PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES PROCEDURE Document i TM 14 Fovislon Status: 20 Cony No: Prapared By ‘A Sowineki, Sonior Technical Oicer ‘Checked By P. Leornoruni, Track Materials Enginoor ‘Approved By 8, Hold, Manager, Track Engineering ‘Auhoreed By tesued By | R. Detaring, Group Manager, Engineering Services ‘Track Materals Engineer ity Rf Lora burren © PTC infrastructure OWision, 1997TECNICA PUBLIC TRANSPORT CORPORATION rere INFRASTRUCTURE DIVISION Vensowan MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES RECORD OF AMENDMENTS Revision | Date Authority Description 00 Oct 1994 Initial issue 10 May 1995 ‘Amendments, additions, renumbering and deletions. 20 17 Apr 1997 | Manager, Track Revised format. Revised chair lubrication Engineering 1. sopra “Tack Mataras TTB Pega TSETECHNICAL PUBLIC TRANSPORT CORPORATION Taiae INFRASTRUCTURE DIVISION Ge MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES CONTENTS 1 SCOPE ..... eee 2 REFERENCED DOCUMENTS 24 AUSTRALIAN STANDARDS: 22 PTC SPECIFICATIONS .. 23 QUALITY ASSURANCE DOCUMENTS: 3. DEFINITIONS .. : 4 DRAWINGS . Su 4a DRAWINGS SUPPLIED BY THE CORPORATION... 7 42 DRAWINGS TO BE SUBMITTED BY THE CONTRAGTOR FOR APPROVAL eee 43 METRIC EQUIVALENTS eee 5. PURCHASE OF MATERIALS . 54 GENERAL . 52 MATERIALS: 53 MATERIALS NOT PURCHASED FROM THE CORPORATION 6. MATERIAL SPECIFICATIONS «0.0.0.0 0000665 .9 61 RAILS, FISHPLATES & SLEEPER PLATES . =o 62 GREY IRON CASTINGS... -3 63 MALLEABLE IRON CASTINGS ...........cseseeeseee 10 64 ‘SPHEROIDAL IRON CASTINGS ............200005 + 10 65 CARBON STEEL CASTINGS ............ece0000 + 10 66 MANGANESE STEEL CASTINGS . et - 10 67 ROLLED STEEL ... eee are 10 68 FORGINGS ‘ eens 10 69 RIVETS . : eee 10 6.10 FASTENINGS ..... 10 6.11 WASHERS n z MANUFACTURING FACILITIES ... 1" 7A MANUFACTURING LOCATIONS AND FACILITIES... "1 72 PATTERNS, JIGS, DIES AND TEMPLATES........ "1 8 CONSTRUCTION . "1 a1 GENERAL .... " 82 ‘SAWING OF RAILS. 12 83 ‘SHEARING OF RAILS . 12 a4 FLAME CUTTING .... 12 85 BENDING, CURVING AND SETTING OF RAILS | 12 86 STRAIGHTENING . 12 a7 MACHINING... 12 a8 GRINDING .... 13 89 DRILLING . 13 8.10 PUNCHING OF HOLES 13 8.11 RIVETING ... perio) 8.12 FORGING AND HOT FORMING 813 CASTING 8.13.1 General ....- ne 8.132 Manganese Steel Sarasa "Tack Materials T/T Page 2 of 38Da TECHNICAL 4b A PUBLIC TRANSPORT CORPORATION arate ee INFRASTRUCTURE DIVISION VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.14.3 8.14.34 8.14.32 8.14.3. 10. 1 WELDING General Rolled Steels General parece Procedure and Welder Approvals Welding Procedure Weld inspection . Cast Stools... eee General .. Procedure and Welder Approvals Weld Preparations Welding Procedure Weld Inspection . Weld Documentation Repair of new Carbon Steel Castings . General .. Procedure and Welder Approvals. Weld Preparations Weld Inspection . Repair Sizes . Repair of new cast Manganese Steel inserts and Blocks . General . ee Procedure and Welder Approvals, Weld Preparations Welding Procedure ‘Weld inspection . Weld Documentation Definition of Zones Repair Sizes ... Repair Schedule Table . Concessions ... HEAT TREATMENT . Castings ... Point Heel Ferrules Rails ..... General a Quench and Temper Process Hardening . Flame Hardening of Ralls . DEPTH HARDENING OF MANGANESE STEEL INSERTS AND BLOCKS . NON-DESTRUCTIVE TESTING ........ MACHINING AND ASSEMBLY ......- General . Points . Crossings Third Rail Trackwork Units... Assembly Ultlising Swage Lock Fastenings TOLERANCES ....... LUBRICATION . ‘TRIAL ASSEMBLIES ... VARIATIONS TO APPROVED PROCEDURES AND MATERIALS . . MARKING . vores "Track Materials W757 Pages o136da PUBLIC TRANSPORT CORPORATION aeamecenenn! INFRASTRUCTURE DIVISION ‘Semon MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES WA GENERAL . ag 3 412 COMPONENT AND ASSEMBLY IDENTIFIGATi + 32 41.3 MANUFACTURING/TRACEABILITY IDENTIFICATION + 92 11.4 MANUFACTURER'S IDENTIFICATION «0... ---.esereeeeee + 32 12, RUST PROOFING 124 GENERAL .. 122 INTERNAL RUST PROOFING . 123 EXTERNAL RUST PROOFING ese 13, HANDLING, PACKAGING AND TRANSPORT ........ 13.1 GENERAL 13.2 13.3 13.4 13.4.1 13.42 4. QUALITY ASSURANCE, : 15. INSPECTION .... 16. WARRANTY . 35 16.1 GENERAL WARRANTY : ee 35 162 WARRANTY FOR WELD REPAIRED NEW MANGANESE STEEL 35 7 RESOLUTION OF DISPUTES . eee perk ao) 18. DELIVERY ... - 36 APPENDIX “A' = Page Al of 4 DRAWINGS SUPPLIED BY THE CORPORATION . + Page At of 4 APPENDIX "B* . Page Bi of3 STOCK CODE / DRAWING CATALOGUE Page Bt of3 APPENDIX "C" : cesses Page Ct of 1 PROCEDURE AND WELDER APPROVALS... Page C1 of 1 APPENDIX "D" ...... Fi Page D1 of 1 MATERIAL WHICH MAY )M THE CORPORATION . Page D1 of 1 ‘Sonnaneae “Track Watorale WOT Page 40136A TECHNICAL PUBLIC TRANSPORT CORPORATION aaa INFRASTRUCTURE DIVISION ‘VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 1. SCOPE ‘This specification sets out the manufacturing requirements for track assemblies and components for railway trackwork purposes. ‘Specific requirements relating to points, crossings, guard rails, third rail trackwork units, platework, braces, blocks and associated components are detaled in this specification, relevant drawings and the schedule. 2, REFERENCED DOCUMENTS 2.1 AUSTRALIAN STANDARDS: Reference may be made in this specification or associated drawings to the current editions of the following Australian Standards:- 1085 174 1262 1442 1448 1554.1 1830 1932 1988 2074 3678 3679.1 3998 9002 A384 B157 Raliway permanent way material - Steel rails Fishplates Sleeper plates Fishoolts and nuts Spring washers Flled stool clip fastening sleoper plates Part 11 Head hardened rails Part 16 Cast sleeper plates. Methods for magnetic particle testing of ferromagnetic products and components. High strength stee! bolts with associated nuts and washers for structural engineering. Carbon steels and carbon-manganese steels - Hot rolled bars and semi-finished products. Carbon steels and carbon-manganese steels - Forgings. Structural steol welding - Welding of steel structures. Iron castings - Grey cast iron. Iron castings - Malleable cast iron. Welding of steel castings. Methods for non-destructive penetrant testing of products and components. 0 a oN ROS Steel castings. Structural steel - Hot-rolled structural stee! plates, floorpiates and slabs. Structural steel - Hot rolled bars and sections, Non-destructive testing - Qualification and certification of personne! - General engineering. Quality systems - Model for quality assurance in production, installation and servicing. Dimensions of rivets from %4" to 134" diameter. High strength steel! bolts with associated nuts and washers for structural engineering (inch series) Caeeae “Track Matera WAST Page 50136TECHNICAL PUBLIC TRANSPORT CORPORATION SPECIFICATION TM 14 ‘nernarrmucruns ‘orn INFRASTRUCTURE DIVISION Venson:20 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 22 23 PTC SPECIFICATIONS ™24 Serviceable rail for manufacture of trackwork assemblies, ‘Sketch OD 308 Standard glossary of V crossing. Sketch OD 309 Standard glossary of points. Sketch OD 310 Standard glossary of tumout. QUALITY ASSURANCE DOCUMENTS PTC Quality Assurance document SQA 9002.2 Revision 1". 3. DEFINITIONS 34 32 33 3.4 35 ‘SUPERVISING ENGINEER ‘The Officer of the Corporation responsible for ensuring that all works of this contract comply with ‘hese spectications. The Officer shall be the Track Materials Engineer. The term shall include the appointed representative of the Supervising Officer. POINTS ‘An assembly of switches and stock rails which are machined from rail, and associated components used to direct traffic from one track to another. Points comprise two half sets. ‘These are normally referred to as left or right hand denoting the tumout direction as viewed from. the toe end. 3.2.1. Standard pivot heel points utiise a switch blade which terminates and pivots at the heel block. 3.2.2 Fixed heel points utlise a machined reduced section rail flange to permit localised flexing of the switch blade ahead of the permanently fastened heel blocks. CROSSINGS ‘A trackwork assembly of machined and set rails and associated components. These are arranged to provide the necessary flangeways to enable wheel flanges to pass across the running rails at the intersection of rails. The most common types are "V" and "K". 3.3.1 Fabricated crossings utlise rails in the wheel transfer area. 3.3.2 Rail Bound Manganese crossings utilise a manganese casting in the wheel transfer area. GUARD RAILS A rail and block assembly used to control the passage of wheel axles across the gaps of ‘crossings. Check or continuous guard rails may be used parallel to running rails in special locations to control wheel axles. THIRD RAIL TRACKWORK UNITS ‘A trackwork assembly arranged to permit traffic of two different track gauges fo turn out or transfer on one common rail. The units include fixed points and transfers. came "Track Materials 17497 Page 6186A TECHNICAL A PUBLIC TRANSPORT CORPORATION | —S#Ea#EATION _ y T™ 14 ee INFRASTRUCTURE DIVISION 7 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 4 3.6 DUAL GAUGE TRACKWORK UNITS s A trackwork assembly arranged to permit traffic of two different track gauges to tum out. 3,7 TURNOUTS, CROSSOVERS, COMPOUNDS AND DIAMONDS Trackwork layouts comprising combinations of points, crossings, guard rails and associated ‘components. 3.8 HARDENING PROCESSES 3.8.1 Fumace Hardening employs fumace heating and ol/water quenching to increase the hardness of rails or steal components. 3.8.2 Flame Hardening employs flame heating and air quenching to increase the surface hardness of rails. 3.8.3 Explosive Hardening employs detonation of sheets of explosive material to work harden a manganese casting surface. 3.9 SWAGE LOCK FASTENINGS ‘Ahigh tensie strength mechanical fastening system employing swaging of a collar onto annular locking grooves of a fastening utlising a special hydraulic tool. The system is designed to provide consistent and predictable installed values of tension. 