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GENERAL SPECIFICATION FOR BALLAST-FREE 1/13

EG - C - 407E
PERMANENT WAYS ON PRECAST CONCRETE MODULAR REV.
SYSTEM 2

REVISIONS
IT: ISSUE A - PRELIMINARY C - FOR INFORMATION E - FOR CONSTRUCTION G - AS BUILT
TYPE B - FOR APPROVAL D - FOR QUOTATION F - AS PURCHASED H - CANCELED

Rev. IT Description By Ckd. Appr. Auth. Date

0 C TO BE INCLUDED IN THE SPE JCC FSP HR MB 11/30/10

1 C GENERAL REVISION JCC LMM MB GJ 12/02/13

ITEMS 3.0, 4.0 & 8.0 REVISED AND

2 C INFORMATION CLASSIFICATION RPS LMM MB GCC 11/13/17
ADDED

This document is designed to advise and define guidelines for the development of Vale’s Projects. Its application and adequacy is under the
responsibility of the Project Team. Principles of safety and value maximization for Vale shall be taken into account.
Alternative solutions, that may be proposed by the contracted designers, should be directed to Vale's Project Team with the justification for
approval.

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TABLE OF CONTENTS

ITEM DESCRIPTION PAGE

1.0 PURPOSE 3
2.0 APPLICATION 3
3.0 REFERENCE DOCUMENTS 3
4.0 CODES AND STANDARDS 3
5.0 DEFINITIONS 4
6.0 SCOPE 4
7.0 GENERAL CHARACTERISTICS 5
7.1 SYSTEM COMPONENTS 5
7.2 FABRICATION OF CONCRETE MODULES 7
7.3 SYSTEM INSTALLATION 10
7.4 TRANSITION FROM A BALLAST-BASED CONSTRUCTION SYSTEM TO A PRE-
CAST CONCRETE TIE BALLAST-FREE PERMANENT WAY 12
8.0 HEALTH, SAFETY AND ENVIRONMENT REQUIREMENTS 13

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1.0 PURPOSE

This general specification defines the basic requirements for ballast-free permanent way on
pre-cast concrete modular systems used in Vale’s rail lines and railway yards.

2.0 APPLICATION

This specification applies to all Vale project development and implementation areas.

3.0 REFERENCE DOCUMENTS

Documents listed below have been used in developing this document or include instructions
and procedures applicable to it. They shall be used in their latest revision.

CP-B-506E Design Criteria for Railways

CP-C-501E Design Criteria for Concrete Structures
CP-N-501E Environment Criteria for Engineering Designs
CP-R-501E Health and Safety Criteria for the Development of Engineering
Designs
EG-C-401E General Specification for Concrete
GU-E-400E Glossary of Terms and Acronyms Used in Project Implementation

4.0 CODES AND STANDARDS

Codes and/or standards listed below have been used in developing this document or include
instructions and procedures applicable to it. They shall be used in their latest revision.

 ABNT – Associação Brasileira de Normas Técnicas (Brazilian Association for

Technical Standards)

NBR 5738 Concreto - Procedimento para moldagem e cura de corpos de

prova (Concrete - Procedure for molding and curing concrete test
specimens)
NBR 5739 Concreto - Ensaios de compressão de corpos-de-prova cilíndricos
(Concrete - Compression test of cylindric specimens - method of
test)
NBR 6118 Projeto de estruturas de concreto - Procedimento (Design of
concrete structures - Procedure)

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NBR 7212 Execução de concreto dosado em central - Procedimento (Ready-

mixed concrete - Procedure)
NBR 7480 Aço destinado a armaduras para estruturas de concreto armado -
Especificação (Steel for the reinforcement of concrete structures -
Specification)
NBR 7678 Segurança na execução de obras e serviços de construção
NBR 8400 Cálculo de equipamento para levantamento e movimentação de
cargas - Procedimento (Cranes and lifting appliances - Basic
calculation for structures and components - Procedure)
NBR 9062 Projeto e execução de estruturas de concreto pré-moldado
(Design and execution of precast concrete structures)
NBR 11768 Aditivos químicos para concreto de cimento Portland – Requisitos
(Chemical admixtures for Portland cement concrete -
Requirements)
NBR 12655 Concreto de cimento Portland - Preparo, controle, recebimento e
aceitação - Procedimento (Portland cement concrete -
Preparation, control, receipt and acceptance - Procedure)
NBR 14931 Execução de estruturas de concreto - Procedimento (Execution of
concrete structures - Procedure)
NBR NM 67 Concreto - Determinação da consistência pelo abatimento do
tronco de cone (Concrete - Slump test for determination of the
consistency)

Vale requires full compliance with regulatory standards issued by the Brazilian Department of
Labor and Employment, as per ordinance 3214, from June 8 th, 1978, and its updates, as well
as full compliance with effective local legislation health and safety requirements.

