CONTRACT C830

contract C830

pmf submission

group 41 trackwork

METHOD STATEMENT

Mainline TRACK

INSTALLATION Plan

PMF

THE APPLICABLE DOCUMENT REVISION IS THE ONE AVAILABLE IN THE REFERENCE SYSTEM

Reference systemConfidentialityBroad distribution

Software / Filename :WINWORD 97 / 83001-07-Y000-MTI-0001_B.doc

RevDateModifications ContentWriterFunction

A02 July 2005First IssueR.MENONTrackwork Engineer DOCPROPERTY "Manager" \* MERGEFORMAT

B23 June 2006Second IssueR.MENONTrackwork Engineer DOCPROPERTY "Manager" \* MERGEFORMAT

Group VerificationH.L.SngGroup ApprovalJ-F. CHASSIN

Entity / FunctionConstruction ManagrEntity / FunctionTrackwork Manager

Date & Sign.02 June 06

Date & Sign.02 June 06

Verification P. DUPONDApproval J. PERKINS

Entity / FunctionProject ManagerEntity / FunctionProject Director

Date & Sign.

Date & Sign.

Reserved to the Engineer

T A B L E O F C O N T E N T S

61.introduction

2.REFERENCE DOCUMENTS AND DEFINITIONS72.1.Reference documents72.2.Applicable documents72.3.Definitions83.PLANT, EQUIPMENT AND TOOLS93.1.mainline Standard methodology93.2.Mainline Alternative Methodology94.MATERIAL114.1.Incorporated in the final product114.2.Supplies required for the activity125.LABOUR135.1.Mainline Installation Workforce136.MethodOLOGY146.1.Survey146.2.Installation Temporary Track at shaft146.3.Installation of temporary Turnout156.4.Tracklaying156.4.1.Turnout laying156.4.2.Welding156.4.3.Tracks and turnouts adjustment166.4.4.Cable trough and drainage installation166.4.5.Concreting176.4.6.Conductor rail installation186.5.Walkway Installation186.5.2.Position of walkway196.5.3.Transportation and distribution of High level walkway components196.5.4.DURING TRACK PANEL LAYING196.5.5.installation of the temporary support jig and positioning of walkway support196.5.6.POSITIONING AND installation OF LEVELING SCREWS AND SUPPORT BRACKET226.5.7.FINAL ADJUSTMENT OF HIGH LEVEL WALKWAY SUPPORTS236.5.8.REMOVAL OF LEVELLING SCREWS AFTER CONCRETING236.5.9.INSTALLATION OF STEP UNITS246.5.10.DELIVERY OF WALKWAY COVERs (COPING SLAB) AND CHEQUERED PLATE HINGED COVERs246.5.11.installation of walkway covers (COPING SLAB )266.5.12.INSTALLATION OF CHEQUERED PLATE HINGED COVER276.5.13.INSTALLATION OF cross passage ramp and walkway ramp at turnout276.5.14.Inspection method of walkway306.6.Stress Equalisation (TEST TRACK) and homogenizing306.7.Cleaning306.8.Electrical Testing306.9.As built Survey306.10.Records317.Sequence of works328.Y-Junction33 Sequences of work of Y-Junction:349.INSPECTION AND TESTING359.1.Inspection method359.2.records3510.SAFETY36

1. introduction

This document purpose is to describe and define, from a construction point of view, the requirements for Mainline installation of Trackwork and Conductor rail for the Circle Line Project.

According to site constraints two methods of installation could be performed:

1. Track installation piece meal or by gantry

2. Concreting- Direct Pumping or by Concreting Train

2. REFERENCE DOCUMENTS AND DEFINITIONS

2.1. Reference documents

Standard UIC code 860/0 Technical Specification for the supply of Rails,

Standard UIC Code 861/3/0 60 kg/m Rail Profile, Standard ASTM E 709,

Standard ASTM E 164, Technical specification for the following:1. Turnouts,2. Sleepers,3. Concrete,