8.10 SERVICEABLE MATERIAL Previously used or part wom material which is sutable for re-use. This material shall be subject to inspection and acceptance by the Supervising Engineer prior to use. DRAWINGS 4.1 DRAWINGS SUPPLIED BY THE CORPORATION All drawings required for the performance of this contract as listed In Appendix “A* and such other drawings as may be considered necessary shall be supplied by the Supervising Engineer. No drawing shall be copied or supplied to any third party without the written consent of the ‘Supervising Engineer. All rack components and assemblies manufactured to this specification shall be in accordance ‘with the latest issue of the relevant drawings, unless otherwise specified. The Contractor shall maintain an adequate Engineering Data Control System to ensure conformance to the latest issue of drawings. The system shall include recording of drawing receipts, issues and recalls for superseded drawings. : 42 DRAWINGS TO BE SUBMITTED BY THE CONTRACTOR FOR APPROVAL Detailed drawings shall be provided with all requests for variations from specified drawings or modifications to existing designs, patterns, jigs, dies and templates. No variations shall be permitted until approved in writing by the Supervising Engineer. ery "Tack Maiatale TT Page TTSTECHNICAL PUBLIC TRANSPORT CORPORATION aTmaae INFRASTRUCTURE DIVISION venewonae MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘The contractor shall supply all drawings as may be requested within this specification or other ‘specification provided at the time of ordering. 43 METRIC EQUIVALENTS 43.1 General Metric equivalents of any imperial sizes and dimensions shown on drawings shall be subject to approval of the Supervising Engineer. Patterns Existing pattems wih bolt holes centres which vary from those specified on the relevant ‘current drawings (Le. 127 mm in lieu of 130 mm) for 47 kg and 53 kg rail sections may be utlised unil pattems are renewed or a written direction to change Is provided by the ‘Supervising Engineer. When a pattern is renewed or changed, all pattems for the relevant trackwork unit shall be renewed. 5. PURCHASE OF MATERIALS 5.1 GENERAL ‘The Contractor shall be responsible for the provision of all materials necessary for the works Materials shall be new, unless otherwise specified or approved in writing by the Supervising Engineer, of commercial quality and free of defects which may be detrimental to their end use. ‘Materials shall comply with relevant Austratian Standards and with relevant Quality Assurance requirements as specified. ‘Al scrap materials and materials damaged during manufacture shall remain the property of the Contractor unless otherwise specified. The Contractor Shall ensure sufficient minimum stocks of materials to ensure continuity of manufacturing programs, 5.2 MATERIALS PURCHASED FROM THE CORPORATION ‘The Contractor may purchase from the Corporation, the materials listed in Appendix "D" at the rates specified. Other materials of services may also be obtained at ruling rates. Materials purchased from the Corporation under the terms of this agreement shall be used ‘exclusively for the works of this agreement except for scrap and damaged materials. Materials to be supplied by the Corporation, shall be ordered from the Manager, Supply, Infrastructure Dision through the Supervising Engineer who shall certify that the materials are required to fulfil orders which have been placed with the Contractor. ‘The Contractor shall arrange and shall be responsible for the cost of delivery of the materials from the Corporation's Permanent Way Materials Depot, Spotswood or other location to his works. Sanaa Track Matarials 1/497 Page 80198TT —T TECHNICAL Sh A PUBLIC TRANSPORT CORPORATION a aaae 4 INFRASTRUCTURE DIVISION Vensoneze MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘All materials supplied by the Corporation and found to be defective may be retumed to the Corporation for credit or replacement as arranged with Manager, Supply, Infrastructure Division. The Contractor shall be responsible for advising the Supervising Engineer of any defective materials at the earliest detectable stage of production. The Supervising Engineer shall authorise all material credits or returns. The transport cost of material retums and re-delivery shall be bome by the Corporation as arranged with Manager, Supply, Infrastructure Division. 5.3 MATERIALS NOT PURCHASED FROM THE CORPORATION Rails, fishplates and sleeper plates which are not purchased from the Corporation shall be inspected and passed by an Authority approved in writing by Manager, Supply, Infrastructure Division. For points, crossings and accessories which are manufactured from rails, fishplates and sleeper plates not purchased from the Corporation, the Contractor shall provide copies of the following documents to the Supenising Engineer on request or at the time of inspection and to Manager, ‘Supply, Infrastructure Division, with each delivery: ‘@. Certificate of inspection from the approved inspection Authority or an approved ‘equivalent certificate, b. Certificate of Analysis and Tests from an approved Authority, and ©. Contractor's certificate stating that only inspected and approved rails, fishplates and sleeper plates have been used in the manufacture of items in the delivery. 6 MATERIAL SPECIFICATIONS 6.1 RAILS, FISHPLATES & SLEEPER PLATES. Rails and fishplates used in the manufacture of points, crossings and accessories under this contract shall conform to the relevant clauses of Australian Standard Spectfications and drawings, viz., Stee! Rails - A.S. 1085, Parts | and Ii; Fishplates - A.S. 1085, Part 2 and Plan No. 913-60. Rolled steel sleeper plates shall conform to the relevant clauses of A.S. 1085, Parts 3 and 9. Cast iron sleeper plates shall conform to relevant clauses of this specification and shall be approved in writing by the Supervising Engineer. Serviceable 47 kg rail for the manufacture of 47 kg track assemblies or components shall ‘comply with Specffcation TM 24 or shall be subject to prior inspection and acceptance by the ‘Supervising Engineer. 62 GREY IRON CASTINGS Grey iron castings shall be comply with A.S. 1830/T-260. Copper or molybdenum alloying elements shall be utilised in manufacture. ‘The castings shall be utiised for the manufacture of components as specified on drawings, including some cast iron blocks for crossings, guard rails and point heel blocks (47 and 53 kg). Sarna Track Materials TAT Page 9 of 56TECHNICAL PUBLIC TRANSPORT CORPORATION SPECICATION T™ 14 INFRASTRUCTURE DIVISION Version 20 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 6.3 MALLEABLE IRON CASTINGS Malleable iron castings shall comply with A.S. 1832/510-4, ‘The castings shall be utilised for the manufacture of components as specified on drawings. 6.4 SPHEROIDAL IRON CASTINGS Spheroidal iron castings shall comply with A.S. 1831/500-7. ‘The castings shall be utlised for the manufacture of components as specified on drawings, including cast sleeper plates. 65 CARBON STEEL CASTINGS Stool castings shall comply with A.S. 2074. ‘The castings shall be utilised for the manufacture of components as specified on drawings. Grade C4-1 shall be utilised where cast stee! is specified for point heel and crossing blocks, braces, point stops and spreader brackets. Grade L1A shall be utilised for tapered washers. 66 MANGANESE STEEL CASTINGS Manganese steel castings shall comply with A.S. 2074/H1A. The castings shall be utlised for the manufacture of components as specified on drawings, ‘including inserts for rail bound manganese crossings and blocks for third rail trackwork units. 67 ROLLED STEEL Mild steel plates, bars and flats shall comply with A.S. 3678 or 3679.1 Grade 250 or where specified on relevant drawings A.S. 3678 or 3679.1 Grade 350. ‘Components manufactured from this materia! include point slide chairs, crossing and rail base plates, spreader bars and 60 kg spreader brackets. Point heel ferrules shall be machined from material complying with A.S. 1442/81045 or approved equivalent. 68 FORGINGS Stoel forgings shall comply with AS. 1448. 69 RIVETS ‘Stee! rivets utlised in points shall comply with A.S. 1448-S1 and shall conform to the shapes and dimensions of A.S. A.34, 6.10 FASTENINGS . : ‘Swage lock fastenings shall comply with the intentions of A.S. 1252. Heel bolts shall comply with Plan No. 123-78 and A.S. 1085, Part 4. Sanaa Track Matotale THAT Page Oatsaa TECHNICAL PUBLIC TRANSPORT CORPORATION SPECICATION y / T™ 14 IerRAgTRUCTURE ‘orvawon INFRASTRUCTURE DIVISION VERSION:20 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 6.11 WASHERS High strength, round, fat, structural steel washers shall comply with A.S. 1252 and B 187 (inch series for dimensions). The washers shall be utilised, as required, with swage lock fastenings and shall suit the relevant fastening diameter. Cast stool tapered washers shall comply with Plan No. 939-83 for crossings, Plan No. 449-87 for foed heel points, this specification and the relevant Australian Standard Specifications. The washers are used to adjust the seating angle of fastenings. ‘Spring washers for M27 heel bolts shall comply with A.S. 1085, Part 7. 7. MANUFACTURING FACILITIES 7A 72 MANUFACTURING LOCATIONS AND FACILITIES ‘The Contractor shall advise the Corporation in writing of the proposed manufacturing locations and of any change of locations of:- : foundries at which castings are manufactured and - works where components and assemblies are fabricated and assembled. PATTERNS, JIGS, DIES AND TEMPLATES Patterns, jigs, dies and templates shall be provided by and at the expense of the Contractor ‘and shall be approved by the Supervising Engineer. On completion of the agreement, the ‘whole of such pattems, jigs, dies and templates shall become the property of the Corporation, ‘and together with such other pattems, igs, dies and templates separately purchased by the Corporation under any agreement or otherwise supplied by the Corporation, shall be handed over free of charge and in good condition to the Corporation upon written request from the Manager, Supply, Infrastructure Division. The cost of pattems, jigs, dies and templates, if required, shall be quoted separately for each item or group of items. 