Legal requirements shall always prevail over the requirements herein, except for the cases in
which the latter are more stringent.

5.0 DEFINITIONS

General definitions, common to the universe of project implementation, may be found on

GU-E-400E.

6.0 SCOPE

Supply and implementation of the ballast-free permanent way on precast concrete modular
system in accordance to the technical characteristics, guidelines, procedures and executive

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methodology to be used in the fabrication of parts, described in the design, in this general
specification and in the corresponding technical requisition.

7.0 GENERAL CHARACTERISTICS

The modular system consists of a ballast-free permanent way in which the rails are laid with
continuous support on pre-cast concrete modules.

The railway design shall comply with the guidelines in SPE document CP-B-506E.

Figure 7.1 - Section type of single line

7.1 SYSTEM COMPONENTS

This ballast-free permanent way system consists of prefabricated reinforced concrete

modules that are laid on the sub-ballast (foundation soil). Pads are laid onto these structures,
and rails are positioned and fastened onto those pads. These elements are defined as:

 Concrete modules: prefabricated modular structures in reinforced concrete,

consisting of two beams wrapped in geotextile fabric and interconnected by
gauge bars. These structures are sized as per axle load requirements,
operating speed and the intensity/frequency of cargo transportation, and the
rolling stock to be used. The resistance of the foundation soil (sub-ballast) on
which they will be laid is also taken into account. These modules are
designed and constructed in accordance with the application site, rail
switches, circular curves, transition branches, and tangents. Curved modules
are cast straight, with clearly identified angled shoulders to which rails are
fastened, with the use of spring clips. They can be developed and used for
both single gauge (metric, international, large) and mixed gauge tracks.
Modules are designed in such a way as to allow for the production of pieces
with appropriate geometric sizes and weight aimed at transporting, laying and
final field positioning of the equipment. The number and application direction
of steel molds are shown in relief in some of the module's component legs.
The compressive strength of the concrete to be used shall reach the value
defined by the design at 28 days;
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Figure 7.2 - Typical module for mixed track – plan

Figure 7.3 - Typical module for mixed track - A-A cut

Figure 7.4 - Typical scheme of modules for use in rail switches

 Gauge bars: galvanized steel bars welded to steel rings girding the concrete
beams. Their function is to ensure that the track’s gauge is maintained;

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Figure 7.5 - Typical detail – cut

 Pad: consisting of a mixture of cork and rubber placed between the rail base
and the upper face of concrete beams. This material dampens vibrations
caused by rail traffic;
 Sub-ballast: selected layer of soil, treated or not, located on the top of the
railway platform’s fill, upon which the concrete modules will be laid. The
resistance of this support material is crucial for sizing the precast concrete
modules.

7.2 FABRICATION OF CONCRETE MODULES

The fabrication of concrete modules includes the following stages:

 Concrete modular structures design;

 Modeling and assembling steel forms according to the design and work
implementation schedule;
 Construction of the facilities for pre-molding;
 Inserting the rebar frame for the structure, placement of spacers, and
enveloping in geotextile fabric;
 Positioning the rebar frame, geotextile fabric/gauge bars, and steel rings on
the steel molds, and placing/attaching the steel grids;
 Pouring and compaction of concrete;
 Curing and formwork stripping;
 Storing modular structures.

7.2.1 Design of Concrete Modular Structures

The design of concrete modular structures shall take into account the geometrical
characteristics of rail track, the geotechnical characteristics of the sub-ballast, especially the

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support resistance; load per axle; the intensity and frequency of cargo transportation, the
typical rolling stock to be used, and the operational speed to be used.

The design shall take into account the requirements in standards NBR 6118 and NBR 9062,
and in document CP-C-501E.

7.2.2 Modeling and Assembly of Steel Formwork

The types and quantities of steel forms to be used for the works shall be sized and shaped by
using the dimensional and structural characteristics of the various concrete modules
considered for the rail project to be implemented and the planned construction deadline. This
sizing shall be carried out in a way that avoids the possibility of any deficiencies that may
result in the failure to meet agreed-upon deadlines in the project’s schedule.

7.2.3 Erection of Pre-Casting Facilities

Sizing the modular concrete structures’ manufacturing facilities shall depend on the needs
arising from the types and quantities of steel forms associated with the planned completion
dates. The execution of plant-mixed concrete shall comply with requirements in NBR 7212
standard and in document EG-C-401E. They may be located at points distributed along the
layout, if necessary, to reduce costs associated with the transportation of materials for
manufacture and products for application, taking into account, among others:

 The proximity to aggregate and water sources for preparing the concrete;
 The proximity to the power supply source for operating the industrial facility;
 Room for implementing the industrial areas, whether sheltered or not, and
areas for storing finished pieces;
 Easy access to the existing road system.

