bom ~~ Publle Transport DIVISION. ‘Corporation. PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM31 FOR MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT ‘SPECIFICATION Document id TM 31 Revision Status: 1.0 Copy No: Prepared By ‘A. Sowinski, Senior Technical Officer Gilicde 7 (Checked By , Leombruni, Track Materials Engineer Bl farmnfern ‘Approved By ‘8. Held, Manager, Track Engineering - ‘Authorised By FR. Detering, Group Manager, Engineering Services (CO %ise= 3/67 Issued By Track Materials Engineer © PTC Infrastructure Division, 1997 o anatasPecreano PUBLIC TRANSPORT CORPORATION caren INFRASTRUCTURE DIVISION TM 31 ‘VERSION: 1.0 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT RECORD OF AMENDMENTS Revision | Date ‘Authority Description 0.0 _ | December 1996 Initial issue (draft). 1.0 dune 1997 | Manager, First Issue. Reformatted, clauses renumbered. Track Engineering Updated - Cl 10.2 amended: Appendix A2 - 41 kg ‘Tram rail amended, Crane rail added; Appendix A3 - Mechanical properties added, qaorataw Track Materials 21607 Page 2 of ttOO TECHNICAL Ga \ PUBLIC TRANSPORT CORPORATION — INFRASTRUCTURE DIVISION T™ 31 “— VERSION: 1.0 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT. CONTENTS: 1 PURPOSE .. 2 SCOPE .. 3 REFERENCE DOCUMENTS | 3.1. AUSTRALIAN STANDARDS - 32 OTHER DOCUMENTS . 3.3 QUALITY ASSURANCE DOCUMENTS - 4 DEFINITIONS AND DESIGNATIONS 5 RESPONSIBILITIES . 6 INFORMATION SUPPLIED BY THE CORPORATION 6.1 RAILDETAILS ..... 62 WELD DETAILS . 63 DRAWINGS ... 64 HAZARDOUS CHEMICALS " 6.5 PACKAGING, HANDLING AND TRANSPORT 7 MATERIAL SUPPLIED BY THE CORPORATION .. 8 INFORMATION SUPPLIED BY THE CONTRACTOR 81 CONSUMABLES . 82 EQUIPMENT . 8.3 PACKAGING . : 8.4 RECOMMENDATIONS OR CODES OF PRACTICE 8.5 TECHNICAL INFORMATION |... 8.6 MATERIAL SAFETY DATA SHEETS . 8.7 QUALITY ASSURANCE SURVEY . 9 MATERIALS ... 40 MANUFACTURE... 10.1. MANUFACTURING LOCATIONS AND FACILITIES 10.2 CONSUMABLES ...... 10.3 EQUIPMENT ........ 11 ACCEPTANCE TESTING . 11.1 GENERAL, 11.2 TYPE TESTI 11.3, PRODUCTION Bi 12 PACKAGING AND LABELLING 12.1 PACKAGING. 122 LABELLING . 13 HANDLING AND TRANSPORT... 14 QUALITY ASSURANCE . 14.1 GENERAL ...... 142 INSPECTION 14.3 RECORDS 15 VARIATIONS TO APPROVED PROCEDURES AND MATERIALS .... © © 0000 & BOO BOBO INI NV YNSNNooo © oaa00m 4 o ana 4 ow 16 VARIATIONS TO APPROVED EQUIPMENT AND PACKAGING .. ‘aawrataw "Track Materials 2/607 Page 3 of 11Za oreoneaton Sn PUBLIC TRANSPORT CORPORATION T™ 31 INFRASTRUCTURE DIVISION ‘Sesoee VERSION: 1.0 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT 20 RESOLUTION OF DISPUTES 21 DELIVER’ 22 RECORDS . APPENDIX "A" ‘aawrstaw “Track Materiale 20607 Page 4 of ttDa mecneon y “A PUBLIC TRANSPORT CORPORATION sree INFRASTRUCTURE DIVISION TM 31 Sa VERSION: 10 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT 1 PURPOSE This Specification sets out the manufacturing, testing, supply and delivery requirements for aluminothermic rail welding materials and equipment for trackwork purposes. ‘The Specification shall be applicable to welds for tee rails and grooved tramway rails as listed in the ‘Schedule or as otherwise ordered. Specific requirements are detailed in this Specification, relevant drawings, the Schedule and orders. 2 SCOPE This specification applies to all Contractors and Corporation Infrastructure Division personnel involved in the supply or procurement of aluminothermic rail welding materials and equipment for the Public Transport Corporation. 3 REFERENCE DOCUMENTS: Reference may be made in this document to the current editions of the following standards, ‘specifications or drawings:- 3.1. AUSTRALIAN STANDARDS: as 1085.1 (1977, 1981 & Current) Permanent Way Material - Stee! rails As 1085.11 Permanent Way Material - Head-hardened rails as 1085.15, Aluminothermic rail welding ASINZS ISO 9002 Quality system for production and installation. 3.2 OTHER DOCUMENTS BHP Rail Track Material handbook. 3.3 QUALITY ASSURANCE DOCUMENTS PTC Qu ‘Assurance document SQA 9002.2 Revision ''. 4 DEFINITIONS AND DESIGNATIONS 4.1 GENERAL: Definitions and designations shall be in accordance with AS 1085.15, Clauses 3 and 4. 4.2 CONTRACTOR: In the context of this Specification, Contractor shall include tenderer, manufacturer and supplier. 