8. CONSTRUCTION at GENERAL All components and assemblies shall be manufactured in a workmaniike manner and shall conform to relevant drawings, templates and gauges. All rolled steel products shall be straight and true before commencement of fabrication. ‘Components shall be free of damage which may be detrimental to their end use. “Track Waters TAT Page 11 136a PUBLIC TRANSPORT CORPORATION |__ SPECICATION _| Mn TM 14 INFRASTRUCTURE DIVISION nrnasrRucTURE ‘VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 82 SAWING OF RAILS Rails may only be cold sawn. Mavimum permissible out-of square in saw cut rail ends shall be 1.0 mm over the width and/or height of the rail As supplied rail ends shall be re-sawn if the condition does not comply with this tolerance. Lengths of rail shall be set out and cut to achieve maximum utilisation and a minimum of scrap rail. 8.3 SHEARING OF RAILS If shearing of ral flanges is employed, the flanges shall be machined after shearing to remove all shearing irregularties. 8.4 FLAME CUTTING Flame cutting of rails and fishplates is prohibited. Holes shall not be flame cut in any material. Flame cutting or gouging of casting's is not encouraged. If utlised, the heat affected zone and any areas of stress concentration shall be removed by grinding or machining. Where plates to AS. 3678 or equivalent are to be stripped from plates of larger width, such stripping shall be carried out by automatic machine gas cutting and the cuts shall be made continuously along the full length of plate without interruption. All stag, bumt metal, scale or other defective material shall be removed by machining, grinding or other approved method. Arrises on cut edges and ends of plates shall be ground or machined to radius of 2 millimetres. 8.5 BENDING, CURVING AND SETTING OF RAILS Ralls shall only be bent, set or curved when heated within the range of 25°C to 150°C. Under ho circumstances may rails be heated above the higher temperature. 86 STRAIGHTENING Plates, sections and shapes shall be level, straight and square before and after fabrication and shall be free of twist. Any small deviations in straightness may be rectified cold. In all other cases, material shall be heated prior to straightening. 8.7 MACHINING {All machining operations must be carried out by methods approved by the Supervising Engineer. Machining shall conform to approved templates and gauges and shall be finished in a workmanlike manner. All sharp edges and burrs shall be removed. ‘Approval of the Supervising Engineer shall be oblained, unless otherwise specified, prior to machining of flame hardened surfaces or more than 1.0 mm depth of explosive hardened surfaces. Sareea "Yack Materials 17457 Page aotTECHNICAL PUBLIC TRANSPORT CORPORATION aT INFRASTRUCTURE DIVISION DePRATRUCTURE ‘VERSION: 20 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 88 8.10 att a12 GRINDING Grinding operations shall be carried out with due regard to the material being ground to ensure that acceptable heat input is not exceeded and that notches are not formed. ‘Special care must be taken when grinding rolling brands from rails. DRILLING Drilled holes shall be accurately driled to jigs, templates and/or gauges conforming to the ‘centres and dimensions shown on the relevant drawings. All driling burrs must be removed, preferably by chamfering. Rolling brands must be removed from rails prior to jig driling where such rolling brands will ccontact jig location or reference faces. All castings to be jig drilled, shall be dressed to size before being drilled. Incorrectly dried holes in rails shall not be plugged and re-drilled without the consent of the ‘Supervising Engineer. PUNCHING OF HOLES Punched holes shall be hydraulically punched and shall comply with templates and/or gauges ‘conforming to the centres and dimensions shown on the relevant drawings. Punched holes shall be without burrs, cracks, or other damage to the parts thus punched. Local deformation from punching shall be corrected by pressing or grinding. RIVETING Rivets shall be heated uniformly from head to point and shall be hydraulic or pneumatic squeeze riveted Rivet heads shall not be heated to more than a bare white heat. All loose rivets and rivets with cracked, deficient or mis-shaped heads shall be cut out and replaced by sound rivets. FORGING AND HOT FORMING Forged and hot formed products shall be free of fins, tears and defects detrimental to their end use. Hot forgings shall comply with A.S. 1448. Hot forming of stee! to A.S. 3678 or 3679.1 shall be carried out within the temperature ranges of 550°C to 600°C oF 870°C to 930°C. Off tool samples shall be approved in writing by the Supervising Engineer prior to commencement of production for all new, rebuilt and modified dies. Sanaa "Tack Materials 177 Page 15036PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.13 CASTING 8.13.1 8132 General * Castings shall comply with relevant Australian Standards and shall be heat treated as specified in the relevant standards. Castings shall be true to pattems, conform to dimensions shown on relevant drawings and comply with relevant dimensional tolerances, Protrusions, sharp fins and sand holes on the surface shall be removed. Castings shall be free of sand holes, gas pockets, cold shuts and other imperfections which would appreciably weaken the casting, impair wearing qualities or otherwise reduce serviceability. Castings shall be free from defects such as shrinkage cavities, hot tears and filamentary shrinkage unless they are of such size and in such location as to not adversely affect the service life of the castings. Bolt holes in castings shall not be enlarged by cutting or reaming with an oxy-acetylene torch. ‘All castings shall be clearly embossed or stamped to identify the component and the trackwork unit in which itis utilised. FFiting surfaces shall be dressed by grinding or machining as detailed in specifications and drawings. Manganese Stee! Heat or cast analysis shall be made to ensure element percentage compliance in accordance with this specification. Castings shall be cleaned and fettled prior to heat treatment which shall be in accordance with A.S. 2074, Clause 4.1.2. Weld repair of new unhardened manganese castings is permitted when carried out in strict conformance with the relevant clauses of this specification. Shrinkage defects shall not be permitted to remain in any wheel contact surface. ‘As cast, wheel contact surfaces within 65 mm of the gauge line and flangeway walls ‘25mm down from the top running surface shall be free of imperfections, unless they are so small that they will be practically removed by finish grinding. Castings shall be free from twist and be reasonably true, both as to general surface and alignment, and shall not show signs of straining or undue denting from the straightening operation. ‘The bottom part of the casting which rests on plates or ties shall be reasonably straight ‘and without twit, and shall be free of surface irregularities or imperfections that would prevent a good bearing. Castings shall be without sharp comers at the base, having minimum radii of 6 mm at the intersection of the inside vertical wall and the bottom, and 3 mm at the intersection of the outside vertical walll and the bottom. : Carper ‘Track Matorale 17/47 Page 1a 0136TECHNICAL hk A PUBLIC TRANSPORT CORPORATION Stas INFRASTRUCTURE DIVISION IPRASTRUCTURE VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.14 WELDING 8.14.1 General . Welding shall be permitted only as specified on drawings and in these specifications. Welding of rails is prohibited. Welding shall be by electric arc, manual metal arc, gas shielded or self shielded processes utlising approved techniques and electrodes or semi-automatic wire or any other process subject to approval by the Supervising Engineer. Weld procedures and supporting documents shall be submitted to the Supervising Engineer for approval. Approval in writing shall be received from the Supervising Engineer prior to commencement of welding. Welders shall be approved in writing by the Supervising Engineer prior to commencement of welding. [At the discretion of the Supervising Engineer, witnessing of the welder qualification tests may be required. Welding procedures and welders that are already approved by the Supervising Engineer are listed in Appendix "C". ‘Application to the Corporation for welder approval shall be accompanied by N.AT.A. endorsed test certficates. The Corporation's Scientific Services laboratory is N.A.T.A. cerified and may undertake to conduct the relevant tests and provide test certificates. ‘The Supervising Engineer, at his discretion, may request additional test pieces to be provided by the Contractor for testing to prove compliance with these specifications. ‘The Supervising Engineer shall conduct visual inspections and may, at his discretion, carry out further testing by any method deemed suitable by him. If, in the opinion of the Supervishg Engineer, any portion of the weld or parent metal is defective, it shall be rectified ina manner approved by the Supervising Engineer and to his satisfaction. 8.14.2 Rolled Steels 8.14.21 General Rolled steels shall be welded in accordance with A.S. 1554, Part 1. Welds shall be GP category unless otherwise specified. Where shown on drawings, additional specifications or orders, welding shall be carried out in accordance with the S.P. weld category spectfied in AS. 1554, Part 1, Section 1.3. 