The specific needs for each project shall include:

 Concrete plant and areas for storing aggregates;

 Concrete reinforcement work facility;
 Sheltered area for pouring the modular structures’ concrete;
 A yard, that may or may not be sheltered, for curing finished pieces,
depending on the adopted process;
 Protected areas for storing industrial inputs (steel, geotextiles, galvanized
bars, and O-ring seals, steel shapes, concrete admixtures, etc.);
 A yard for handling and maintaining the concrete module inventory prior to
use on the track;

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 Water reservoirs with a planned strategic reserve in the event of any

problems in the operation and supply of inputs, etc.

The use of additives in the composition of concrete to be used shall comply with
requirements in NBR 11768 standard.

7.2.4 Structure Reinforcement, Placement of Spacers and Geotextile Fabric Enveloping

Concrete beams that make up concrete modules will be reinforced as per the structural
design provided. Rebar sizes and spacing requirements shall be complied with. Spacers shall
be placed in such a way as to ensure the required covering. Rebar frame is then wrapped in
a geotextile fabric envelope prior to being placed on the steel molds. The metallic material
shall comply with requirements in NBR 7480 standard.

7.2.5 Positioning the Rebar Frame/Geotextile Fabric Set, Gauge Bars, and Steel Rings
on The Steel Molds, and Placement/Fastening of Steel Grids

The set comprising the rebar frame and the geotextile fabric is placed together with the
gauge bar/steel rings on the steel molds as per the design for the type of piece being
executed. Then, prior to pouring the concrete, the steel grids are placed and attached to the
bottom surface of the concrete modules (exposed concrete face of the beam on the steel
mold) so as to form grooves on the part that will rest on the sub-ballast.

7.2.6 Concrete Pouring and Compaction

The concrete shall be poured with the use of a pump, with the aggregate ratio defined for the
mix, starting at the closed part of the geotextile envelope. The pump piping is inserted into a
hole located at the other end of the modules’ concrete beams. The pipe is removed as the
module is being filled until the piece has been completely filled. This can be seen as the
geotextile matting expands between the O-ring seals on the module’s exposed part. If air
bubbles start to form, they can be eliminated by sticking a sharp object into the exposed side
of the matting. The date on which the piece was made shall be displayed on the gauge bar.
Concrete preparation, control, receipt and execution shall comply with requirements in
NBR 12655 and NBR 14931 standards.

7.2.7 Curing and Formwork Stripping

The module shall initially be kept in the steel mold to cure. The piece shall only be removed
after at no less than 18 hours and when the concrete’s compressive strength reaches a value
of 6 MPa. Curing can be done by using chemicals, coverings, or water spray. The modules
shall be cured under cover for at least 4 days. Control of concrete applied shall comply with
requirements in NBR 5738, NBR 5739 and NBR NM 67 standards.

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7.2.8 Storage of Modular Structures

The parts may only be stored in a stack of no more than 6 units and separated by pieces of
wood so as to prevent damage after a minimum compression strength of 20 MPa has been
attained.

7.3 SYSTEM INSTALLATION

The system’s installation phase consists of the following steps:

 Turning, loading, transportation, and unloading the concrete structures;

 Placing the pieces as per the track geometry on the sub-ballast layer;
 Placing the pads over the concrete modules;
 Laying and fastening rails;
 Leveling rails according to the geometric design;
 Assembly of rail switches;
 Preparing the forms for regularization and closing the concrete module joints;
 Pouring concrete for regularization and between concrete module joints;
 Concrete curing;
 Releasing the track to traffic.

The execution of works shall comply with requirements in NBR 7678 standard.

7.3.1 Turning, Loading, Transportation and Unloading the Concrete Structures

Concrete minimum compression strength shall be 20 MPa for handling and transportation of
pieces on vehicles designed for such purpose, with maximum piling height of 4 units, for
application or intermediate support points, and with the same precautions taken during
storage. A method which does not cause damages to the concrete structure shall be used
when turning the piece so that it may be transported at the same position as it will be placed.
The requirements defined in NBR 8400 standard shall be considered for the equipment to be
used in executing of such activities, as well as in positioning of pieces as defined by the
design.