4. Conductor rail,

5. IRJ,

6. Cable trough and drainage.

7. Sp Vipa Baseplates

2.2. Applicable documents

Contract 830 DCPS,

DAR/830/TRW/3001/BLine General Layout CCL 1 & CCL 2

DAR/830/TRW/3016/AConductor Rail General Layout CCL 1

DAR/830/TRW/3017/AWalkway General Layout CCL 1& 2

DAR/830/TRW/3016ATypical Details at Crossover Location CCL Stages 1

DAR/830/TRW/3002/-Location & Arrangement of Turnouts At DBG Station Sheet 1 of 2

DAR/830/TRW/3005/-Location & Arrangement of Turnouts At BLV Station Sheet 3 of 3

DAR/830/TRW/2003BLocation & Arrangement of 'Y'-Junction Between CVC and MLN Stations

DAR/830/TRW/----Y'-Junction Sectional Details

DAR/830/TRW/-----Fuel/Oil Storage & Oil Interception Detail In Staging Area

Method Statements :Refer to clause 3.1

2.3. Definitions

MLN-Millenia Station

CVC-Convention Center

MSM- Museum station

DBG- Dhoby Ghaut

UPL-Upper Paya Lebar

IT INNER TRACK

OT OUTER TRACK

3. PLANT, EQUIPMENT AND TOOLS

3.1. mainline Standard methodology

Equipment and tools are specified in different method statements for the main line. Please refer to these method statements.

Survey 83001-07-Y000-MTI+101,

Pre-assembly panels and track laying 83001-07-Y000-MTI+102,

Flash-butt welding 83001-07-Y000-MTI+103,

Formworks and track adjustment 83001-07-Y000-MTI+104,

Concreting 83001-07-Y000-MTI+105,

Track Stress Equalizing 83001-07-Y000-MTI+108,

Thermit Welding 83001-07-Y000-MTI+109,

Conductor rail installation 83001-07-Y000-MTI+110,

Turnouts pre-assembly and installation 83001-07-Y000-MTI+106,

Buffer stop 83001-07-Y000-MTI+107,

IRJ 83001-07-Y000-MTI+113,

Cable trough and Drainage 83001-07-Y000-MTI+112,

Signs and Markers 83001-07-Y000-MTI+114,

SCCCS 83001-07-Y000-MTI+117 ,

3rd Rail Testing 83001-07-Y000-MTI+122,

Work Train Operating Procedure 83001-07-Y000-MTI+123,

Electrical Testing 83001-07-Y000-MTI+124.

3.2. Mainline Alternative Methodology

The plant and tools used for the alternative method will be listed as per the depot method statement:Equipment used for piece meal method will be:

1 Mobile crane,

1 Forklift,

1 Tetra Truck

Track tools.

Rail Changers

Rail rollers

Direct Pumping

Concrete trucks,

1 Mobile concrete pump,

Concrete pipes (125 mm internal diameter),

Concreting tools.

4. MATERIAL

4.1. Incorporated in the final product

Precast sleepers equipped with fasteners,

Single blocks,

Rails UIC 60,

Turnouts,

Concrete,

Weld kits,

Welded Mesh

Conductor rails,

High Speed ramps (for test track),

Low Speed ramps,

Expansion joints,

Brackets,

Anchors,

Insulators,

Protective covers (standard, expansion joints,),

Fastenings,

Splice joints,

Bolts,

Huck-bolts,

Nuts,

Supports for protective covers,

Cable Terminals,

Pads for brackets,

Cable troughs,

Drainage System,

IRJ,

Buffer stops,

Signs and markers,

Ducts,

Jumper box,

Vipa Baseplates.

4.2. Supplies required for the activity Oil,

Diesel,

Formworks,

Form oil,

Nails,

Screws,

Abrasive cutting disks,

Lubricants,

Timber Wedges,

Specific formworks (for lateral adjustment in case turnbuckles could not be applied on platforms or columns) please refer to the figure 1 below:

5. LABOUR

5.1. Mainline Installation Workforce

Foremen,

Skilled labourers,

Unskilled labourers,

Surveyors,

Track laying gantry operator,

Concrete pump operators,

Shuttle hopper driver,

Thermit welders,

Workstrain operators,

Workstrain Shunters.

Workstrain Supervisor

Riggers

Safety Supervisor

Lifting Supervisor

Signalman

Surveyors

Assistance Surveyors

6. MethodOLOGY

6.1. Survey

The setting out will be performed in accordance with the drawings and the method statement Survey reference 83001-07-Y000-MTI+101. Reference points used for the construction shall be marked on the trackbed and platforms performed by Civil Contractor.The survey offset marking will be done on the tunnel lining .