8142.2 Procedure and Welder Approvals Weld procedures for rolled steels shall be qualified in accordance with the recommendations of A.S. 1554, Part 1, Section 4 and the following additional requirements: ror "Track Malerals TAT Page 136"FESHRICAL PUBLIC TRANSPORT CORPORATION Sa INFRASTRUCTURE DIVISION Vensowzo MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES a. Preparation of a suitable test piace to simulate final welding conditions, b. Provision of results of:- (Visual and magnetic particle examination of the test piece welds. (i) Aminimum of one macrosection through a typical section of weld. (i) Aminimum of one heat affected zone hardness traverse for ‘a weld in any material not covered by A.S. 1554. c. Provision of names of welders qualified to perform the weld procedure. The welder or welders may use the test plece to qualify ita previous qualification is unsuitable. Welders shall be qualified for GP or SP category welds, as applicable, in accordance with A.S. 1554, Part 1, Ciause 4.11. 8.14.23 Welding Procedure Welding shall be carried out in accordance with the approved procedure and inan orderly manner designed to minimise distortion and contraction stresses and to the satisfaction of the Supervising Engineer. Plates and sections to be welded shall be free from paint, oll, scale, rust, cr any other substance, which in the opinion of the Supervising Engineer may affect the quality of the welding, ‘Work to be welded shall be correct aligned and located. Leading edges of any plates, sections, or members to be connected by welding shail be closed by means of metal clamps or jigs. Welds shall show good even contours of the specified shape and there must be no break in the continuity of a weld. Welds shall be of the size nominated on the relevant drawings and shall be made continuous around all sides of the connected parts, unless spectied otherwise on drawings or otherwise directed by the Supervising Engineer. 8.14.24 Weld inspection ‘The requirement for non destructive testing and frequency of tests shall be «as specified on drawings, additional specifications or orders. lfnon destructive testing is specified, welds shall be tested in accordance with AS. 1988 or AS. 1554, Part 1, as applicable, and these specifications. The permissible level of imperfections shall be in accordance with A.S. 1554, Part 1, Table 6.2 corresponding to the relevant welding category. Sarma "Wack Materals T7487 Page 16 0136TECHNICAL PUBLIC TRANSPORT CORPORATION Te INFRASTRUCTURE DIVISION VERSIONE 22 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.14.3 Cast Stools 8143.1 General Casting defects in new cast steel components may be prepared and repair welded, unless otherwise specified or advised by the Supervising Engineer. Weld repairs shall be performed in strict conformance with recommendations of A.S. 1988 and this specification. Weld repairs shall be dressed smooth to the required profile of the relevant section. Defects for which a concession request is proposed by the Contractor shall not be repair welded without approval of the Supervising Engineer. 8.14.3.2 Procedure and Welder Approvals. Weld procedures shall be qualified in accordance with the recommendations of A.S. 1988, Clause 9.1. Welders shall be qualified for the approved welding procedures in accordance with A.S. 1988, Clause 9.2. 8.14.3.3 Weld Preparations Weld preparations shall comply with AS. 1988, Sections 4, 6 and 8 - “Preparation and Precautions". ‘The defect shall be completely removed by machining, grinding or arc-air gouging. 8.14.3.4 Welding Procedure Welding shall be performed strictly in accordance with the approved procedure. ‘After welding, any stress concentrations shall be removed by machining ‘or grinding. 8.14.3.5 Weld Inspection Visual examinations shall be performed between weld runs and at the conclusion of welding and dressing. Weld repairs shall be examined by magnetic particle or dye penetrant method, as specified, to ensure freedom from defects. 8.14.3.6 Weld Documentation ‘The postion, size and inspection data of each repair preparation shall be documented on a weld map. The component details, heat number, name of qualified walder performing the weld repairs and date of preparation and welding shall be included on the weld map. canes "Yrack Matorale 1707 Page 1713lw TECHNICAL PUBLIC TRANSPORT CORPORATION Sia INFRASTRUCTURE DIVISION Soames MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.14.37 ‘The Contractor's Quality Assurance Representative shall certify the ‘accuracy of the document and that preparation, welding and inspection have been performed in accordance with this specification. ‘Acopy of the certfied documentation shall be provided to the Supervising Engineer at the time of final inspection, on request or at delivery. Arrecord shall also be maintained by the Contractor and shalll be available at all reasonable times to the Supervising Engineer. Concessions Applications for concessions shall be made in writing to the Supervising Engineer stating the grounds for concession and any compensatory offers such as additional warranty or cost reduction. The applications shall be accompanied by:- - detailed preparation/weld maps clearly showing the position and ‘size of all preparations for which a concession is requested, : detailed preparation’weld maps clearly showing the position and size of all other preparations and welds on the casting, : any other relevant procedure qualification or inspection data. Concessions shall be subject to inspection of preparations prior to repair welding, inspection of completed repairs and written approval from the ‘Supervising Engineer. 8.14.4 Repair of new Carbon Steel Castings 81444 8.1442 8.14.43 8.14.44 General Preparations and repair welds shall conform to the requirements specified ‘above for Welding, Cast Steels and these additional requirements. Procedure and Welder Approvals, Test pieces shall not be necessary, provided preparation for welding, as detailed in the procedure documentation, is in strict conformance with the recommendations of A.S. 1988, Section 4 and all other procedure details are in strict conformance with A.S. 1988, Table 2.1. Weld Preparations Weld preparations shall be examined by magnetic particle method to” censure that defects have been completely removed. ‘Weld Inspection ‘Weld repairs shall be examined by the magnetic particle method to ensure freedom from defects. Sanmareene "Track Materials TA87 Page 180136TECHNICAL PUBLIC TRANSPORT CORPORATION aaa INFRASTRUCTURE DIVISION po MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 81445 Repair Sizes Defects of up to one quarter (%4) section thickness may be welded out. ‘Smaller defacts may be blended out subject to approval ofthe Supervising Engineer. Repair of larger defects may be open to concession. 8.14.5 Repair of new cast Manganese Steel Inserts and Blocks 8145.4 81452 8.1453 8145.4 8.1455 8.14.56 8.1457 8.1458 General Preparations and repair welds shall conform to the requirements specified above for Welding, Cast Steels and these additional requirements. Repair welding of depth hardened surfaces is not permitted but may be ‘open to concession. Procedure and Welder Approvals, ‘Test pieces shall be explosively hardened using the same procedures as ‘employed on the insert casting to ensure that the weld deposit and parent metal hardness are comparable. Weld Preparations Care shall be exercised if using arc-air gouging to minimise heat input and the heat affected zone shall be removed by grinding or machining prior to welding. ‘The weld preparations shall be dye penetrant examined to ensure that defects have been completely removed. Welding Procedure Welding shall be performed strictly in accordance with the approved procedure. Weld Inspection Weld repairs shall be dye penetrant examined to ensure freedom from defects. Weld Documentation Weld documentation shall include crossing number or unit type, repair zone, as defined below, and surface area, if applicable. Definition of Zones. Repair zones of manganese castings shall be as defined in the repair schedule table. ‘Maximum permissible repairs to new manganese steel castings in the defined zones shall be as specified in the repair schedule table. ‘Sapenaieeae “Track Matodale TART Page 1996Ol TESrRCAL y A PUBLIC TRANSPORT CORPORATION Saat leeasaraacreen! INFRASTRUCTURE DIVISION camras MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ‘ACCESSORIES _ REPAIR SCHEDULE ZONE DEFINITION REPAIR SCHEDULE A Wheel contact ‘No repair welding surfaces of nose toa permitted. section width of 25 mm, at gauge li including the flange to a depth of 25 mm from top running surface. B Allother top surfaces | Max. single preparation and flangeways to a area of 1500 mm? (i.e. depth of 25 mm from 50 mm x 30 mm) and 6 top running surfaces. mom depth. All top wheel contact Max. 10% total area in areas of blocks for zone. Third Rail Fixed Points. c All other flangeways. Max. preparation area of 1000 mm? and 6 mm depth may be blended out. Larger defects of length less than % of insert height may be welded out. D Base of inserts, outside | Max. preparation area of wall, webs, flanges and | 400 mm and 6 mm ribs. depth may be blended out. Larger defects less than % of section thickness may be welded out. E Holes. No repair welding permitted. F Fitting surfaces. Max. 10 mm pad build- up. J Notes (Zone B): Adjacent weld preparations shall be separated by a distance equal to or greater than half the smallest dimension across the smaller of the two weld preparations. Adjacent defects, in such close proximity that the Preparations run into each other, shall be prepared as for one defect provided the maximum area for one defect is not exceeded. Sannneeae "Wack Wateviae T7087 Page 50 0136"TECHNICAL PUBLIC TRANSPORT CORPORATION anata INFRASTRUCTURE DIVISION Vensiow2o MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.14.5.10 Concessions With the exception of zones (a) and (@), the defined limitations may be ‘open to concession. For concession requests in zone B, the total percentage surface area of weld preparations in this zone shall be stated. 