“J | PUBLIC TRANSPORT CORPORATION |_ENG-TE-SPE-4505 ww ENGINEERING SERVICES DIVISION VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE SPECIFICATION MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES D. M. Patterson, Project Manager | 80 Orrong Re, Armadale Signature | Date Tel: (03) 9248 3617 or Fax: (03) 9248 3535, A. Sowinski, Senior Technical Officer 13-99 P. Leombruni, Senior Engineer - Track Materials 01-49 Discipline Review |B. Held, Manager Track Engineering flee 223-4 ‘© Copyright Public Transport Corporation, Engineering Services Division, 1999 Tack Enpneeing SPE-AS057 doe Page ortoae | PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-4505 a ENGINEERING SERVICES DIVISION VERSION 4.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES RECORD OF AMENDMENT/CHANGE “The amendments noted in the undermentioned amendment ist have been incorporated in this copy of the publication: TENGEN] VERSION ] VERSION SAT OF ANGE Soc THe One sone [a rare ig Tek re FTL ore Reet ad aaa TW gc 3 it 5/3/99 _ | Renumbered, Reformatied, Cover & Amendment sheets added. [BA 22/3/49 n 3 ¢ ; ; : Track Engineering SPE-#505v1.1 doe Page 2 of 107 PUBLIC TRANSPORT CORPORATION ENG-TE-SPE-4505 vv ENGINEERING SERVICES DIVISION VERSION 4.4 ‘MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES TABLE OF CONTENTS CLAUSE PAGE 1 GENERAL 4 1.4 PURPOSE, 4 12 SCOPE Te oo 4.3. REFERENCE DOCUMENTS. 4 1.3.1 Australian Standards. 4 43.2 Drawings... . 4 1.3.3. Quality Assurance Document 4 1.4 DEFINITIONS. 5 1.5 RESPONSIBILITIES 5 1.6 RECORDS. 5 2 MATERIAL SUPPLY 5 3 SPECIFICATION... 5 3.1 MATERIAL 5 3.2 MANUFACTURE 6 32.1 — General = 6 32.2 Manufacturing Locations And Factties, 6 3.2.3. Patterns, Jigs, Dies And Templates, 6 33 PROFILE 6 3.4 RUST PROOFING 6 4 QUALITY SYSTEM 6 4.1 QUALITY ASSURANCE. 6 444 General 6 412 — Test Certificates 7 42 PRE-PRODUCTION SAMPLES 7 43 TESTING AND FACILITIES 7 44 INSPECTION... 8 45 VARIATIONS TO APPROVED PROCEDURES AND MATERIALS. 8 46 WARRANTY 8 4,7 RESOLUTION OF DISPUTES. 8 5 SUPPLY. 8 6.1 HANDLING, PACKAGING AND TRANSPORT 8 52 DELIVERY. ses 9 APPENDIX “A” INFORMATION TO BE PROVIDED BY THE SUPERINTENDENT ..... “Track Engineering SPE-4505v1.1 doc Page 3 0f 10ah ENGINEERING SERVICES DIVISION VERSION 4.1 PUBLIC TRANSPORT CORPORATION |_ENG-TE-SPE-4505 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES. 1A 12 13 GENERAL PURPOSE, This specification sets out the material, manufacture and supply requirements for dogspikes used for railway trackwork. ‘SCOPE This standard applies to items manufactured for rail tracks controlled by the Principal. Purchasing guidelines are provided in Appendix “A. REFERENCE DOCUMENTS: 1.3.1 Australian Standards Reference may be made in this specification to the current editions of the following Australian Standards unless otherwise nominated:- 1085 Railway permanent way materi Part8 — Dogspikes ASINZS ISO 9002 Quality systems - Model for quality assurance in production, installation and servicing, 132 Drawings 1.32.1 Brawings Supplied by the Superintendent All drawings required for the performance of this service shall be supplied by the Superintendent as detailed in Appendix “A No drawing shall be copied or supplied to any third party without the written consent of the ‘Superintendent All items 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 issues and recalls for superseded drawings. 1.3.2.2 Drawings to be Submitted by the Contractor for Approval ‘The Contractor shall supply all drawings as may be requested within this specification or other specification provided at the time of ordering. Detailed drawings shall be provided with all requests for variations from specified drawings. No variations shall be permitted until approved in writing by the Superintendent. 1.3.3 Quality Assurance Documents - SQA 9002,2 Revision 1 Quality Assurance Document ‘Track Engineering SPE-4505v1.1.doc - Page 4 of 10(aw | PUBLIC TRANSPORT CORPORATION |_ENG-TE-SPE-4505 of ENGINEERING SERVICES DIVISION VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES 4.4 DEFINITIONS Contractor: Contractor shail include tenderer, manufacturer and supplier. Principal: Principal shall mean the Public Transport Corporation (PTC), and any ‘successors to the Public Transport Corporation. ‘Superintendent: ‘Superintendent shall mean the Principal's representative. The term shall include any appointed representative of the Superintendent. Techni Representative: Technical Representative shall mean a suitably qualified and experienced representative appointed by the Superintendent, The ‘Track Materials Engineer is currently the Technical Representative. Unless otherwise specified, the Technical Representative shall be Senior Engineer — Track Materials, Sinclair Knight Merz, Track Engineering, Melbourne. 