PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES REVISION 0 ISSUE DATE: OCTOBER 1996 Track Materials Engineer Engineering Services GroupPUBLIC TRANSPORT CORPORATION INFRASTRUCTURE _ DIVISION ‘TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES CONTENTS: 1. SCOPE ee ee Page 2 TECHNICAL REPRESENTATIVE wee wena dee ee eee e eee eee Page REFERENCE DOCUMENTS: . Page 3.1 Australian Standards ..... a “Page 32 PTC Quality Assurance Documents ............ Page 4. STANDARD SPECIFICATIONS AND CODES OF PRACTICE .. Senpencosoalx) 5. DRAWINGS SUPPLIED BY CONTRACTOR . . . Page 6. DESIGN OF CAST SLEEPER PLATE ...........0 5000222 se cess ee eenn nese eee nes Page 7. MANUFACTURE OF CAST SLEEPER PLATE - Page 8. TOOLING os ceeeerees eee eee e ence ene n ene eens . Page 9. TESTING AND FACILITIES Page 10. QUALITY ASSURANCE Page 10.1 General....... . Page 10.2 Test Certificates Page 12, PACKAGING ......... epndoeou6soHonseHs5 ceeeees Page 43, SUPPLY ............. beveeteenes - ceveeeeee ees Page 44, DELIVERY occ ccccecteceteeer cette et tn ee tneecneagens coves Page Aarsrecrmuasees! Revision 0, October, 1996PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES ‘SPECIFICATION 4. SCOPE This specification sets out the design, manufacture, supply and delivery of clip fastening cast sleeper plates used for railway trackwork. Specific requirements relating to the cast sleeper plates to be supplied are in this specification, relevant drawings and the Schedule. 2. TECHNICAL REPRESENTATIVE ‘The Corporation's Technical Representative shall be the Track Materials Engineer Tel: (03) 9619- 4436 or 9619-4434, who will be responsible for all technical matters including that for Quality ‘Assurance. 3, REFERENCE DOCUMENTS 3.1 Australian Standards Unless otherwise nominated, reference is made in this specification to the current editions of the following Australian Standards:- 1085 Railway permanent way material - Part 1 Steel rails Part 16 Cast sleeper plates ASINZS ISO 9001 Quality system model for quality assurance design, development, production, installation and servicing. 3.2 PTC Quality Assurance Documents, PTC Quality Assurance Document SQA 9001.2. 4, 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 be taken to include the latest supplements, amendments, addenda, corrigenda and errata, etc. relating thereto, and currently in force at the time of purchase agreement. It shall be the Contractor's responsibility to ascertain the existence, and comply with the provisions of all such latest issues and variations of the standard specifications, rules and codes of practice. arsrecruascot Revision 0, October, 1996 Page 1nt by Lo ‘AamsrecrTuascept Revision 0, October, 1996 - Page 2 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES: DRAWINGS SUPPLIED BY CONTRACTOR ‘The Contractor shall prepare at his own expense all design drawings required for the manufacture of the cast sleeper plates. The Contractor shall bear full responsibility for the detailed design, accuracy, correctness and practicability to manufacture the required product. ‘The Contractor shall forward one copy of each drawing to the Corporation, In the case of any amendments to these drawings the Contractor shall provide the Corporation one copy of the revised drawing prior to the manufacture of the iter. In addition to the manufacturing drawings the Contractor shall provide: = design drawings of each rail fastening assembly for the cast sleeper plate fastened to timber sleeper and direct fixation to concrete slab. = load - deflection curves of the clips showing - (i. the yield stress of the clips, (ii) the design working stress range, (ii) the maximum clip stress during application. DESIGN OF CAST SLEEPER PLATE The cast sleeper plates shall be designed in accordance with the following conditions: () Compatibility to AS 1085.16. i) Rail 47, 50, 53 and 60kg to AS 1085.1 (ii) Track gauge 1600/1435mm. (iv) Sleeper spacing 685mm. (V) Minimum curve radius 100 metres. (vi) Maximum train speed 130knvhr. (vil) Maximum train axle load 25 tonnes. (vill) Fastened to timber sleeper or concrete slab. (%) _ Plate fixed with lockspikes, PTC screw spikes or bolts as required. () Location and type of fixing for plates to be approved by the Corporation's Technical Representative.8 10. ‘Aarsrecrtuascest Revision 0,., October, 1996 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES (xi) For use with PR401A and 1821 Pandrol rail fastening clips. (xii) Clip anti-back off feature shall be utiised in all designs. MANUFACTURE OF CAST SLEEPER PLATE The cast sleeper plates shall be manufactured and tested to conform in all respects with AS 1085.16 and additional requirements as detailed in this Specification and the Schedule. Manufacturing dimensions and tolerances of the plates shall be in accordance with the relevant drawings and AS 1085.16. Items not conforming to these dimensions and material specification shall be rejected. TOOLING All dies, fixtures, patterns, coreboxes and gauges shall be provided by the Contractor and shall be retained and maintained by the foundry at his expense such that they are in a satisfactory condition Prior to use. TESTING AND FACILITIES All costs incurred by the Contractor in the provision of test certificates, labour and appliances necessary for the mechanical, dimensional, non-destructive testing, general tests and inspections at his works during the currency of this agreement shall be included in the contract price. QUALITY ASSURANCE 10.1 General The Contractor shall comply with PTC Quality Assurance Requirements as detailed in document SQA 9001.2. ‘The Contractor shail implement and maintain a Quality System to meet the requirements of ASINZS 1SO 9001 and this Specification. The Contractor shall perform and maintain records of results for all inspection and testing operations which demonstrate that the cast plates are manufactured in accordance with this ‘Specification. All documentation shall be certified by the Contractor's Quality Assurance Representative. ‘The format of all inspection record forms, test data forms and Certificate of Compliance shall be submitted to the Corporation's Track Materials Engineer for approval prior to being implemented. ‘The Corporation reserves the right to perform compliance audits of the Contractor's Quality ‘System and to undertake any or all functions nominated in Clause A4 of AS 1085.16.1. 12, 13. 14. ‘AcrsrecrTuacet Revicion 0, October, 1996 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM29 FOR DESIGN, MANUFACTURE AND SUPPLY OF CLIP FASTENING CAST SLEEPER PLATES: 10.2 Test Certificates ‘The following test certificate shall be provided to the Corporation's Track Materials Engineer with each delivery of cast plates:- © Contractor's Certificate of Compliance. The following test certificates shall be retained by the Contractor and provided to the Track Materials Engineer on request:- © Chemical composition of the iron used to manufacture the cast plates. ¢ The results of all tests performed to establish compliance with this specification including mechanical, non-destructive testing, dimensional and tolerance criteria. © The results of any additional testing as nominated by the Corporation’s Quality Assurance Representative. WARRANTY ‘The Corporation reserves the right to reject any cast plates which within one (1) year of delivery, are found not to conform to this Specification. Any rejected cast plates shall be repaired or replaced by and at the cost of the Contractor. PACKAGING ‘The cast plates shall be stacked and securely banded on to pallets. The total weight of each pallet shall not exceed one tonne gross. SUPPLY The supply commencement date and rate of supply shall be specified by the Contractor or as mutually agreed with the Corporation. DELIVERY 14.1 The packaged cast plates shall be delivered F.1.S. to the Permanent Way Materials Depot, McLister Street, Spotswood. 142. Delivery shall be deemed to be provisional until the Corporation or his/her representative certifies that the whole of this service is in accordance with this Specification and its associated documents and is in every respect to his/her satisfaction.