8.15 HEAT TREATMENT 8.15.1 Castings 8.15.2 8.15.3 Castings shall be heat treated, as applicable, in accordance with relevant Australian ‘Standards. Point Heel Ferrules Point heel ferrules shall be heat treated by the quench and temper process to achieve ‘a surface hardness in the Brinell hardness range of 225 minimum to 260 maximum when the decarburised layer has been removed. Rails 8153.1 General Heat treatment processes shall be approved by the Supervising Engineer. ‘Applications to the Supervising Engineer for approval shall be accompanied by the treaiment and control procedures, drawings showing the typical hardness distribution pattems and N.A.T.A. endorsed test certificates. The certificates shall include results of micro etching, hardness and magnetic particle or die penetrant tests. ‘Machining operations shall be completed before heat treatment. Distortion resulting from the treatment process shall be rectified and scale removed before the final assembly. ‘The hardness of heat treated rails on the centreline of the head within the specified treated zone shall be in the Brinell hardness range of 320 minimum to 375 maximum when the decarburised layer has been removed. The hardness region shall merge gradually to the surface at the end of the treated zone. It is desired that the hardness zone be in the Upper half of the required hardness range and the technique used should bbe such as to normally produce this resutt. Testing for hardness shall be carried out using a certified portable Brinell tester or similar instrument. ‘Sanaeae "Track Matorala 17087 Page at of36PN TECHNICAL PUBLIC TRANSPORT CORPORATION Stat INFRASTRUCTURE DIVISION an MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.15.32 8153.3 Hardness surveys for rails treated by the quench and temper process shall be carried out either on a test specimen or on one rail from each treatment batch. Hardness surveys shall be carried out on all rails treated by the flame hardening process. These hardness surveys shall be recorded and this record shall be available at all reasonable times to the ‘Supervising Engineer. ‘A micro etched hardened sample, or N.A.T.A. endorsed test certificate shall be provided to the Supervising Engineer to prove compliance with this ‘specification, when requested. Quench and Temper Process Hardening Nose rails of fabricated crossings manufactured from rail to AS. 1085, Part 1 shall be fumace heat treated, oil quenched and tempered for @ minimum distance of 1000 mm from the nosa. The hardness on the centre line of the head shall comply with specifications. Nose rails which are longer than 3600 mm may be flame hardened. Flame Hardening of Rails Specified components manufactured from rail fo AS. 1085, Part 1 shall be flame hardened as specified below. The transformation zone shall cover the full width of the rail head and shall be a minimum 6 mm deep. Below this depth, the hardened zone shall ‘merge gradually with depth into the standard rail material. The hardness ‘on the centre line of the head within the specified treated zone shall ‘comply with specifications for a minimum depth of 2 mm. At the discretion of the Supervising Engineer, surfaces which have been flame hardened shall be checked for cracks by an approved method such ‘as magnetic particle or dye penetrant test. Fabricated V Crossings - Wing rails of crossings of No. 10.0 and below shall be treated from 800 ‘mm in front of the nose to 300 mm behind the nose. ‘Wing rails of crossings of No. 12.0 and above shall be treated from 1000 ‘mmm in front of the nose to 500 mm behind the nose. Eabricated K Crossings - Running wing rails of K crossings shall be treated from 300 mm behind ‘one nose to 300 mm behind the other nose. ‘ail Bound Manganese Steel V Crossings - Heel rails shall be treated for a minimum distance of 1000 mm from the fitted end. Wing rais of crossings of No. 8.7 and below shall be treated on each side of the knee set from 300 mm on the wing end side to 500 mm on the nose ond side. Sarnaane “Track Wateriale W747 Page 22196TECHNICAL PUBLIC TRANSPORT CORPORATION Sanat INFRASTRUCTURE DIVISION = Fj MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘Wing rails of crossings of number greater than No. 8.7 shall be treated on ‘each side of the knee set from 300 mm on the wing end side to 800 mm. ‘on the nose end side. ‘Bail Bound Manganese Steel K Crossings - Running heel rails shall be treated for a minimum distance of 600 mm {from the fitted end. ‘Third Rail Fixed Points - Common Rail Units ‘The nose rail shall be heat treated for a minimum distance of 1800 mm from the nose end. ‘The common rail shall be heat treated from 3500 mm in front of the nose to 300 mm behind the nose. Dual Gauge Trackwork Units Heat treatment of rails shall be as specified on drawings or orders or as nominated by the Supervising Engineer. 8.16 DEPTH HARDENING OF MANGANESE STEEL INSERTS AND BLOCKS ‘Spectied manganese steel inserts and blocks shall be depth hardened by the use of flexible sheet explosive. The hardened areas of inserts of crossings shall be as specified on relevant drawings. Manganese blocks for Third Rail Fixed Points, Common Rail units shall be hardened on the top surfaces. The hardened areas shall attain a minimum surtace Brinell hardness number of 330 after completion of all machining or grinding operations, (On crossing inserts, one hardness survey shall be taken on each hardened area. This reading shall be at the intersection of lines 25 mm from and parallel to the gauge and guard edges. (On Third Rail Fixed Points blocks, one hardness survey shall be taken in the centre on each ramp, on the flange running plateau and on the lower top surface, The readings shall be taken in the centre of the flangeway. In the event of any hardness survey not complying with the specification, two additional surveys shall be taken, one on elther side ofthe original impression, within 25 mm distance and parallel with the gauge or guard edge. If both these surveys comply with specifications, the original survey shall be disregarded. ‘The hardness surveys shall be recorded and this record shall be available to the Supervising Engineer. Castings which fail to meet the hardness specifications may be accepted subject to the hardening process fee not being charged. The top of the insert tang of crossings adjacent to the heat number or other position as directed by the Supervising Engineer, shall be clearly stamped *UNHARDENED* in minimum 15 mm letters. ~ Sanaa "rack Materials THAT Page 25 0736TECHNICAL Sh A PUBLIC TRANSPORT CORPORATION Erie seanenme! INFRASTRUCTURE DIVISION ‘ovine ‘VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.17 8.18 Distortion resulting from the depth hardening process shall be rectified before the final assembly. NON-DESTRUCTIVE TESTING Non-destructive testing shall be carried out as specified in this document, on drawings, additional specifications or orders. ‘Magnetic particle testing shall be performed in accordance with the requirements of A.S. 1171. Penetrant testing shall be performed using a solvent removable die technique, or approved ‘equivalent, in accordance with A.S, 2062. ‘All non-destructive testing operators shall have successfully completed a sutable training ‘course and obtained adequate experience in the relevant method. The training program may be in-house or in accordance with A.S. 3998, Clause 7.2. Non-destructive testing operators shall be certified by the Contractor's Quality Assurance Manager. The Supervshg Engineer may request relevant documentary evidence of training, experience and certification. Certification of tests shall be included in documentation as specified in the relevant "Quality Assurance" Clause. ‘The Supervising Engineer, at his discretion, may request additional tests to prove compliance with these specifications. MACHINING AND ASSEMBLY 8.18.1. General ‘A suitable level platform, approved by the Supervising Engineer, shall be provided by the Contractor at his works for the purpose of assembly of railway trackwork assemblies. ‘The Contractor shall make due allowances for variations in rail sizes for the machining of ral parts and blocks. Rails and other materials shall be straight and true prior to commencement of machining or assembly. Rails containing welds shall not be used in manufacture, unless approved in writing by the Supervising Engineer. Distortion of parts caused by machining or other operations shall be corrected before assembly. Rall parts shall be straight, where required, without pressure being applied to the parts. All parts required for the works described in this contract shall be fitted with accuracy to the dimensions and within the tolerances shown on the relevant drawings and this + specification, Rolling brands shall be removed from rails where they rhay interfere with accurate fit. All machining, grinding and drilling materials shall be removed from fitting areas. Saunas "Track Matariale W707 Page 20 196TECHNICAL k » PUBLIC TRANSPORT CORPORATION Sata aeceurmacriee INFRASTRUCTURE DIVISION 7) MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES Cast blocks shall be finished to fit accurately over 90 per cent of their fitting faces. ‘Any block which permits the insertion of a 0.5 mm feeler gauge between the rails and fiting faces of the cast blocks shall be rejected. Epoxy filers shall not be used as & substitute for accurate machining. ‘The running edge of assemblies shall be to true alignment at a depth of 16 mm below the top surface of the rails or as specified on relevant drawings. ‘Adequate clearance shall be provided between fastenings and adjacent components. All rail ends of 47 and 53 kg points, crossings, third rail and dual gauge trackwork. Units shall have three (3) holes, 27 mm diameter drilled at standard centres to permit ‘the use of 6 hole fishplates and swage lock fastenings. The No. 15.0A V REM, 53 kg crossing, which is designed for welding into track, is excluded from this requirement and shall be deiled in accordance with the relevant drawing. All heads of un-machined rails at the ends of assemblies shall be bevelled 2 mm at 45 degrees over the full width of the heads. Epoxy resin filer (Araldite K105 or approved equivalent) shall be used where specified. The filler shall be mixed and applied strictly in accordance with the manufacturer's ‘current specifications and recommended safety directions. Rails and blocks shall be free of scale, rust and contaminants prior to application of the filler. Excess filer shall be removed from rails and blocks. Fastenings shall be inserted with all heads on the one side where-ever practical. The correct side is indicated on the relevant drawings. Unless otherwise specified, the length of bolts shall be such as to provide 3 mm minimum to 15 mm maximum projection of the end of the bolt beyond the nut when finaly screwed into position. 