1.5 RESPONSIBILITIES This specification applies to Contractors who are involved in the manufacture of dogspikes. ‘The Superintendent shall be responsible for ensuring that all works are carried out in compliance with this specification. ‘The Technical Representative shall be responsible for technical matters including those for Quality ‘Assurance. 4.6 RECORDS ‘The Contractor shall provide the Superintendent with, and shall maintain, records as detailed in the Quality Assurance clause of this specification. 2__ MATERIAL SUPPLY ‘The Contractor shall be responsible for the provision of all materials necessary for the works ofthis agreement Materials shall be new and of commercial quality, unless otherwise specified or approved in writing by the Superintendent Materials shall comply with relevant Australian Standards and with relevant Quality Assurance requirements as specified. All 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. 3___ SPECIFICATION 34 MATERIAL Dogspikes shall be manufactured from steel complying with the requirements of AS 1085.8. Track Enginesing SPE-ABOEVT. aoe Page Sof 0ae | PUBLIC TRANSPORT CORPORATION | _ENG-TE-SPE-4505, a ENGINEERING SERVICES DIVISION VERSION 4.4 4 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES 3.2 MANUFACTURE 3.24 General 33 34 44 All dogspikes shall be manufactured in a workmanlike manner and shall conform to relevant drawings, templates and gauges. 3.22 Manufacturing Locations And Facilities ‘The Contractor shall advise the Superintendent in writing of the proposed manufacturing locations and of any change of locations of works. 323 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 Technical Representative, PROFILE Dogspikes shall be 19 mm with square shanks and to the ordered length ‘The profile, dimensions and finish of the dogspikes shall comply with AS 1085.8. In addition, the dogspikes shall be supplied either:~ (a) Without fins, or (b) With fins to dimensions detailed in AS 1085.8 provided:- (The maximum acceptable major diameter shall be 48.0 mm in lieu of 64.0 mm. (i) The maximum fin minor diameter shall be 45.0 mm and this circumference shall be a maximum of 22.5 mm from the centre line of the dogspike shank. RUST PROOFING ‘The dogspikes shall be coated by dipping in Shell Ensis Fluid SDC or equivalent approved ‘compound. QUALITY SYSTEM QUALITY ASSURANCE 444 General ‘The Contractor shall comply with Quality Assurance Requirements as detailed in document SQA 9002.2. ‘The Contractor shall implement and maintain a Quality System to meet the requirements of AS/NZS 1S 9002, and this specification Engineering SPE-4S05vi,1 doc Page 6 of10PUBLIC TRANSPORT CORPORATION _|_ENG-TE-SPE-4505 wh ENGINEERING SERVICES DIVISION VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES 42 43 ‘The Contractor shall perform and maintain records of results for all inspection and testing ‘operations to demonstrate that the items are manufactured in accordance with this specification, ‘As applicable, the records shall include:- - material test certificates (e.g. B.H.P. test certificates) = allrrelevant dimensional and tolerance criteria - testing data. ‘The records shall be certified by the Contractor's Quality Assurance Officer and a copy shail be provided to the Technical Representative at the time of inspection, Certificates of Compliance and other documentation as required by document SQA 9002-2 shall be addressed to the Technical Representative and shall be provided with packing and delivery documentation. Certificates of Compliance, where applicable, shall include a statement that testing was performed in accordance with the approved procedures and by approved personnel ‘The format of all inspection record forms, test data forms and Certificate of Compliance shall be approved by the Technical Representative prior to being implemented. ‘The Superintendent reserves the right to perform compliance audits of the Contractor's Quality ‘System and to undertake any or all functions nominated in Clause AS of AS 1085.8, 412 Test Certificates The following test certificates shall be provided with each delivery:- - Contractor's Certificate of Compliance. = Chemical composition of the steel used to manufacture the items. = The results of all tests performed to establish compliance with this specification including mechanical, dimensional and tolerance criteria - The results of any additional testing as nominated by the Technical Representative. PRE-PRODUCTION SAMPLES: Pre-production samples shall be submitted to the Technical Representative. The samples shall be ‘accompanied by Final Quality Plan and Inspection Documentation. ‘The Contractor shall provide a minimum of 3 No. off-tool production samples (accompanied with completed inspection reports). Production shall not commence prior to approval in writing from the Technical Representative. TESTING AND FACILITIES All costs incurred by the Contractor in the provision of test certificates, labour and appliances necessary for the mechanical, dimensional, non-destructive testing, general tests and