DEDICATED FREIGHT CORRIDOR CORPORATION OF INDIA LIMITED Lae Deda Frelgh Conor Corporation) ‘Systra Mott Macdonald (iV) S¥STIA Oe RR an Dedicated Freght Catdor— Eastern cordon MUGHALSARAL-NEW BHAUPUR, CONTRACT PKG 2018202 [METHOD STATEMENT TRACK LAYING FOR [DEPOT CONNECTIVITY & YARD LINES DrceyrmacMsyoot aS [eH | IGG root) { Tare [snare Ser Taine ‘Orga Semisen | RSET ae i ie PROLECT DRECTO"PROTECT: Eastern Dedeated Freight Coridor Package 201 8202), EW GAR Seen mr Teste ee Rovson: 00 Introduction. For execution of track work we wil establish main Tak Depot at Pahara for C201 & at Rama for C? 202. These depos wl be equipped with requ facies for mechanixed trac ying ‘The Dapot wil have connection with IR Station Pabars & Ramwa for directly reeling ‘pti rakes loaded with 260m longa panel rom approved source linda Steel Toestablsh conection of éepet with yard, DFC track rom depot to IR station shall have tobe in advance by ser mechanized method. ‘Thistrack length il also function as launching pad fe fly mechanized tec ying, whlch Is essen requirement pir to laying track by Tac laying machine. Connectivity with station shal be execute in twe phase ast phase OFC ne willbe connected with IR ne and remaining works shal be executed in 2 phase at per requirement of Purpose ‘The purpose ofthis document is to specify procecure fr laying OFC Track to connect Pahara& Rana Depot with IR yard & Loep Lines. This methodology shal be of imited us fr lying DFC track to connect Depots with IR Yard and loop lines and is issued as supplement :9 Skelton wack laying methodology trendy submitted and approved for matnline. ‘Track Structure Following technieal Parameters in respect of track structure sal be adopted for Depot nes DFC. connecting ines, & the in 12 turnout fo temporary connecionn Depots, willbe purchased frm ROSO approved vendors as pe norms, SN] Telfer [ore tne Depa Go 1678 1h OG) 7 |i ag TS a | UE 900 Oa 7 ae | RG ero B tar | Rone Be a, age 26‘PROJECT: Eastern Dedicated Freight Corridor (Package 203 & 202) GAR Teena Oso Tastee Tali eaion ose ‘OR Sin i awices co Ke crossing on PSC Tanai Temporary | OR INES slches GORE ORTINES plches REE onmecontemeendFCe | REMS crossngon sT/SC. | CMS cresingonST/PSC Depots sleepers. slesers. ‘OR Tin BS wishes ORE [ORT WBS wwiches OREO | on PSC leepers: sc sleepes Reference ‘+ anual of instruction on Long Welded Rais (Revised 2006) with Addendum & Cotigendum Sip 26 15 of tune 2012 SpecFatons for Track Sallatt -GE-L June 2008 Correction Slip ne. 3 eos.09 Manel fr Flash Butt Welding of Rais (Revised January 2012) with Correction Sipro.2 Fusion Welding of Ralls by Alumino-Thermic Process revised 2012. ‘Manual for Ultrasone Testing of Rails and Wels 2012 (New Manval Revised 2013) ‘uldines for handing of alls (Noversber 2006) Employer requrement Indan Ralway Standard Speci for Fat Sotto Rais IRSTH22008 and acersum and Cotigendu 3 ete line 27,2012 Indian Raleays Permanent Woy Manual {RPWM) {Second Reprint 208, achonce orton sip Ho 134 dated ul 18" 2013)"Methed statement ~ Track Lying fr Depot on GAR Beare ow | ale Meth tatement or als supply & stacing. Meth taterent Sleeper spel stacking Meth tatement or Rall soppy & stacking Math tatemant or Traut instal. Method tatement or Destrssing CHR. Drawings and specification ‘Track wil be constructed per approved GEC drawings and ail track materials wil be procured {rom ROSO approved verrs conforrng to approve érawing & specication mentioned below. PMC approval shal be taben for al Track materials tobe used far Design nwingio [Speciation Ta UE SOUS SEE ca Messed enemeseeser 2 | paso sone 7 ‘Dia Tet Cpe GOORTREES | —posomzy| RROMBETP Serute 20/2007 Sa ne =a Taare — | — sr Gee = ed roses —[ Ws Eis Fstering Cig" rosfessia—[ WT Su oRwide Ta EOE Tonos RSTO crossing on PSC sleepers ipso 1nS /T-45, cee ore TaESEOE Tae |S crossngon seer Weeonoeieswic THESE | posoyr ease | wsTHORS Fak Patcinong Grooed wih compe | ROSS] THOS SE [WSTAORTGAR en | =" | Organisation “roel oxgoitation charts given below. Overall organization char with contact numbers willbe provided before actual execution wok start 6.1 Organisation Chart for Management it anager iinet 6.2 Organisation Chart for Survey, Quality & 16Plant and Equipment "Method Statement ~ Track Laying for Depot crcc/TeckuMsion connectivity oviion: 00 PROJECT: Eastern Dedicated Freight Coridor (Package 201 & 202) a0 For efficent exeetion of tack work, under mentioned machines are proposed to be Free 13m ral, aeady approved by PMC, shall be tansferred by road trae to spectied locations and shal be