5 RESPONSIBILITIES Contractors shall be responsible for conformance to this document. The Corporation's Technical Representative (Track Materials Engineer, ph (03) 9619-4436), shall be responsible for all technical matters, including Quality Assurance. aerate Track Materials 2/607 Page Sof 11SPEGIrIEATION Sn 4X PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ™ 31 VERSION: 1.0 ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT MANUFACTURE AND SUPPLY OF 6 INFORMATION SUPPLIED BY THE CORPORATION 61 62 63 64 65 RAIL DETAILS Rall size, section and hardness details shall be as specified in the Schedule and/or orders. Details, including ral chemistry and mechanical properties, for rails are provided in Appendix WELD DETAILS ‘The weld process and gap sizes shall be specified in the Schedule and/or orders. DRAWINGS All rail section drawings required for the performance of this contract as listed in Appendix shall be supplied by the Manager, Supply, Infrastructure Division, PTC. HAZARDOUS CHEMICALS ttis a requirement of the Corporation's Hazardous Chemicals Policy that all chemical products are evaluated and approved for use. Refer to Clause 7, “Information supplied by the Contractor” for Contractor's obligations. PACKAGING, HANDLING AND TRANSPORT Packaging, handing and transport requirements, # other than approved Contractor standard, shall be as specified in the Schedule andlor orders. 7 MATERIAL SUPPLIED BY THE CORPORATION “The Contractor may obtain sections of ral free of charge from the Corporation. Arrangements and costs {or collection and delivery to the Contractor's works shall be made and borne by the Contractor. 8 INFORMATION SUPPLIED BY THE CONTRACTOR: 8.1 82 CONSUMABLES: ‘The Contractor shall provide details, as specified in AS 1085.15, Clause A3, for each weld type ‘and process combination specified in the Schedule. ‘The Contractor's part number or ordering reference shall be provided for each item. ‘Additionally, the shelf life and any special storage and handling requirements shall be detailed. EQUIPMENT ‘The Contractor shall provide detailed equipment requirements for each weld type and process combination specified in the Schedule. The interchangeability of equipment for the various processes shall be detailed. ‘The Contractor's part number or ordering reference shall be provided for each item. Materials, general dimensions and mass of equipment shall be provided. aaorataw Track Materials 2/67 Page 6 oftLr TECHNICAL ad PUBLIC TRANSPORT CORPORATION secre INFRASTRUCTURE DIVISION TM 31 one VERSION: 10 ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT MANUFACTURE AND SUPPLY OF 83 a4 85 86 87 PACKAGING ‘The Contractor shall provide details of proposed component packaging, including the contents, weather proofing and mass of cartons and kits. Details of proposed shipment packaging shall be provided and shall include mass, weather proofing and provisions for mechanical handling. RECOMMENDATIONS OR CODES OF PRACTICE “The Contractor shall prove detailed recommendations for preparation and manufacture for each ‘weld type and process combination specified in the Schedule. The recommendations shall detail any risks associated with the consumables, equipment and processes and provide occupational health and safety information to avoid or minimise these risks. TECHNICAL INFORMATION ‘The Contractor shall provide weld defect analysis information to assist with assessment of defects and weld failure causes. fay oor echnical rfomaton relevant to the welding materials, equipment and processes shall be provided. MATERIAL SAFETY DATA SHEETS ‘The Contractor shall provide Material Safety Data Sheets for all chemical substances. The data sheets shall be prepared in the Worksafe Australia format or equivalent. QUALITY ASSURANCE SURVEY ‘The PTC "Tenderer’s Quality Assurance Survey" document TQA 3900.1 shall be completed and submitted with the tender. 9 MATERIALS ‘All materials utilised for manufacture of consumables and equipment shall be of merchantable quality ‘and comply with relevant Australian or equivalent Standards, if applicable. 