PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM 44 1 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS REVISION 0 ISSUE DATE: OCTOBER 1995 (REFORMATTED: OCTOBER 1997) Track Materlals Engineer Engineering Services Group ‘AaisPEcmisicos Revissn lssuad Oct 1995, Ratormatad Oct. 1997MIMIC AT eee UNe UIVISION TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS, ea CONTENTS is Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 2 2. Page 2 3. Page 3 sees Page 3 32 Page 3 33 Page 3 34 Page 3 3} 35 Page 4 36 : Page 4 4, TESTING .. ste eeeeeeeeeteeeteeersseees Page 4 8. QUALITY SYSTEM ooo. ceeeee . - Page 5 6. WARRANTY .... cs - Page 6 7, _ RESOLUTION OF DISPUTES ..... Page 6 8. SUPPLY AND DELIVERY REQUIREMENTS ........ sesesssee Page 6 aavseecmisicos Revision, lssued Oct, 1995, Reload Oct, 1997 i— es es PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS 1.) GENERAL 1.1 Scope This specification details the dasign, manufacture, supply and delivery requirements of prestressec concrete railway sleepers with cast-in rail fastening shoulders to suit "Pandrot type resilient rail clips. 12 tf tractor The supply of *Pandrot* type rail clips, H.O.P.E. rail pads and rail foot insulators are not Included ir this Contract. 1.3 Supply Requirement of Contractor ‘The Contractor shall provide all materials other than that listed in Clause 1.2, labour, plant, testing. designs and all associated requirements to carry out this Contract. ‘The Contractor shall provide the Corporation with design calculations, material specifications and detalled drawings of the proposed concrete sleeper, together with an estimated service life of the sleeper subject to the design requirements specified in Clause 2. ‘The quality of materials supplied by the Contractor shall comply with the relevant clauses of this specification. 1.4 Dimensions an: All items supplied must be strictly in accordance with the dimensions end tolerances shown on the Drawings. ttems not conforming with these dimensions will be rejected 1.5 Standard Specifications and Codes of Practice In all cases where Australian, British, or American standard specifications, rules, or codes of practice are referred to under this Contract, such reference shall always ba teken to Include the lates: supplements, amendments, addenda, corrigenda and errata, etc. relating thereto, and currently in force at the time of tender. ‘It shall be the Contractor's responsibilty to escertain the existence, and ‘comply with the provisions of all such latest issues and variations of the standard specifications, rules and codes of practice. 1.6 Inspection The Contractor shall permit access at all reasonable times to all places where the work is bei cartied out and shall provide all the necessary facities for inspection and testing of all materials an workmanshij The sleepers shall be provisionally inspected at the works of the Contractor. Such provisiona! inspection shall not be a bar to rejection at the place of delivery in the evant of it not being received in good order and condition to the entire satisfaction of the Corporation's Suservising Engineer. No sleepers shall leave the works of the Contractor until such work has been provisionally inspec and approved by the Supervising Engineer or his authorised representat All sleepers are to be inspected by an authorised representative of the Corporation during load testing. The Contractor shall give at least 48 hours notice of his intention to pour concrete and perform load tests. 0 esved Cet, 1995, Ralormstad Oet 1997 Page 117 24 22 23 24 25 26 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY ANO DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS Contractor's Drawings Apart from the Drawi ‘expense all other drat Contract, 38 supplied by the Corporation, the Contractor shall prepare at his own $s (Contractor's drawings) which may be required for the completion of the Contractor's drawings shall show all details, sizes, dimensions, ete. ‘The Contractor shall submit for the review of the Corporation's Supervising Engineer, two-prints for each Contractor's drawing prior to commencing any fabrication. A minimum of 2 weeks shall be allowed for such review. The Contractor shall bear full responsibilty for the accuracy, correctness and practicabilty of ail Contractor's drawings used in the work, and their review by the Supervising Engineer shall not reliev> the Contractor of this responsiblity. All drawings shall be produced by computer drafting using a Microstation or Microstation com system. A file will be made available tor drawing transfer of the PTC Title Block which, 0 ‘completion of the Contract, shall be retumied with all completed drawing CAD files to and remain the property of the PTC. No work shall begin until approval of the Contractor's drawings has been re Corporation's Supervising Engineer. 