placed end to endin paisGR, | boe. Nos "Method Statement ~ Track Laying for Depot éceytacmsjon connectivity Revlon: | 00 ‘PROVECT: Eastern Dedicated Freight Corridor (Package 201 & 202) a [Conversion of 13m single als to 260m long panels would be done inst on formation, ‘byMobile Fash Bult Welding plan, working in mobile mode. In his case Ral wil remain ‘stalonary and Maile woling plan will move lo each joint for weting. Ateratvely Welding plant wl be kept stalonary and LAR sing wl be moved forward 13m by tractor on role conveyor and next ral fed into poston. This process wl be ‘epested unt the requied sting length is acioved. Detaled Methodology and Test plan for Flash But Welding ie covered in separate Netod statement ready approved. Spreading, Laying & Regulat 10.1 Pre Ballasting over Blanket Laver > Tack ligament shal be marked by 2 surveyor a5 per designed centerline ofthe horizontal alignment at 20m {fr straight) & 10m (for curved) intel a5 per spproved track eo-ocates by Total Station, ‘sting lin le pulled to mark ballast edges for guidance of staff oy fst layer af tas. Price othe commencement finial Balas lylg, an approve RE from PMC wile ensued that the formations complete fo lying of ballast. ‘Akeady tested and approved ballast from selected quaries or stacked at ‘nominated location alalong the proposed tracker stacked on formation ullbe {spread on completed formation io required quantities with the help of Dumper {Grader in two compacted layers of 100 rem each ach aye of Salas il be compacted wth vibratory oad rll iin inimum | passes foreach aye. Batast top level in center ofeach rack wile kept lower to avid center binding of sleeper. (on completion of Balast bod, Visual nspction shall be carried out joint wth Engineer to record observations on under mentioned pains, Approved Balast used forint layer “Yes/No With offaid Boast is adequate ses No Balast Depth okatevery20minteral = Yes/No Contes tine fs marked Yes/NoMethod Statement ~Track ying for Depot PROJECT faster Dedated Freight Coridr (Package 201 & 202) aay reefs ceonneetiaty INITIAL BALLASTING WITH ‘CENTRE LINE MARKED ‘Track Installation 11.1 _Auailiary Track Laying: Mechanized slf-propeled Portals are proposed to be deployed for unloacng of sleepess and long weld alison the proposed alignment For Operations and runing of Mechanized self-propelled Portal, we propose to make one km of Aviary trackof 3m gage for starting the work with Ral ‘Aternatively we may alto use the LR panel which has been moved to site via rollers for linking Auiary track deending upon te site conditions ‘The Ausiary track willbe dismantled 8 carried forward and li shes for ext day's wore fonce tack has been linked in the particular patch. However 300 m of aur track wil sways be let along the newly linked track for movemant of petals $0 as to faciate tunloacing & carving of PC sleepers and long welded ra panels from special purpose rail and PSC sleeper carries 41.2 Tracklaving Activities SC sleepecs shall be wansported to ste by special purpose cartes Sleepers willbe unloaded fom these special carers, which have atved a se by thal own ‘motive power from the bse depot of PSC sleepers.PROJECT: Eastern Dedicated Freight Corridor (Package 201 & 202) oe. Ne ‘Method Statement = Trak ayng fr Depot 2FCcfTae/NsOn connectivity Revson: 00 ‘Seepers shall be spread on the proposed alignment at proper spacings by Self propeled “Mechanized Portal and lid onthe pre prepared ballast bed to the corectline, lve and spacing a per the specifications > rubber Pads & Elsie Clips are stibuteon athe lepers for ing and fastening of rack > 260 m weed rail strings willbe placed on sleepers by Ral Threader and Track fastenings arefved. "Non welded alin willbe jointed temporary wth 1m long fshpatesand“C"darmps tl they are welded 260m long welded call pane ace futher welded IN-SITU by 2 Mobile Flah bute Welding Pant to convert 260m pane nto 1040 log panel after supplementation of balat and ‘manual pacing ny damage caused to DEC ack Ralls or Sleepers during em mechanized laying stall be replaced Modification of track /OHE / Signal work willbe executed by IR and hence traffic lock wil also be arranged by IRPROJECT Eastern Dedicated Freight Corridor (Package 203 & 202), a rete GAR mens ae Revlon: | 00 11.3 Post tracklaving operations: ‘Track Parameter correction + Once the days work of track ning I fnishes, Squering of PSC sleepers, Algnent and other tack parameters wl be checked and rected if necessary. Boxing & Dressing Ballast ‘+ Required balst for bong and filing wil be unloaded by all cum Road Tuck / satin houte developed ackhallast cares. 