10 MANUFACTURE, 10.1 102 10.3 MANUFACTURING LOCATIONS AND FACILITIES ‘The Contractor shall advise the Corporation in writing of the proposed manufacturing locations and of any change of locations of works at which consumables and equipment are manufactured. CONSUMABLES ‘All consumables shall be such as to produce welds fully complying with the chemical and mechanical properties as specified in AS 1085.15, Clause 6, unless otherwise specified or approved. EQUIPMENT {All equipment shall be suitable for the production of welds conforming to AS 1085.15, suit the relevant weld process and shall comply with relevant drawings. Where applicable, equipment and materials for equipment shall comply with relevant Australian or equivalent Standards. anata Track Materials 2687 Page 7 of 11a SPECICATION be 4 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TM 31 4 VERSION: 19 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT 11 ACCEPTANCE TESTING 11.1 GENERAL The Contractor shall advise of locations and provide details of facilities and equipment for acceptance testing. 11.2. TYPE TESTING ‘All weld processes, including consumables, equipment and procedures shall be subject to Type ‘Testing approval n accordance with AS 1085.15, Clause 62, unless otherwise exempted in writing by the Corporation. “The Contractor shall detail which welds have passed Type Testing, for which rail system, and what documentary evidence is available. Documentary evidence shall be provided for each ‘weld type or process prior to the contract being awarded. Such documents shall be treated by the ‘Corporation in commercial confidence. 11.8 PRODUCTION BATCH PROOF TESTING 11.8.1 Consumables ‘All consumables shall be subject to proof testing in accordance with AS 1085.15, Clause 6.3, unless otherwise exempted in writing by the Corporation. 11.8.2 Equipment All equipment shall_be inspected to ensure merchantable quality, suitabilty for the relevant processes and consumables and conform to relevant drawings and Specifications. 12 PACKAGING AND LABELLING 12.1. PACKAGING ‘All components for dispatch shall be adequately packaged to ensure that no damage or loss ‘occurs during handling and transit. Packaging shall be of suitable size and construction and shall comply with AS 1085.15, Clause 5.3 and any other requirements as detailed in this Specification, ths Schedule or rer. 12.2 LABELLING Labelling shall comply with AS 1085.15, Clause 5.3. Igniter containers shall be suitably labelled to wam against storage with portions. Addon, packagos shal be ceafy marked in Bock lets wih Public Transport Corporation, 13 HANDLING AND TRANSPORT Packages requiring mechanical handling shall be provided with suitable mechanical handling f Provision shall be made when loading for dispatch to permit unloading by suitable mechanical handling ‘equipment. ies. aawrotaw ‘Track Materials 21697 Page 6 of 1SPEGIIGATION PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ™ 31 VERSION: 18 ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT MANUFACTURE AND SUPPLY OF 14 15 16 The size, shape, mass and construction of individual packages shall, as far as practical, permit safe ‘manual handling without risk to health and safety. QUALITY ASSURANCE. 144 142 143 GENERAL The Contractor shall comply with “PTC Quality Assurance Requirements” as detailed in document SQA 9002.2 Revision". The Contractor shall demonstrate compliance with this Specification, in accordance with AS 1085.15, B4 "Suppliers Quality System* by the implementation and maintenance of a Quality ‘System to meet the requirements of AS/NZS ISO 9002 and this Specification. INSPECTION ‘Allcosts incurred by the Contractor in the provision of test certificates or provision of labour and ‘appliances necessary for tests and inspections at the works during the currency of this agreement shall be included in the tendered price. The Corporation reserves the right to perform compliance audits of the Contractor's Quality ‘System and to undertake any or all functions nominated in AS 1085.15, Clause A6. RECORDS 14.3.1 General In addition tothe requirements of AS/NZS ISO 9002 and AS 1085.15, the Contractor shall maintain records of results for all inspection and testing operations to demonstrate compliance with this Specification. 