PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS REVISION 1 ISSUE DATE: JULY 1995 Revision 1, July, 1995 - Re numbered from TM 12 and reformatted (Original issue February 1995) Track Materials Engineer 2 5 Engineering Services GroupCONTENTS GENERAL. See 1.1 Nature and Scope of Works .. 1.2 Technical Se 1.3 Details and illustrations 1.4 Compliance with Specification and Standards... 4.5 Technical rt. 1.6 Moulds. 1.7 Material Su tion MANUFACTURING DETAILS QA TYPO ernnnnnnn 2.2 Manufactur — 2.3 Concrete Testing During Production . 24 Rails psseeceseeees 2.5 Track Gauge. QUALITY ASSURANCE .. INSPECTION. WARRANTY... RESOLUTION OF DISPUTES. SUPPLY AND DELIVERY ...... 7A Supply... 72 Delivery. APPENDIX "A"DRAWINGS AND TECHNICAL DOCUMENTS APPENDIX "B"MATERIAL SUPPLIED BY THE CORPORATION .. APPENDIX "G”PRICING SCHEDULE ...PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS 4. GENERAL 1.1 Nature and Scope of Works 12 13 14 15 16 Ww TMISSTOF ‘The work to be carried out under this contract comprises the manufacture, supply and delivery of 120 No, STEDEF concrete sleepers, Technical Representative ‘The Corporation's Technical Representative shall be the Track Materials Engineer, Telephone No. (03) 619-4436 or 619-4434, who will be responsible for all technical matters including that for Quality Assurance. Details and Illustrations A fully detailed drawing of the STEDEF sleeper shall be supplied to the tenderer. ‘Any proposed modifications to the original design shall be submitted to the Superintendent Engineer for his approval before any modifications are undertaken. A complete set of drawings showing the proposed modifications shall be submitted to the ‘Superintendent Engineer. ‘The STEDEF sleeper is shown on Drawing No. E360/Ill Rev C. ‘The following Technical Documents are to be read in conjunction with this drawing:- i Concrete Sleepers TSA 396 STEDEF Specification NFF 51-101 Compliance with Specification and Standards. ‘The tenderer shall state whether it is possible for him to conform to all requirements of these ‘Specifications, Drawings, referenced Technical Documents and all other relevant Australian or International Standards. Technical Support Preference will be given to a well established firm with long experience in the manufacture and ‘supply of concrete sleepers which is capable of providing technical and general advice. Moulds ‘All moulds produced for this contract shall become the property of the Public Transport Corporation. The moulds shall be manufactured and tested in accordance with Technical Document TSA 396. ‘The price of fabricating these moulds shall be listed separately. Material Supplied by the Corporation The Contractor shall obtain from the Corporation all material fisted in Appendix “B". This material ordered by and delivered to the Contractor shall, for all purposes, be valued at and Revision 1, July 1995 Page 1% PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS charged to the Contractor at the rates specified in Appendix “B” MANUFACTURING DETAILS 24 22 23 24 25 Type ‘The STEDEF sleepers shall be suitable for a high volume rail trafic with axle loads up to 16 tonnes. Manufacture ‘The STEDEF Concrete sleepers shall be manufactured in accordance with Drawing No. E 360/111 Rev. C and Technical Documents TSA 396 and NFF 51-101. The concrete used to manufacture the sleepers shall be of high quality low permeability concrete as detailed in Technical Document TSA 396. The compaction of the concrete shall be by immersion poker vibrators and the product shall be steam cured prior to discharge from the moulds. The STEDEF concrete sleepers shall be manufactured with the tie bar hot dipped galvanised to AS 1650 with the minimum average thickness of 84 microns. The galvanised bar shall be tested in accordance with AS 1650. The galvanised coating shall be sufficiently adherent to withstand normal handling during transport and installation. Scratched or slightly damaged areas of galvanised coating shall be repaired by low melting paint, zinc alloy repair rods or powders specially for the above purpose. All costs associated, with testing and repairs shall be bome by the Contractor. Concrete Testing During Production ‘The Contractor shall arrange for all tests as required in Technical Documents TSA 396 and NFF 51-101. The tests shall be carried out by a laboratory registered by the National Association of Testing Authorities, Australia (NATA). All test certificates shall be approved by a NATA endorsed Officer and forwarded to the Track Materials Engineer Fax (03) 619 4440 Phone (03) 619 4436 or 619 4434 prior to delivering of the STEDEF sleepers. ‘All costs associated with these tests shall be borne by the Contractor. Rails ‘The concrete sleepers shall be manufactured to utilise 60kg rail to AS 1085.1. Track Gauge ‘The concrete sleepers shall be manufactured to achieve a track gauge of 1600 + 2, - 4mm, QUALITY ASSURANCE ‘The Contractor shall maintain a Quality System in accordance with AS3902/ISO9002 and as detailed in the attached document PTC Quality Assurance Requirements SQA 3902.2 Rev "0" (See Appendix A). TMISSTOF Revision 1, July 1995 Page 2PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS: ‘As part of the tender evaluation process the PTC document Suppliers Quality Assurance Survey SQA 3900.1 shall be completed and returned with the tender. For this Contract the Corporation's Quality Assurance Representative shall be the Track Materials Engineer. ‘The Contractor shall maintain records of all inspection and testing operations performed and results obtained. As applicable, the records shall include: - concrete test certificates = allrelevant dimensional and tolerance criteria - concrete compressive strength test