7.3.2 Positioning of Pieces as per the Track Geometry on the Sub-ballast Layer

The concrete modules are laid combining the track geometry to specific parts made for each
segment. The horizontal plane as per the geometric design shall have been adjusted at this
first positioning phase, preserving the joint to be considered (100 mm) between sequential
units, avoiding the need for any additional handling to the extent possible. The method used

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in the positioning the modules shall prevent damage from being done to their structure,
materials, and components.

In the case of rail switches, a 100 mm joint shall be used as reference, with the exact
distance between adjacent pieces being identified in the specific design.

7.3.3 Placement of Pads over Concrete Modules

After the modular structures have been laid, the pads are then placed along the entire track,
with the horizontal plane geometry having already been defined.

7.3.4 Laying and Fastening Rails

After pads have been placed, welded rail bars are laid and fastened, followed by the track’s
final horizontal positioning.

7.3.5 Leveling Rails

The tracks’ final leveling shall be done in accordance with the geometric design, and shall
allow a layer of concrete to be poured over the modules with a thickness ranging from 50 mm
to 80 mm, using appropriate equipment. Wedges may be used beneath the modules to
position them at the correct elevation. If track lifting jacks or any other type of equipment that
enables vertical alignment is used, their supports may only be located beneath the steel
components.

7.3.6 Assembly of Rail Switches

The procedure for assembling rail switches follows the same system described for the
continuous track.

7.3.7 Preparing the Formwork for Regularization and Closing of Concrete Module Joints

Once the final horizontal and vertical alignments have been made, the forms shall be
positioned and locked for the later pouring of concrete to regularize the modules and fill the
joints between them. This step will be carried out in two sequential phases. The first is
represented by the forms that enable the modules to be regularized, and the second for filling
the joints between them. The forms used to contain the regularization concrete shall not be
positioned at a distance exceeding 100 mm from the beams’ outer edges and with a height
not less than 20 mm above their bottom.

7.3.8 Pouring Concrete for Regularization and between Concrete Module Joints

This activity shall be developed in two equally sequential phases, starting with concrete
pouring to regularize the modules, which shall done to ensure the space between them and
the sub-ballast layer have been completely filled. Before pouring the concrete, the sub-ballast
surface shall be wetted down in order to prevent water from escaping the mixture and

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running toward it. Concrete shall age for 28 days, and compression strength shall be at least
15 MPa. The concrete may contain synthetic polypropylene fibers, or an approved
alternative, in the proportion indicated by the ratio in a way so as to prevent the mixture from
retracting. The concrete shall be poured only on one side of the concrete beam to get rid of
any air bubbles that may have formed underneath the piece.

7.3.9 Concrete Curing

Curing starts as soon as the concrete has been poured. The mixture shall be covered and
wetted down at least twice a day for the first two days. The cover may then be removed and
the mixture irrigated three times a day over the next three days. When choosing chemical
curing, the manufacturer's specifications shall be complied with.

7.3.10 Releasing the Track to Traffic

The track joints shall be welded as quickly as possible after the system has been installed so
the track can be released to traffic. No damage may be caused to the pad, steel components,
and the geotextile fabric during welding and grinding. Spaces in relation to the top of the
concrete module for welding to be carried out shall therefore be created on turnouts.
Whenever possible, track welding shall coincide with joints between modules. When that is
not possible, the welding surface plane (rail base) in contact with the beam shall be ground.

7.4 TRANSITION FROM A BALLAST-BASED CONSTRUCTION SYSTEM TO A PRE-

CAST CONCRETE TIE BALLAST-FREE PERMANENT WAY

If a transition is needed between the ballast-based construction system and the ballast-free
system using precast concrete modules, the structure to be prepared will take up a space of
around 15 m and shall consist of reducing the spacing between the ties in the section with
ballast and applying special transition modules with gauge bars on all of the spring clips, i.e.,
all fastenings. Although this transition may be carried out on curved sections, it is
recommended that it be carried out in tangent so as to avoid horizontal forces that take place
on the track in that situation.

Figure 7.6 - Transition segment of the construction systems – longitudinal cut

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Figure 7.7 - Special transition module – plan

8.0 HEALTH, SAFETY AND ENVIRONMENT REQUIREMENTS

A risk analysis shall be performed for each situation and design in order to identify, not only
the risks associated to the equipment itself, but also those resulting from its interfaces with
other system equipment, as well as from the environment in which it is installed.

Health and safety requirements described in document CP-R-501E, and the environment
requirements described in document CP-N-501E, shall be complied with.

QUESTIONS, COMMENTS OR SUGGESTIONS

For questions, comments or suggestions regarding the SPE, please access the online central SPE
Responde, available on the Project Portal, or contact us via email at spe@vale.com.

Your participation is essential for the SPE collection improvement and maintenance processes.

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