1d from the ‘Any material ordered or work done by the Contractor before his drawings or any amendments thereto have been approved shall be at the Contractor's own tisk. DESIGN AND MANUFACTURE REQUIREMENTS ‘The design shall be in accordance with AS 1085.14-1990 "Rallway Permanent Way Material, Part 1¢ ~ Prestressed Concrete Sleepers" unless approved otherwise by the Corporation's Supervising Engineer. The Contractor shall submit full and detailed design calculations and drawings and loads for type tests within 28 days of the date of letter of acceptance from the Corporation. ‘This is an all-inclusive Contract and it shall be the Contractor's responsibilty to negotiate with th: ‘owner of any concrete sleeper design that the Contractor may wish to use in the performance of th contract. The Corporation has a conorete sleeper design which maets the requirements of this ‘Specification. The design shall allow for the installation of both 53 kgim rail (fo AS 1085 - 1 (1981) now superseded) and 60 kg'm rail (to current AS 1085 - 1 “Steel Rails"). The Contractor shall design the concrete sleeper for the use of the folowing "Pandrol” type ra: fastening components: Resilient Rail Clip PR 401 A Rail Foot insulator IN 55187 Rail Pad H.0.P.E. Smm thick RP 65119. ‘The concrete sleepers shall be cured by low pressure steam curing to AS 3800 - 1988. Avian 0, lensed Oct. 1995, Rlormso¢ Oct. 1937 Page patible. Wwt ri a7 28 31 32 Ss 33 34 ® PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS: Each sk follows: er shall be marked on the upper face between the rail seats with indented letters as A “PTC2" in letters 75mm high. B. The year of manufacture in letters 50mm high, C. — Amark identifying the manufacturer. The depth of indent shall not reduce the minimum cover to reinforcement. All indented letter and ‘markings shall be submitted to the Corporation's Supervising Engineer for approval Numbers or letters identifying the mould and the in paint on one end of each sleeper. line in which the sleeper was cast shall be stencilled ‘The Corporation reserves the tight to change this specification and to negotiate changes in the designs, procedures and details submitted by any Tenderer. CRITERIA FOR SLEEPER DESIGN AND MANUFACTURE ‘The design rail seat load shall be used as the determining factor for the design, taking precedence over all the other factors listed below, which are supplied in accordance with Appendix B of AS 1085.14 - 1990. Desion Standard Design shall be in accordance with AS 1085.14 - 1980 unless epproved olherwise by the Corporation's Supervising Engineer. Inf ) rallway system Public Transport Corporation of Victoria i installation locations metropolitan and country tracks fi) track gauge 100mm y rail size 53kg and 60kg vy) max axle load 25 tonnes v) annual gross tonnage 20 MGT vi) max. train speed 115 kmvhr vil) gradient 1in40 ®) minimum radius 200 metres. » track circuits Yes; Insulation required for metropolitan tracks x) electrification Yes; 1500 volts DC for metropolitan tracks. x) climate temperate -4mm to +2mm cant of rails 1 in20 ii) ballast depth 300mm crushed stons i) formation CBR 20 ‘Sleéper Desian information ) impact factor allowed for in rail s DY sleeper spacing 685mm ii) sleeper dimension limits nominal length = 2700mm min width at rail seat =) ‘max width of bottom face = =) a8 height at centre =) per height at rail seat =) design max height at shouléer =) ASISPECTUACos! Revision 0, lssued Oct. 1995, Ratormattat Oct. 1997 Page 335 3.6 4. 4a 42 43 44 45 46 47 PUBLIC TRANSPORT CORPORATION S INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS. » design bending moments: positive at rail seat das egative at rail seat )per positive at centre ) design Negative at centre ) design rail seat load 187 kN astenit mation D clamping force at each rail seat: 14 KN ) See Clause 2.5 i) acceptable type of pads: Smm H.D.P.E. ) ‘Manufacturing Information i type of cement GP of HE to AS 3972 a acceptable curing method: low pressure steam curing TESTING A line of sleepers shall be defined as a batch of sleepers taken from one continuous prestressi, bed, one sleeper in width. In no case shall a line represent a batch of more than 65 sleepers. ‘A bed shall be defined as a group of parallel lines in which concrete is cast at the same time across the full width of the group and which is vibrated simultaneously. ‘The Corporation's Supervising Engineer shall determine the number of sleepers considered to form alline and a bed. ‘Sampling for concrete cylinder compressive tests shall be as follows: 6 test specimens shall be taken from each bed, of which 2 shall be taken from the last sleeper cast in the line. Cylinders for the determination of transfer strength shall be cured in the same manner as the sleepers up to the time of transfer of prestress by release of the prestressing wires. Cylinders for testing at 28 days will be cured in the manner specified in AS 1085.14. f Where the sleepers are cured by low pressure steam curing, cylinders shall be placed near the, | concrete sleepers under the steam covers midway between 2 adjacent points of steam entry, but not closer to any point of steam entry than half the width of the bed, . To test transfer strength, 2 cylinders shall be tested at the time of release of prestressing wires. Th? minimum compressive strength at transfer shall be 30 MPa, but provided thal the difference between the strengths of the 2 cylinders is less than 20% of the average strength, PTC will accept th= concrete ifthe average compressive strength is greater than 30 MPa. To test 28 day strength, 4 cylinders shall be tested at 28 days eiter casting. The minimum compressive strength at 28 days shall be 50 MPa, but provided that the difference between the, strengths of the 4 cylinders is less than 10% of the average strength, PTC will accept the concrete i! the average compressive strength is greater than 50 MPa. To prove the sleeper design, the type tests nominated in AS 1085.14 - 1990 Section 6.3 shall b= conducted and the criteria for acceptance shall be as stated in Section 6.4. For existing designs tha: have already been so tested, further testing will not be required if complete