8.18.2 Points Blades and stock rails shall be machined accurately to the dimensions and sections. shown on the relevant drawings. Flun-out of top machining of blades shall not be less, than 25 mm from the heel ends of the blades. Notching for run-out of machining of heads and flanges of stock rails shall conform to the relevant drawings, shall be finished smoothly and shall be no deeper than required. All 60 kg points shall be fitted with point slide chairs conforming to Plan No. 495-81. The chairs shall be pre-lubricated and attached to the stock rails with 25.4 mm swage look fastenings. Spreader brackets shall be fastened to the blades with the appropriate slopes of the brackets bearing against the flanges of the blades. The spreader bracket bolt holes shall be at right angles to the base of the blades. A 25.40 mm plug gauge shall be ‘capable of insertion in the spreader bracket hole for the full depth after the spreader brackets have been fastened to the point blades and temporary spreader bars have been fitted. apenas "Yack Matorale 1757 Page 25 0196TECHNICAL PUBLIC TRANSPORT CORPORATION SPECIFICATION TM 14 INFRASTRUCTURE DIVISION [eso —_| MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES 8.18.3 Points ordered in sets shall be fitted together with temporary spreaders and spreader bracket bolts and shall be gauged to correct gauge of track. Gauge and alignment shall be measured at 16 mm below the top surfaces of the rails. The blades shall give the required amount of throw without undue spring. Unless otherwise specified, the toe ends of set stock rails shall be in true alignment with the running edge of the mating blade, Each half set of pivot hee! (non fixed heel) points shall be assembled with a temporary rail (not less than 1200 mm long) at the heel. In the closed position, the blade shall be in alignment with the temporary rail at the heels. The underside of flanges of stock rails and mating blades shall be parallel in a transverse direction for the entire length of the blade. Flange clearance between blades and stock rails shall conform to the relevant drawings. ‘The machined portions of heads of blades shall fit neatly against the machined portions of heads of mating stock rails and shall not allow the insertion of a 0.5 mm. feeler gauge at any point. Point stops shall just touch the webs of stock rails or blades, as applicable, over the full section of the point stop ends when the blades are fiting against the stock rails. (On fixed heel points, an epoxy resin filler shall be applied to the fitting faces and void areas of heel blocks. ‘tthe heel blocks of fixed hee! points, the head of the swage lock fastening shall be installed on the rail which is perpendicular to the axis of the fastening. Cast steel tapered washers, to Plan No. 449-87, shall be utilised under the collars of swage lock fastenings to adjust the seating angle. Seating angle shall conform to the requirements detailed in the swage lock fastenings clause. ‘Where rivets are specified on drawings for fastening of spreader brackets and point stops, 22.2 mm swage lock fastenings may be utlised in lieu. Adequate clearances shall be maintained between the fastenings and rail or other adjacent components. Crossings “The running edges shall be to true alignment at a depth below the top surface of the rails as specified on the relevant drawings. Notching at the scarf of crossings shall be finished to a comer radius of 6 mm. Nose, knee (throat), male and female scarf and wedge scarf blocks shall be machined on the fitting faces to fit accurately over 95 per cent of their fitting faces. ‘Any work which permits the insertion of a 0.5 mm feeler gauge between the rails and fiting faces of the blocks shall be rejected. Cast tapered washers shall be used under the head and collar of each fastening if adjustment of seating angle is required. Cast tapered washers shall be cast steel to Plan No. 939/83 or approved equivalent. Cast stool washers may be ground to suitable tapers to adjust seating angle. Sonmaraeae "Track Wattale TART Page 25 0138TECHNICAL PUBLIC TRANSPORT CORPORATION Sa INFRASTRUCTURE DIVISION VeRsoN 20 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘Alternatively, two cast steel washers may be used back to back subject to dressing of ‘any protrusions and the outside curved face to ensure full head and collar seating. ‘An epoxy resin filor shall be applied to the areas detailed below:- = Fabricated Crossings - Fitting faces and void areas of blocks with the exception of nose, scarf and knee (throat) blocks, unless otherwise specified. - Rall Bound Manganese Steel Crossings - Fifing faces of the manganese inserts and blocks. The point of intersection of each “K" crossing shall be marked with low stress (rounded) centre punch marks at the knee (throat). The marks shall be made on the cent line of the head of both running rails. The theoretical nose location of each rail bound manganese *V" crossing shall be ‘marked wit low stress (rounded) centre punch marks. The marks shall be made on the centre line of the head of both wing rails. 8.18.4 Third Rall Trackwork Units ‘Third rail work track units shall be machined and assembled as specified in clauses for points and crossings and to the tolerances in the relevant clause of this ‘specification. If ordered in sets, they shall be assembled and gauged in sets and shall be suitably match marked in sets. ‘An epoxy resin filer shall be appliad to the fiting faces of blocks including manganese blocks. 8.18.5 Assembly Utilising Swage Lock Fastenings High tensile swage lock fastenings shall be used for the assembly of all crossings, including rail bound manganese steel crossings, third rail trackwork units and fixed heel points. Where specified on drawings, orders or additional specifications, swage lock fastenings shall be utlised on dual gauge trackwork units. Fastenings shall be 25.4 mm diameter unless otherwise specitied. All collars shall be flanged type. ‘Swage lock fastonings shall be installed strictly in accordance with the manufacturer's current specifications. Round, flat, 25.4 mm diameter, high strength structural steel washers may be used {o adjust the grip length of each fastening. A maximum of 4 washers shall be used ‘on each fastening and these shall generally be equally distributed under the head and collar of the fastening. ‘Awasher shall be utilised in all cases where a hole is greater than 27 mm diameter. Cast steel or machined washers of sutable thickness and size may be utlised, where necessary, to provide clearance during assembly for the nose cone of the swage lock fastening tool. The designs and materials of such washers and installation procedures shall be approved in writing by the Supervising Engineer. anaaeae "Tack Malerals WAST Page a7 196aa PUBLIC TRANSPORT CORPORATION —_ | SPECIFICATION _| inermasrmucrunt "Sivimon INFRASTRUCTURE DIVISION TECHNICAL T™ 14 ‘VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘The head and collar seating of swage lock fastenings shall be within:- 1 degree under the head and 3 degrees under the collar of normal to the axis of the fastening, unless otherwise specified or approved by the ‘Supervising Engineer. ‘Temporary bolts shall be installed and tightened for initial assembly. Bolts shall then bbe replaced individually by swage lock fastenings, generally commencing in the centre of the assembly, altemating in each direction towards the ends Threaded swage lock fastenings shall be assembled with a 25.4 mm diameter high strength structural steel washer under the nut. Installation shall be such that ‘mhimum of one and maximum of 3 full threads shall protrude beyond the nut. A high strength anaerobic retahing compound (Loctite 262 or approved equivalent) shall be utlised on the thread. The thread shall be clean and dry and the retaining compound applied strictly in accordance with the manufacturer's safety procedures. A cleaning agent as approved by the retaining compound manufacturer shall be used, if required. The fitted clearance of all 47 and 53 kg blocks which have web clearances shown on drawings shall be 1.5 mm + 0, - 0.5 mm prior to the installation of fastenings. Where align bored holes are specified on drawings, the rails may be pre-drilled and ‘spacer blocks cored, only for assemblies completely utilising high tensile swage lock fastenings. equivalent holes. ‘The diameters of these holes shall be equal to the diameters of Al sharp edges shall be ground off the protruding ends of swage lock fastenings after installation. 