18 and loaders shal be usedto load ‘these ballast carers / Tuck. ‘+The bolas carers will unioad the balast on newly lnked track continuously from fe end to other The vloaded ballet wil be Ud for boxing ond filng of cribs ane shoulders of he newt inked track per designed balls profi, to feltate tng of track and achievement of eaured cushion. Track Tamping ‘+ To bring track geometry within mits, packing of track stall be done by off track Tampers To bring the track to designed alignment and level, reference shal be taken from reference sakes eretes eater after completion of cil werk [Adaisonal round of ballastn, lilting and packing wil be implemented tl track reaches the fina evel and algrnent. Super elevation and versine fr horizontal & ‘erica curves shall be provided as per designed vale. Finally track wil be taped by C Track taping machine to correct track geometry. ‘After achieving the desired track geometry as ern down standard, ballast salle Property dressed to complete the profile s per LWR manual 11.4 Conversion to CWR and De-stressing Conversion to CWR shall be done ol after Machine packing and dynamic sablisation of track, Detaled Methodology and Test pan for conversion of WR Inte CW anc De stressing covered under separate Method statement‘PROJECT: Eastern Deccated Freight Coridor (Package 20 Re ‘Method Statement ~ Trak Lyirg for Depot orca cece [ee 12 Environmental management ‘The purpose of the Envirenmental Management process to ensure Works are planned, cared out and contrlled which contributes to the long term protection ofthe Region and Local Environment. Comply with the relevant acts, contractual and legal requirements, Continually inprove the environmental performance, Correct eisposalof dangerous substance, 13° Job safety analysis, Risk Assessment Safety induction courses and tralnng shal be even tal elevant sta and workers ror to commencement of tock works at worksite. [A the commencement ofthe respective tasks al Track lying works Personnel shall be taken throug the Pre Work Briefing by the Superisor and shall sign the _chnowledgemert form confiing that such insruction as necessary has taken place “The kay isk 0 follow: Manus handing, Covpling and sncouping materials ain from TRACK LAYER “Mechanically moving parts arms kag) Working in hat, Wied oF Dust, Materials loading and unloading, Gantres moving on top ofthe materials train, Fallure of fig, locking & dragging equipment Teac management/protecion at level crossing Precaution ding ral panel handing to avoid injury Emergency response plan 13.2 General Safety > All persons wil wear standard personal protective equipment which as @ minimum wil indude hard hat, Hiv vest or shirt and safety footwear. Where specie risks are ideniied mere specaised protective equipment willbe issued and used. f‘PROJECT: Eastern Dedicated Freight Corridor (Package 201 & 202) im Doe to: ‘Method Statement = Tack Laying fr Depot ddd orcerraeyms/o. ‘connectivity trinng in the use of PPE is required this wil be ven to specific workers and recordedon 2 Mati AAPrework Se sha be caries ou by te supervisor prot to esa ec Si 12: new task, wih all relevant personnel attending, to adress spec areas of cncer or new hazard or acts that may fect the work tobe cared out Pre- work Briefing shall be recorded with al attendees sgring the attendance shee. Completed forms ae tobe returned tothe safety deparement for ing and audit parposes Weelly Tool-box tals shall be conducted by the supervisor and personnel valved ior to the commencement of works. Safety toolbox records tobe furished to PMC. The aim ofthese meetings sto focus on health an safety issues and any other vorkrelated issues that personnel may wish to raise. These meetings shall be ‘corded wit ll attendees signing the attendance sheet. Completed forms are to brretured tothe safety department fr fing, ‘rks generally intended tobe undertaken during nal working hur, but work fostside of normal hours, and right wotk, shall be cred out asthe programme requires o for ether operational reasons. _Asequat lighting shal be mad avalale in care of ight work. Safety warring signs shall be placed to prowde adequate warning fed & Green Fag with requled manpower shall be posted during operation of Machine for the safety of workers Red Banner Flag shal be placed i rear ofthe machine to warn the operators of other machines working in ear. Fest id kts shall be provide to all ight vehicle, tool trucks, work rains, tack ‘machines an ll designated work