (80%)(BS 812, Part 105.1/1989); and: (vi) Particle size distribution: Square mesh sieve | Percentage retained (% by mass) 63mm 0 50. mm 80-90 28mm 10-20 14mm 0-2 ©KTMB Rev.0 Page 8 of 12Permanent Way Manual Part I KTM Ballast, Sub-Ballast, Quarry Material and Chapter 8 @KTNB, Geotextiles In interpreting the requirements of this specification, reference shall be made to BS EN 13043:2002. "Single size road stone and chipping” and BSEN 932-6:1999- Tests for general properties of aggregates Samples of ballast from each source of quarry shall, as directed by the KTMB's Representative, be taken in his presence. In general, the samples shall be taken as follows: (i) Before the supply commences; (ii) For every two thousand (2000) cubic metre of production; and (iii) From every stratum of rock in the quarry The Supplier shall transport the ballast by road to designated depots a stockpile the same at the depot. The Supplier shall also arrange to load the ballast into the railway wagon(s) from the stockpile. The designated depots referred to above shall be within the KTMB reserve or station yards on the main line as approved by KTMB. Further to this, the Supplier shall provide all the necessary equipment for all the tests. From time to time, KTMB's Representative shall carry out the sieve tests and all the other tests necessary to ascertain the grading and quality of the ballast. If the ballast is found not to conform to these specifications, it shall be rejected. Whenever the {quarry site is changed, all the specified laboratory tests stated in paragraph 4 above shall be carried out by the Supplier and to be approved by KTMB before the supply ‘commences, Rev.0 Page 10 of 12Permanent Way Manual Part Il KTM Ballast, Sub-Ballast, Quarry Material and Chapter 8 Geotextles SALIENT TECHNICAL FEATURES OF THE SPECIFICATION FOR THE SUPPLY OF QUARRY CHIPPINGS. 1. Composition: Quarry chippings shall be from crushed rocks obtained from approved hard stone quarries of igneous origin, such as granite or equivalent. The rocks shall be free from quarry crust, dust, oll, debris, sand or other foreign matter. 2. Size of Chippings: Chippings shall conform to the grading as indicated below. 3. Sieve: Chippings shall conform to the grading as indicated below. ‘Square Mesh % age passing through 25mm 100% 20 mm 52% to 78 % 18mm 26 % to 56% 412mm not more than 10% 63mm not more than 2% 4, Shape of Chippings: 1. The percentage (by weight) of chippings larger than 31.6mm in length and passing through a 25mm sieve shall not exceed 4. 2. The percentage (by weight) of chippings that can be dropped through a sieve with mesh of 6.3mm shall not exceed 2 %. 3, Homogeneity: The proportion of weight of damaged metal shall not be more than three percent (3%) by weight 5. Cleanliness: Foreign particles such as sand and dust shall not exceed 1 % by weight. @KTNB Rev.0 Page 14 of 12Part Il Chapter 8 Permanent Way Manual Ballast, Sub-Ballast, Quarry Material and Geotextiles Annexure 8.2 - Enveloping Curve for Sub-ballast and Blanketing material. 140% 19 Ent 3001 ZOE) aur 40 NaoLOGD aL (o1- “C NVHL 3YOW ATEVERI3Yd NYHL SS37 3SVO ON NI (09—G) LN3IOL4S300 ALINSOSINN “Ea OL at GOT 30° NYO SNVG Sid OUSV'G NON AV Sond % G1 GHHOXG LON crNOHS AL SUSVTG GY WWRALYA TDINVTE CISOGOMS SLM SANG CSNOTW 30 OL SMVED SON TS GNY_AWID ob 0% oF 0S OL 001 ONISSVd WOS 40 LHOIAM 30 3OVLN30N3d Page 12 of 12 Rev. 0 ©KTNB