8.19 TOLERANCES Tolerances are permitted in the rolling of rails and due allowances for variations in rail sizes must be mad When mill length rails are used for stock rails they shall not vary in length by more than 2 mm from the stock rail lengths shown on the drawings. Except where otherwise shown on drawings and in this specification the following tolerances shall be permitted: RAIL LENGTHS Points Blade and Stock rails Crossing Nose, Scarf and Wing rails Guard rails 42mm, -2mm 42mm, -2mm 42mm, -2mm ‘Trackwork Unit rails, unless otherwise specified 42mm, -2 mm. Closure rails Capnariene "Track Materials TWAT Page 28 0136TECHNICAL PUBLIC TRANSPORT CORPORATION Sata INFRASTRUCTURE DIVISION Vensionaa MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES Stock rail or blade rail hee! overhang 42mm, -2mm Heel spread 42mm, -O mm Toe thickness +1 mm, -Omm Sot stock rail heel end offset 42mm, -2mm Blade ise at heel +1 mm, -O mm Point stop fit against stock rail or blade +0 mm, -0.5 mm ‘Spreader bracket location +2 mm, -2 mm Gauge of points 42mm, -1 mm Rall flange clearance 42mm, -1 mm Cross level of ral bases +0.5 mm, -0.5 mm Longitudinal twist mmm Peaking or dipping 0.8 mmm | CROSSINGS (FABRICATED & RAIL BOUND MANGANESE) ] ‘Overall lengths 42mm, -2 mm Flangeway widths Nose width Rall flange clearances Flangeway depths Point of Intersection (P of ) to nose +1 mm, -1 mm Relative lengths from nose to ends of "V" crossings 42mm, -2 mm Relative lengths from P of | to ends of "K" crossings 42mm, -2mm Alignment of running edges and surfaces +1 mm, -1 mm. Wing and "V" end openings 42mm, -2mm Cross level of rail bases 40.5 mm, -0.5 mm Longitudinal twist 1imevm Peaking or dipping 0.8 mm/m RAIL BOUND MANGANESE CROSSINGS: Rolative height of casting to wing and heel rails. Toe and heel spread Gauge face alignment from theoretical line Gauge face alignment, casting to abutting heel rails MANGANESE CASTINGS, Overall length ‘Theoretical point to end of casting Running surface flatness from theoretical top Fiangeway width Flangeway depths Vertical dimensions, unless otherwise specified Maximum twist of casting mr "Track Materials W747 Page 29 f 36PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES —————— ee THIRD RAIL TRACKWORK UNITS ‘Overall length Flangeway width Flangeway depths at wheel contact locations Flangeway depths, other Cross level of rail bases Longitudinal twist Peaking or dipping ‘BOLT HOLES: Longitudinal positions of round holes Longitudinal positions of oval holes Vertical positions of all holes Sizes of all round rail holes Sizes of all oval a ‘TRACKWORK LAYOUTS Toe to Point of Intersection (P of I) +3 mm, -3 mm Toe to Intersection Point (|.P.) of turnout 43mm, -3 mm Location of Point of Curvature (P.C.) 43mm, -3 mm Curved lead offsets 42mm, -2 mm Nose to centreline of guard rail 45mm, -5 mm Track gauge, 1600 mm or 1435 mm, as specified 42mm, -O mm Guard rail gauge, 1557 mm or 1392 mm, as specified +2mm, -O mm PLATEWORK Length and width of plate 42mm, -2mm Positions of lugs, stops, etc. 42mm, -1 mm Rall flange seat width between lugs, stops etc. +1mm,-Omm ‘Angles of lugs, stops otc. 40.5%, -0.5° Positions of spike or screw holes 42mm, -2mm Flatness or twist +40.5 mm, -0.5 rom Gauge and flangeway shall be measured at the gauge point. ‘The gauge point is defned as 16 mm below the top of the head of the rail, for all sizes of rail, unless otherwise shown on drawings. 8.20 LUBRICATION Rocol Spray Switch Plate Lubricant shall be used to lubricate slide surfaces of points and components as detailed below:- : The slide surfaces of all chairs, which are fastened to stock rails and which are located between the toe and the first heel blocks of points. - The slide surfaces of tle plates which are supplied with points. Sanna "Tack Mataials WAST Page 900136TECHNICAL he A PUBLIC TRANSPORT CORPORATION Tr 4} INFRASTRUCTURE DIVISION Vensions ae MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES : ‘The underside of point blades, on points assembled with chairs, in the chair contact, area. - ‘Special pivoting heels of points, as directed by the Supervising Engineer. The lubricant shall be applied strictly in accordance with the manufacturer's current specifications and recommended safety procedures. The slide surfaces to be lubricated shall be thoroughly cleaned to remove all scale, rust, grease, moisture and other contaminants. A non-flammable solvent may be used for degreasing, if necessary. ‘Two liberal, even layers of graphite lubricant shall be applied onto the slide surfaces. The first layer shall be completely dry before the second is applied. Dust and contaminants shall not be permitted to come into contact with the wet lubricant. The point blade shall not be assembled on to the chairs until the lubricant has completely dried. Drying of the lubricant under normal conditions will require approx. 10 minutes and may be assisted by using dry compressed air. The lubricated surfaces shall not be contaminated during subsequent operations such as rust proofing. 9, TRIAL ASSEMBLIES ‘Where indicated in the schedule or order, the Contractor shall trial assemble the unit or layout during or after manufacture, as required by the Supervising Engineer. Assemblies shall be laid out on a flat surface in accordance with relevant drawings. 10. VARIATIONS TO APPROVED PROCEDURES AND MATERIALS Written application shall be made to and written approval obtained from the Supervising Engineer for all proposed variations to specified procedures and material including equivalents. 11, MARKING 41.1 GENERAL Ail materials and assemblies shall be clearly embossed or stamped, for identification and traceabilty, in minimum 15 mm letters and/or numerals, unless otherwise specified. ‘Additionally, the materials and assemblies shall be legibly marked with a white paint pen. The identification and stock code shall be in minimum 25 mm letters and/or numerals and shall generally be . adjacent to the embossing or stamping. The ‘Supervising Engineer may vary the paint identification requirements. canoe "Tack Materials 1707 Page st 136LH crc & PUBLIC TRANSPORT CORPORATION TT eeeaatnacmeen INFRASTRUCTURE DIVISION Vensionao MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND. ACCESSORIES 11.2 COMPONENT AND ASSEMBLY IDENTIFICATION Points shall be clearly embossed on the top of heel blocks, unless otherwise specified. ‘Special points shall be stamped on the field side of the head of the stock rail adjacent to the heel and/or other position as directed by the Supervising Engineer. ‘The crossing number and third rail trackwork unit identification shall be stamped on the head and within 300 mm of the end of one guard wing rail, The heat number, and repair information, if applicable, of manganese steel inserts for crossings shall be clearly embossed or stamped on the top of the insert tang. ‘Special identification such as EH (explosively Hardened) and H.H. (Head Hardened) shall be stamped adjacent to Assembly Identification. ‘The guard rail identification shall be stamped as shown on relevant drawings. Plates shall be legibly stamped as specified on relevant drawings. 11.3 MANUFACTURING/TRACEABILITY IDENTIFICATION All points, crossings, Third Rail Trackwork units, guard rails and other assemblies shall be uniquely marked to permit subsequent manufacturing traceability. ‘The markings shall incorporate the year and month of manufacture. The markings shall be stamped in 10 mm numerals and laters. Except on plates, the markings shall be adjacent to the component and manufacturer Identification markings, On plates, the markings shall be on the opposite side of the plate to the ‘component and assembly identification. 11.4 MANUFACTURER'S IDENTIFICATION Points, crossings, third rail trackwork units and guard rails shall be stamped with the ‘manufacturers intials or trade mark in 10 mm letters adjacent to the manufacturingfraceability markings. . Points shall be stamped on the heel block. Crossings, third rail trackwork units and guard rails shall be stamped adjacent to the identification stamping. RUST PROOFING 12.1 GENERAL All components and assemblies which are subject to rusting shall be rust proofed, unless otherwise specified. ‘Canaan ‘Wack Materials W787 Page oS| TECHNICAL A PUBLIC TRANSPORT CORPORATION aaa ' 7 seeasreecmue INFRASTRUCTURE DIVISION er MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND | ACCESSORIES 12.2. INTERNAL RUST PROORING Interal machined or ground surfaces which cannot be olled after assembly and all fastenings ry for permanent assembly shall be rust proofed by coating with an approved rust proofing compound. ‘Spreader bracket bolt holes shalll be rust proofed. 12.3 EXTERNAL RUST PROOFING All components and assemblies shall be coated with one liberal and uniform application of boiled linseed oll after final inspection. The surfaces of all materials shall be brushed clean and shall be dry before coating. The oil shall not be permitted to come into contact with graphite lubricated slide surfaces of points. ‘The shanks of swage lock fastenings which are supplied for field installation shall be free of ‘ust and shall be coated with boiled linseed oil prior to packing. 13, HANDLING, PACKAGING AND TRANSPORT 13.1 GENERAL The Contractor shall take care to avoid bending and/or distortion of the rail, plates or ‘components by ensuring that material is adequately supported and braced at all stages of ‘manufacture, handling and transportation. ‘All components for dispatch shall be adequately packaged to ensure that no damage or loss. ‘occurs during handling and transit. All small items shall be packaged securely in suitable crates, bags or packages, as specified. Packaging shall be of suitable size and construction. Crates shall be provided with suitable Tunners to permit handling by forklifts and shall have detachable lids bound by steel straps. Provision shaill be made when loading for dispatch to permit unloading by suitable mechanical handling equipment. Each package shall be labelled with the order number, stock code number, general description and quantity of contents. The labelling shall be weather proof. 13.2 POINTS The blades of points shall be securely attached to the mating stock rails. M16 bolts and Ssutable washers shall be used I holes are provided for attachment purposes, otherwise stee! bands shall be used. A minimum of two 19 mm steel bands shall be fitted at the first spreader and at the intersection of heads. On 60 kg M10.0 and Trailable points, the bands shall be increased to a minimum of three at each position. Where the blade overhang, beyond the last block at the heel, exceeds 1000 mm, the blade ‘and stock rail shall be securely attached to ensure that the specified offset is maintain during transit and handling. ‘Timber packing pieces shall be placed in the jaws of cast steel spreader brackets to prevent damage in transit. career Track Matera 1707 Page sofaTECHNICAL JA PUBLIC TRANSPORT CORPORATION Saal faucasanereeal INFRASTRUCTURE DIVISION ‘orion MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES VERSION: 2.0 13.3 CROSSINGS Wide angle crossings and crossings as specified on drawings shall be fited with suitable pipe ferrule spacers and threaded bars to maintain correct openings during handling and transit. The spacers shall be fitted through bolt holes at crossing end openings and shall not be utilised for handling purposes. 