results These records shall be certified by the Contractor's Quality Assurance Officer and a copy shall be provided to the Superintendent at the time of inspection. Certificates of Conformance and other documentation as required by document SQA 3902.2 Revision *O" shall be included with packing and delivery documentation and shall be addressed to Manager, Permanent Way Materials Depot, Spotswood. ‘The Certificates of Compliance shall include statement that all testing were performed in accordance with the approved procedures, utilising approved materials and by approved personnel. These certificates shall be submitted to the Corporation's Quality Assurance Representative prior to delivery of the sleepers. INSPECTION The Contractor shall permit the Superintendent, or his approved representative, access at all reasonable times to all places where the work is being carried out and shall afford all the necessary facilities for inspection and testing of materials and workmanship. These facilies shall include suitable benches. Faciities shall be to the satisfaction of the Superintendent and shall permit inspections to be conducted in all weather conditions. All assemblies and also individual components shall be subject to a provisional inspection, by the ‘Superintendent, at the contractors works to ensure conformity with this Specification. ‘Such provisional inspection and/or approval shall not be a bar to rejection of the material at the specified point of delivery in the event of it not being delivered and received in good order and condition and fully complying with these Specifications. All costs incurred by the Contractor to provide labour, equipment and gauges necessary for the performance, dimensional, hardness, and general inspections at the Contractor's works, shall be borne by the Contractor. Inspection gauges shall be solely used for inspection purposes by the Contractor's, ‘Quality Assurance Officer and the Superintendent. ‘The fabricated moulds shall be provisionally inspected at the Contractors works by the Superintendent prior to the production of the STEDEF Sleepers. ‘The first three production samples shall be provisionally inspected at the works of the Contractor by the ‘Superintendent. These inspections will consist primarily of the following:- a) __ Reinforcement inspection of the STEDEF sleeper (prior to concrete) and, b) Concrete compressive strength inspection. The Contractor shall provide all compressive strength reading equipment at his own expense. ‘TMISSTOF Revision 1, July 1995 Page 3PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS ‘The first six production samples shall be provisionally inspected by the Superintendent for track gauge in accordance with AS1085.14 Clause 6.3.5. Concrete test certificates in accordance with the above Clause 2.3 shall be provided to the Superintendent during intial inspection. ‘Subsequent production shall be inspected by the Contractor using @ sampling plan of 1 in 10 for ‘concrete hardness and track gauge. The Contractor shall, provide the inspection results to the ‘Superintendent prior to delivery. % WARRANTY ‘The Corporation reserves the right to reject any material which within one (1) year of delivery, is found ‘not to conform to this Specification. Any rejected material shall be repaired or replaced by and at the cost of the Contractor. 6. 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 specified tests and if necessary additional tests, carried out by an independent testing authority. This authority shall be registered by N.A.T.A. for the field and classification of tests concerned 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 7. SUPPLY AND DELIVERY 7.4 Supply ‘The Sleepers shall be supplied at the following rate:- 40 No. Sleepers within 4 months from commencement of contract an 80 No. Sleepers over the following 24 months. ‘The supply commencement, delivery schedule and completion times shall be specified by the tenderer. 72 Delivery 7.2.1. The concrete sleepers shall be delivered F.1.S. to: Manager, Permanent Way Materials Depot, McLister Street, Spotswood, Vic. 7.22 Delivery shall be deemed to be provisional until the Superintendent certifies that the whole of the service is in accordance with this Specification and its appended documents and is in every respect to his satisfaction. TMISSTOF Revision 1, July 1995, Page 4f PUBLIC TRANSPORT CORPORATION _ INFRASTRUCTURE DIVISION ) TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF | STEDEF CONCRETE SLEEPERS APPENDIX “A” DRAWINGS AND TECHNICAL DOCUMENTS: 1 SUPPLIED BY THE CORPORATION As referred to in this Specification. DRAWING NO REVISION : 360/111 c ‘Australia Melbourne Loop STEDEF Ballastiess Track - with SC Sleepers. ‘ TECHNICAL DOCUMENT | TSA 306 Concrete Sieepers : NF 51-101 ‘STEDEF Specification QUALITY ASSURANCE DOCUMENT ‘SQA 3902.2 Rev O Quality Assurance } Requirements, : APPENDIX "B” MATERIAL SUPPLIED BY THE CORPORATION As specified in Clause 1.7 of this Specification MATERIAL QUANTITIES RATE 7 Rail, 60kg A.S, 4m length 2No. Free of Charge Rail fastenings to 12 Sets Free of Charge ‘Suit STEDEF Sleepers. TMISSTOF Revision 1, July 1995, Page 5PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ) ‘TECHNICAL SPECIFICATION No. 15 FOR MANUFACTURE AND SUPPLY OF STEDEF CONCRETE SLEEPERS DESCRIPTION STEDEF Sleeper 120 Moulds 1 Set ADDITIONAL INFORMATION TO BE SUPPLIED BY TENDERER 1. Delivery commencement... NO. 2. Delivery Schedule 3. Delivery Completed 4, Percentage of Imported Content 5. Country Of Origin if Imported Content. ‘TMISSTOF APPENDIX PRICING SCHEDULE DELIVERY SCHEDULE sve» Months from Receipt of Order. Months from Receipt of Order. Revision 1, July 1995 ESTIMATED REQUIREMENT PRICE PER UNIT % Page 6