records of the tests are made available to the Corporation's Supervising Engineer within 7 days of request. Favison 0, lnsvad Oct. 1995, R‘simataz Oat. 1997 Page ~8 48 49 4.10 4at 4.12 parseecrusscos ev 3 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE_DIVISION TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS Betore delivery, production quality control tests shall be conducted as follows: A. The length, cross-sectional dimensions, location of centroid of tendons and location of individual tendons of one sleeper per bed shall be checked for compliance with Section 3.2 0! AS 1085.14. It non-compliance is discovered, 5 additional sleepers from that bed shall be checked. If all 5 sleepers are found to comply, the bed may be accepted. If any of the 5 sleepers are founc not to comply, all the remaining sleepers in that bed shall be checked individually. ‘The Bond Development and Ultimate Load Test in Appendix O of AS 1085.14 shall b: performed on one rail seat of one sleeper per bed between 7 and 35 days after casting, an: the resulls shall be checked for compliance with Clause 6.4.5. If non-compliance is discovered, 3 additional sleepers from the bed shall be tested. If all S sleepers are found to comply, the bed may be accepted, f any of the 3 sleepers are founc not be comply, the entire bed shall be rejected. The positive Rail Seat Vertical Load Test in Appendix K of AS 1085.14 shall be performed on cone rail seat of one sleeper per bed between 7 and 35 days after casting, and the results shai: be checked for compliance with Clause 6.4.1. If non-compliance is discovered, 3 additional sleepers shall be tested by both the positive Ra’! Seat Vertical Load Test and the Bond Development and Ultimate Load Test at the same ra’! seat. Ifall 3 sleepers are found to comply, the bed may be accepted, If any of the 3 sleepers are found not to comply, the entire bed shall be rejected. ‘The Contractor shall arrange and pay all costs for the testing defined in this specification to bs undertaken. Testing shall be undertaken using equipment calibrated by NATA approved personne’, and approved by the Corporation's Supervising Engineer. All test results shall be retained by the Contractor. Copies of all test results shall be forwarded to the Corporation's Super of completion of the tests, ing Engineer within 7 days All documentation relating to concrete cylinder tests, load testing and cattbration of equipment sha’: be made freely available to the Corporation's Supervising Engineer on request. QUALITY SYSTEM The Contractor shall comply with the PTC Quality Assurance Requires as detailed in docume= SQA 9001.2 Rev.A. For this Contract the Corporation's Quality Assurance Representativ shall be the Supervis Engineer. The Contractor is responsible for, and shall provide all personnel, eq: carry out Qually Assurance in the design, manufacture and handling of and consumables ?2 concrete sleepers. No part of the Quality System shall be used to pre-empt, precluds or otherwise negate ti requirements of any part of the Contract. All inspection record forms, test data forms and Certificate of Compliance shall be submitted to t Supervising Engineer for approval prior to being implemented. 27. sued Oct. 1995, Ralormanes Cet, 1997 . Page 5% FUuBLIG TRANSPORT CORPORATION a INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. TM 44 FOR DESIGN, MANUFACTURE, SUPPLY AND DELIVERY OF RAILWAY PRESTRESSED CONCRETE SLEEPERS. The Contractor shall maintain records of all inspection and testing operations performed and results obtained. These records shall be certified by the Contractor's Quality Assurance Of provided to the Supervising Engineer, and @ copy shall be WARRANTY The PTC reserves the right to reject any material which within one year of delivery, is found not to Conform to this specification or is defective due to faully material or workmanship. Any rejected ‘material shall be repaired or replaced by and at the cost af the Contractor. RESOLUTION OF DISPUTES {In the event of a dispute arising between the Contractor results of any components, the Contractor and the Cor tests, and If necessary additional tests, shall be registered by N.A.T.A. for the fi ‘and the Corporation regarding the test { poration shall agree to have the specifier” carried out by an independent testing authority. This authoril, _ > ield and classification of tests concemed at the time of testing. The results of such independent testing shall be considered as being final and the costs of testing shall be borne by the loser of the dispute. 8 SUPPLY AND DELIVERY REQUIREMENTS 8.1 The Contractor shall be responsible for all the materials being supplied under this contract and their storage, loading, transport and unloading until they are properly stacked at the delivery site and accepted by the Corporation's Supervising Engineer. Any materials not accepted by the Corporation's Supervising Engineer must be removed from the site by the Contractor at his own cost, and such materials must be replaced with acceptable materials by the Conicactor at his own cost. 8.2 During transport and stockpiling, the sleepers shall be stacked on timber bearers approximately, ‘75mm square which shall be located in the rail seat area of the sleeper. 8.3 The bearers shall become the property of the PTC and shall notbe retuned to the Contractor. é 84 The delivery site shall be the Permanent Way Materials Depot, McLister Street, Spotswoo. Melbourne. aasseecriston Revisen Q tssued Oct. 1995, Reloemazed Oct, 1997