inspections at his works during the currency of this agreement shall be borne by the Contractor. Track Engineering SPEASO5V1.1 doe Page 7 of 10y ENG-TE-SPE-4505 — y a PUBLIC TRANSPORT CORPORATION ENGINEERING SERVICES DIVISION VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES 44 45 46 ar 5A INSPECTION ‘The Contractor shall permit the Technical Representative, access at all reasonable times to all places where the work is being carried out and shall afford allthe necessary facilites for inspection and testing of materials and workmanship. These facities shall include suitable benches. Faciities shall be to the satisfaction of the Technical Representative and shall permit inspections to be conducted in all weather conditions. All dogspikes may be subject to a provisional inspection, by the Technical Representative, at the Contractor's works to ensure conformity with this specification. ‘Such provisional inspection and/or approval shail 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, at the Contractor's works, to provide labour, equipment and gauges necessary for the performance of quality assurance inspections, as specified, and any ‘additional inspections and tests required to demonstrate compliance, shall be bome by the Contractor. Inspection gauges shall be solely used for inspection purposes by the Contractor's Quality Assurance Officer and the Technical Representative. VARIATIONS TO APPROVED PROCEDURES AND MATERIALS ‘Written application shall be made to and written approval obtained from the Superintendent for all proposed variations to specified procedures and materials, including equivalents. WARRANTY ‘The Principal reserves the right to reject any material which within one (1) year of delivery, is found ‘ot to conform to the specification. Any rejected material shall be repaired or replaced by and at the cost of the Contractor. RESOLUTION OF DISPUTES In the event of a dispute arising between the Contractor and the Superintendent regarding the test results of any component, the Contractor and the Superintendent 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.AT.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 borne by the loser of the dispute. SUPPLY HANDLING, PACKAGING AND TRANSPORT Dogspikes shall be packaged in lots of 40 No. Packaging shall be bags which shall ensure that no damage or loss occurs during handling and transit. Track Engineering SPE-4808v1.1 doc Page 8 of 10ENG-TE-SPE-4505 ~v 7 PUBLIC TRANSPORT CORPORATION ENGINEERING SERVICES DIVISION VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES Each bag of dogspikes shall be labelled clearly with:- = Manufacturer's name - Certificate of compliance number = Schedule item number = Schedule description of item = Number of items in the bag. ‘The bags and labels shall be of such quality that they shall be able to withstand exterior weather Conditions for a minimum period of 12 months. Bags shall be stacked and secured on to pallets. Pallets shall be covered with plastic or other suitable material which is able to withstand exterior weather conditions for a minimum period of 12 ‘months. Pallets shall be of solid timber construction. The total weight of each packaged pallet shall not exceed 2 tonnes gross. Provision shall be made when loading for dispatch to permit unloading by suitable mechanical handling equipment. Each pallet shall be labelled with the order number, stock code number, general description and ‘quantity of contents. The labels shall be able to withstand exterior weather conditions for a minimum period of 12 months. DELIVERY ‘The packaged items shall be delivered to the nominated storehouse. Unless otherwise specified by the Superintendent, each consignment shall include Quality Assurance documents as specified in the Quality Assurance, Test Certificates Clause. = The original documents shall be forwarded to: Senior Engineer - Track Materials ‘Track Engineering - Victoria Sinciair Knight Merz PO Box 2500 Malvern Vic 3144 = Acopy of the documents, in a waterproof envelope, shall accompany the consignment. Additional costs, if applicable, for delivery and unloading at‘other nominated locations shall be to the Principal's account. Delivery shall be deemed to be provisional unti the Superintendent certifies that the whole of this service is in accordance with this Specification and its associated documents and is.in every respect to his/her satisfaction. a “Track Engineering SPE-4S05v1 1.d0c Page dof 10,y PUBLIC TRANSPORT CORPORATION wv ENGINEERING SERVICES DIVISION ENG-TE-SPE-4505 VERSION 1.1 MANUFACTURE AND SUPPLY OF RAILWAY DOGSPIKES APPENDIX “A” _ INFORMATION TO BE PROVIDED BY THE SUPERINTENDENT 11 Description of dogspikes which are to be supplied to this specification. 2 Length of dogspikes which are to be supplied. 3 Alist of Drawings relating to the dogspikes, if applicable. 3 Delivery requirements. Track Engineering SPEASOSVI.1 doe Page 100110