bases. These ae for emergency use en, and to ‘movie inital treatment until specialized medical care avaiable. A Gsinated first 3d person sal be nominated in every work crew. ‘oetfecive means of communication shal be established foreach wok rou.Method Seatement~ Tack Laying fr Depot becerreayMso1 ‘connectivity FROJECT: Eastern Dedicated Freight Corridor (Package 701 & 202) owes Jad Appendix A: TP ‘Activity including | Reference | Acceptance Remark ‘| necessaryinspection | document ____criterion Preliminary [ Reproval/ authorised | MTCC | Document to be Wack material check Document for Ral Sleeper verified BRA to Ist approved RF Fiting bbe approved [Approvalorthe raiwelas | MTEC | Oocument tobe | Tack wateral check Test welds in place verified & RFD | ist & approved RF! bbeaporoved | Inease af werks District | Scope & | Document tobe | Pre TRACK AYER ‘Admbisraton approvalin | Method | verified work checklist pace statement Ensure bottom ballet bed [Bottom | Checklist tobe Pre TRACK LAYER 'ssutable for sleeper avrg | ballast laying | verified & RFI to | work checklist & methodology | be provided ___spproved EL ‘Ffset center tine pegs | Setting out | Check ist tobe re TRACK LAYER fetabished toconvol | of design | verified ARF Io | work checklist & sigamentof track track beprovided | approved AF ‘conetrucion coordinates seper MS | Sleeper tying t Verity concrete dlesperiaid | WEE Check Tat tobe TRACKTAYER correct spacing theyare | Speciation | verified working checklist & | Square & pods ae installs approved FL Ral installation & fastening Ensure al alsa taled | WS Checklist tobe TRACK LATER sper specticationand | Specification | verified working checklist & siting Raton Pads [" approved af erty that al fatonings [WEE ‘heck ist wba TRACK LAYER reapplied & salisfully | Speciation | verified wotking checklist sloped AC Si _|sppeoved a Oy T 69 owe RepresentativePROJECT: Eastern Dedicated Freight Corridor (Package 201 & 202) oe. Method Statement ~ Track Laylg for Depat oFceyraky so. connectivy ‘Anpendix8: Track Laying check ist item] Reity Reference | Aezwplance rteron | Vefeation/ | Obser No| document | inspection | vation [oni 1 LI [As peritSTI2SAL—__| Verification of Vercation of inspection cetiate, weld | document for document testcartieat, Test wld | compliance rests Tal panelunloodire rom —| al panel unloading = rake er DSO guide. ne. fall rgister upéated |__| Tai panel stack inspection | Rai pane tacking is | Val hspecton & er approved rowing | RF forralpanel snproved Sleeper a ’As par ROSO drawing RS/ | Verifiation of Verfiation oF | r39manufacturer Test | documents for docament corfiate Inspection | compliance cortiieate Test report | ‘leper unloading, ROS guides | Viualnepacion & stocking Binspecion | flowed for sleeper | RFito be approved stacking. Proper stacking with right size wooden dunnage. Sleeper { reqister to be updated 30 eRe | ‘As par ROSO drawing. | Verifation of Manufsrurer MTC /ic | documents for | Vsuainipection& verification f| compre Repbert | donment be updated “As per RDSO drawing. Verification of 1 War inspection & WanutacurerMte/'€ | docamets for | verifieaton of omplancRepierto | ociment beupdsted Tepe fOSD devine | Vsextonaf salnaecion& Representative Representative7 : OR ee \WeLp or oF pan soineno. | P| chainage 9 au rey sepresenctve age 5 of 18PROJECT: Eastern Dedicated Freight Corridor (Package 201 8 202) | [IIE Doe. ‘Method Statement Track 2yng fer Depot : orcc/Tae/vson connectviy ‘Appendix D Post Vorking Check Uist Track Laying Reference document | Aezeptanceeteion | Observation Verify sleepers | As per specification & Sleeper density 1660" laid at “corec| Methodstatement per km. Rall pads spacing, they are inte caret | square and pact Damaged sleepers reinstalled removed Ensure Rais ae [As per spedfeation & Vil inspection of | instaled 2s per| Method statement rail damage, No det / speaiieation 8 debris on ral seat siting lat on pad Ensure ringing of underfoot of FB weld its for those coming Mechanical jointing of call joints. Gaps between the ral panels sutably foreted Verivai 7 per speciation &] Zero missing Reng. fastening pled | Metnod statement | Damaged Finer & In accordance fastenings replaced. wth the GEN liners correctly | speciation | fixed. Temperature to be recorded at the | ime of xing ERC [reek conection [A par speciation & Lateral algnment of Methodstatement | wack comected to make track ft for ‘materi train, Vertis ‘ligament of wack, cross level, twist coveted 2 make ‘rack fit for material | Loin & ack machines pc Representative Representative