13.4 COMPONENTS 13.4.1. Individual ‘individual stock code items shall be packaged separately, unless otherwise specified. The mass of packaging and contents which require manual handling shall be restricted to 10 kg. 13.4.2 Sets/Pairs Plates, blocks and components associated with sets or pairs of points, crossings, ‘guard rails or plates shall be packaged into suitable wooden crates, if specified in the schedule:- Points - one set of spreader bars, railbase plates and tieplates per crate. Crossings - one set of crossing plates and rail base plates per crate. Guard rails - guard rail biocks, and swage lock fastenings to suit 2 No. guard rails per crate. Plates - ‘as specified in the schedule or order. 14. QUALITY ASSURANCE ‘The Contractor shall comply with the PTC Quality Assurance Requirements as detailed in document ‘SQA 9002.2 Revision 't". For this Contract the Corporation's Quality Assurance Representative shall be the Supervising Engineer. {All inspection record forms, test data forms and Certificates of Conformance shall be submitted to the Supervising Engineer for approval prior to being implemented. The Contractor shall maintain records of all inspection operations performed and results obtained. ‘The records shall include all relevant dimensional and tolerance criteria. As applicable, the records shall also include all appropriate hardness, chemical and physical test data, special purpose weld and repair weld data and non-destructive testing data. These records shall be cerified by the Contractor's Quality Assurance Officer and a copy shall be available to the Supervising Engineer at the time of inspection or on request. Certificates of Conformance and other documentation as required by document SQA 9002.2 Revision 't' shall be included with packing and delivery documentation and shall be addressed to Manager, Permanent Way Materials Depot, Spotswood. Somnneeae Wack Waters TAT Page 34 0196TECHNICAL PUBLIC TRANSPORT CORPORATION rs ‘VERSION: 2.0 INFRASTRUCTURE DIVISION 15. 16. MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES INSPECTION The Contractor shall permit the Supervising Engineer, or his appointed 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 facilities shall include suitable benches. Facilities shall be to the satisfaction of the Supervising Engineer and shall permit inspections to be conducted in all weather conditions. ‘All assemblies and also individual components shall be subject to an inspection, by the Supervising Engineer, at the contractor's works or point of delivery to ensure conformity with this specification. ‘Such 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, microstructural examinations and general inspections at the Contractor's works, shall be borne by the Contractor. Inspection gauges shail be solely used for inspection purposes by the Contractor's Quality Assurance Officer and the Supervising Engineer. WARRANTY 16.1 GENERAL WARRANTY ‘The Corporation reserves the right to reject any material which within one (1) year of delivery, {s found not to conform to the spectication. Any rejected material shall be repaired or replaced by and at the cost of the Contractor. 16.2 WARRANTY FOR WELD REPAIRED NEW MANGANESE STEEL INSERTS AND BLOCKS A three (3) year warranty shall apply to all repairs carried out on inserts and blocks in Zone B as defined in this specification. ‘The warranty shall commence from date of inspection and acceptance of the completed assembly. ‘The Contractor shall be responsible for the repair, including any consequential damage ‘sustained by the inserts or block, or replacement of an assembly which, due to normal service conditions, exhib a detrimental defect in a Zone B repaired area. Responsbblty shall include ‘transportation of the assembly, if required, from the site and retum to the site or Permanent Way Materials Depot, Spotswood, as nominated by the Corporation. ‘The Corporation shall determine if a defect is considered to be detrimental to the service life of an assembly and whether it shall be repaired on site, at the Contractor's works or shall be replaced. ‘The Contractor shall make all necessary arrangements to effect repair or replacement within a period of three (3) months after notification of the defect by the Corporation. Warranty repairs shall be subject to the balance of the original warranty or an additional ‘warranty of one (1) year from date of repair, whichever is the longest. ‘All warranty repairs shall comply with approved specifications which are current at the time of repair. Barnes "Yack Materials TART Page 35 036LH onan bh A PUBLIC TRANSPORT CORPORATION anaiaa eee INFRASTRUCTURE DIVISION venemnead MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES ‘Assemblies which have been repaired in Zone B shall be clearly stamped with the following information in minimum 15 mm letters and numerals:- "REPAIRED" or "R’ DATE (MONTH & YEAR) PASSED AND ACCEPTED 5 1 ql Crossings shall be stamped on the top of the insert tang, adjacent to the heat number and on the guard wing rail adjacent tothe Kientfication stamping. Other assemblies shall be stamped ‘on the guard wing rail adjacent to identification stamping, if applicable, and/or other position as directed. 17. 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 ‘tnecessary addtional tests, carried out by an independent testing authority. This authority shall be registered by N.A.T.A. forthe field 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 bome by the loser of the dispute, 18. DELIVERY Delivery of all material shail be free into store at Permanent Way Materials Depot, McLister Street, Spotswood, Melboume, unless otherwise specified on orders. ‘Additional costs, it applicable, for delivery and unloading at other nominated locations shall be to the Corporation's account. ores “Wack Matera TAT Page 36 36417-75 418-75 790-81 415-75 792-81 419-75 420-75 421-75 221-78 423-75 > 868-86 721-82 1083-84 1309-83 1287-83 1482-86, 1483-86 488-81 489-81 1089-60 1122-60 1123-60 1017-60 605-63 201-89 317-89 '@'0'>B QDO0m0M000 433-75 1519-86 - 1061-83 210-83 27-76 427-75 28-76 428-75 429-75 683-75 451-74 414-74 2004-93 744-83 34-75 425-75 ‘') poo>mo'>>>>'G0 TECHRICAL L. A PUBLIC TRANSPORT CORPORATION Taaiaae mvcarnnereen! INFRASTRUCTURE DIVISION “Semen ‘VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES APPENDIX "A" DRAWINGS SUPPLIED BY THE CORPORATION Points, Points, Points, Points, Points, Points, Points, Points, Fixed, Third Rail, Points, Fixed, Third Rail, Points, Fixed, Third Rail, Points, Fixed, Third Rail, Points, Third Rail, Transfers, Third Rail, ‘Twin guard rail assembly, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, \V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, V Crossings, DESCRIPTION M46 & M5. 47 kg kg M4.6A, VY, 47 & 53 kg M4.6 VYS & VYD, 47 & 53 kg M4.6 F +, VY, 47 & 53 kg MS.8 VYS & VYD, 47 kg M5.8 VYS & VYD, 53 kg M6.9, 47 kg M6.9, 63 kg M91, 53 kg Sections & Heel Blocks, 47 & 53 kg 6.1 VYS & VYD, Fixed Heel, Machining, 60 kg M7.0, Fixed Heel, Layout, 60 kg M7.0, Fixed Heel, Machining, 60 kg M7.0A, Fixed Heel, Layout, 60 kg M7.0B, Fixed Heel, Layout, 60 kg (7.08, Fixed Heel, Machining, 60 kg M7.00, Fixed Heel, Trallable, Layout, 60 kg 7.00, Fixed Heel Trallable, Machining, 60 kg M10.0, Fixed Heel, Layout, 60 kg M10.0, Fixed Heel, Machining, 60 kg TRI, 53 kg TR, 47 kg TRS, 47 kg TR4, 53 kg TR12, 53 kg TRE & TR7, 53 kg TRI1, 53 kg No. 3, and 12, 53 kg No. 3.697, 47 & 53 kg No. 3.697A, 53 kg No. 3.697, Sections, 53 kg No. 5.08, 47 & 53 kg No. 5.06, and 6.11, 53 kg No. 6.0 and 6.08, 47 & 53 kg No. 7.52, 8.7 and 9.73, 47 kg No. 7.52, 8.7 and 9.73, 53 kg No, 7.52A and 8.7A, 47 & 53 kg No. 8.7 RBM, 53 kg No. 15.0 RBM, 53 kg No. 15.04 RBM, 53 kg No. 15.0 RBM, Explosive Hardening, 53 kg Block Arrangements, 47 & 53 kg ‘Typical Sections, 63 kg Sarma "Teck Materials TTABT Page Riotsm PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION TM 14 VERSION: 2.0 MANUFACTURE AND SUPPLY OF RAILWAY POINTS, CROSSINGS AND ACCESSORIES APPENDIX "A" - cont'd DRAWINGS SUPPLIED BY THE CORPORATION PLANO, REVISION DESCRIPTION 683-86 V Crossings, No. 8.7, 60kg 2422-88 Crossings, No. 8.7C, 60 kg 1207-83 D V Crossings, No. 7.52, RBM, 60 kg 1292-83 - V Crossings, No. 7.52, REM, Explosive Hardening, 60 kg 724-82 -D V Crossings, No. 8.7, REM, 60 kg 725-82 - V Crossings, No. 8.7, REM, Explosive Hardening, 60 kg 1333-84 B V Crossings, No. 10.0, RBM, 60 kg 1348-84 = V Crossings, No. 10.0, RBM, Explosive Hardening, 60 kg 496-81 F V Crossings, No. 15.0, REM, 60 kg 502-81 A V Crossings, No. 1.0, RBM, Explosive Hardening, 60 kg 1061-83 A K Crossings, No. 3.697A, 53 kg 210-63 A K Crossings, No. 3.697, Sections, 53 kg 1276 K Crossings, No. 7.52, 53 kg 13-76 B K Crossings, No. 7.52A, 53 kg 7e89 A K Crossings, No. 7.526, 53 kg 20-76 - K Crossings, No. 8.7, 47 & 53 kg 14-76 A K Crossings, No. 8.7A, 53 kg 2283-87 A K Crossings, No.8.7, 60kg 603-86 G K Crossings, No. 8.76, 60 kg 1208-83 K Crossings, No. 7.52, REM, 60 kg 1311-83 - K Crossings, No. 7.52, REM, Explosive Hardening, 60 kg MF-352 A Guard Rails, AT &53kg 1318-77 - Guard Rall Blocks, 47 &53kg 2495-87 C Guard Rail & Blocks, 13.5, 53 kg 64-94 A Guard Rail, 4.3, 53 kg 2058-82 - Guard Rail, M45, 53 kg 727-82 B Guard Rail & Blocks, M3.5, 60 kg 1262-84 Guard Rail & Blocks, M3.5A, 60 kg 2336-88 Guard Rail & Blocks, M4.0, 60 kg 497-81 Guard Rall & Blocks, M45, 60 kg Sanna Tack Mae TIABT Page Reora