14.3.2 Test Certificates The following test certificates shall be provided to the Corporation's Technical Representative with each delivery: (a) Contractor's Certificate of Compliance, (b) Contractor's Certificates, as applicable, to demonstrate compliance with ())_AS.1085.15, Clause 6.3, “Proof Testing of Batches" for portions, {i) Relevant standards, specifications and drawings for other consumables, (i) Relevant standards, specifications and drawings for equipment, (i) Any additional testing as nominated by the Corporation's Technical Representative. VARIATIONS TO APPROVED PROCEDURES AND MATERIALS Variations to approved procedures and materials shall be subjected to Type Testing - Acceptance Procedures as detailed in AS 1085.15, Clause 6.2. VARIATIONS TO APPROVED EQUIPMENT AND PACKAGING ‘Approved equipment and packaging shall not be varied without the written approval of the Corporation. ‘Fowrstaw "Track Materials 2607 Page oof 11TECHNICAL bh A PUBLIC TRANSPORT CORPORATION TM 31 INFRASTRUCTURE DIVISION rae VERSION: 1.0 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT | 17 TRAINING ‘The Contractor shall provide details of available training at his works and at the Corporation's works or training sites. Recommended duration and costs of training shall be specified. 18 AFTER SALES SUPPORT ‘The Contractor shall provide details of after sales support for resolution of problems encountered with all facets of manufacture of welds and supply of materials. Any costs associated with after sales support shall be specified. 19 WARRANTY ‘The Corporation reserves the right to reject any material which within one (1) year of delivery, is found ‘ot to conform to this Specification or is defective due to faulty material or workmanship. Any rejected ‘material shall be repaired or replaced by and at the cost of the Contractor. 20 RESOLUTION OF DISPUTES {In the event of a dispute arising between the Contractor and the Corporation regarding the test results of any component, the Contractor and the Corporation shall agree to have the tests, and if necessary additional tests, carried out by an independent testing authority. This authority shall be registered by N.A.T.A., at the time of testing, for the type and classification of tests concerned. “The results of such independent testing shall be considered as being final and the costs of testing shall be bome by the loser ofthe dispute. 21 DELIVERY ‘The material shall be delivered F.|.S. to Permanent Way Materials Depot, McLister Street, Spotswood, Victoria, unless otherwise specified on orders. ‘Additional costs associated wth delivery and unloading at locations other than Permanent Way Materials Depot, Spotswood shall be to the Corporation's account. 22 RECORDS Records shall conform to the requirements detailed in 14.3 of this specification. ‘aaursiaw Track Materials 2/0/87 Page 10 of 11PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL ‘SPECIFICATION TM 31 ‘VERSION: 1.0 MANUFACTURE AND SUPPLY OF ALUMINOTHERMIC RAIL WELDING MATERIALS AND EQUIPMENT ‘Al DRAWINGS, as referred to in Clause 6.3 of this Specification. APPENDIX “A* INFORMATION SUPPLIED BY THE CORPORATION ‘Drawing No. Revision Description 614-81 - T$1001 BB Ts1002 «C 40 kg (80 Ib) " Rail Rig0 Tram Rail 41 kg Tram Rail AZ RAIL CHEMISTRY, as referred to in Clause 6.1 of this Specification. Fal c 3 Mn P 8 v or Teo | wooo 58-68 | >A 6-9 | coe | 204 AtigTams7so | 48-55] <4 | 120-145 | <005 | «095 atigTemasit | 46-54 | 35 | 9-110 | os | 205 | 09-00 avigascio™ | 58-74 | 23 | 60-95 | 204 | <05 50g AS e882 | 15-50 | 70-100 | 206 | 205 sakgas(iesty | 63-82 | 15-50 | 70-100 | 04 | 05 ekg AS 6-82 | 18-50 | 70-100 | 204 | 205 6OKg AS HH s8-a2 | 15-50 | 70-100 | so4 | <0s Grooved | rico so00 (HH) | so-20 | 4-5 | 20-13 | 2035 | «035 igo $700 45-05 | 238 | 60-10 | 204 | <.065 crane_| 192kg BHP ss-75 | cas | 1as-105 | 205 | <05 EA Notes: Hardness tolerance = 20 Hy © Approximate chemical composition shown for 40 kg (80 Ib) ‘O' rail. 3 MECHANICAL PROPERTIES, as referred to in Clause 6.1 of this Specification. Pai 2% “Tensile Strength Elongation | Hy Pract Sse Mea Gage (Sieace) Mea 250575, ” Tee | 401g'0" 220 41 kg Tram $750 40 750 5 225 41 kg Team HSHL 420 900 1050 “4 280 (Head) 47 kg AS (187) 0@ 200 se 230 50kg AS ‘00 240 10 200 53 kg AS (1981) 500 940 10 280 eOKg AS 500 940 10 260 ekg AS HH 0 1250 12 360 (Head) ‘Grooved | Fo $900 (HH) 20 1928 92 340 (Head) 60 $700 0 720 9 200 Grane | 192kg BHP 500 950 6-12 300 Notes: Machanical properties for 40 kg (80 Ib) 'O' rail are not available. Mechanical properties shown for 47 kg rail (pre 1981 chemistry) are typical. Fawataw Track Waterats 2167 Page 11 of 11