6.2. Installation Temporary Track at shaft

A temporary track will be built using the piece meal method.

This method is same as the Depot track method statement ref: DAR/830/TRW/0047_F. At the shaft location the extreme end of the opening at the track level will be blocked of with temporary bund wall to prevent rain water and concrete lattence from flow into the tunnel. A skecth of this drawing shown below.

Plan View

6.3. Installation of temporary Turnout

Temporary turnout will be laid at the Dhoby Ghaut cross over box. This is a radius 190m and 1:7 turnout. This turnout are with timber sleepers. The turnout will be transported to site and lowered in the shaft at DBG. The installation of the turnout is as per the Depot turnout installation method. A forklift is lowered in the shaft and this will assist the installation of the turnout. Addition percaution is taken as per the safety requirement . There would be regular check on the turnout and additional fire extingusher will in place as per C830 Safety recommendation.

6.4. Tracklaying

SCCC mesh will be installed on reception tracks and will terminate at the IRJs located on reception track at the entrance of the depot. SCCC mesh in the tunnel section are transported by wagons and will be laid manually.

Track will be pre-assembled in staging area in panels which will be laid by means of a track laying gantry as described in the method statement Pre-assembly panels and track laying reference 83001-07-Y000-MTI+102. The track pre-assembly will be laid by means of gantry to the offset line marking given the survey.

During the preassembly the sleepers and rails are orientated such that the the logo and the ID marking are facing the walkway side.

Some section of the tunnel will be constructed by means of piece meal method similar to the depot installation and manual tracklaying installation method staement have been submitted separately.This section will be the shunting track at the shaft , the over run track at DBG and the tracks from Depot to UPL Station.Reference: 83001-07-Y000-MTI+047

6.4.1. Turnout laying

Turnouts will be pre-assembled on the staging area and checked by the Engineer. Turnouts parts will be then transported by works train to the site and installed by means of specific device. (please refer to the method statement Turnouts pre-assembly and installation reference 83001-07-Y000-MTI+106). 6.4.2. Welding

The rail will be joined using the welding method described in the method statement Flash Butt Welding reference 83001-07-Y000-MTI+103.

Thermit welding could be also used according to cases. Please refer to the method statement Thermit Welding reference 83001-07-Y000-MTI+109.

6.4.3. Tracks and turnouts adjustment

The method of adjustment will be the same as described in the method statement Formworks and Track adjustment reference 83001-07-Y000-MTI+104. Turnbuckles used for lateral adjustment will be applied on platforms and depot columns installed by Civil Contractor before Trackworks.

In case where the track is not close by platforms and columns, turnbuckles will be applied against specific Formworks.

The track is lifted to the approximate level with in +/- 10mm of the design leveland is supported by means of a temporary steel chair . This temporary support will be removed once the spindles are in place and adjusted to final level.( Refer sketch below).

6.4.4. Cable trough and drainage installation

Cable trough and drainage will be installed as described in the method statement Cable trough and drainage installation reference 83001-07-Y000-MTI+112.

In principle, cable trough will be installed during the 2nd phase of concreting.

6.4.5. Concreting

6.4.5.1. By Concreting Train

Concreting of track and turnouts will be performed as described in the method statement Mainline Track Concreting reference 83001-07-Y000-MTI+105.

Concrete delivery will be performed by concrete trucks to a mobile pump, which then will deliver concrete to a concrete shuttle hopper, etc

The bonding of the first phase and the second phase will be done by either applying a bonding agent or by chipping. Turnout concreting will be done as a separate operation with direct pumping . The recess at the turnout area will be done as a intermediate concrete before installing the turnout.

6.4.5.2. Concreting direct pumping

Main plant and equipment:

Concrete truck mixers,

Concrete pump,

Concrete pipes.

Concrete will be delivered by concrete trucks directly to a concrete mobile pump and then concrete will be poured by means of pipes on the track concreting area.(Direct pumping Method).

6.4.6. Conductor rail installation

The conductor rail will be installed using method described in the method statement Conductor rail installation reference 83001-07-Y000-MTI+110.6.5. Walkway Installation

Surveyors will set the walkway unit position before installation work can be carried out.

Walkway support base will be embedded after the second stage concreting of the mainline track slab The walkway will be concreted by means of the shuttle .

6.5.1.1. SURVEY SETTING UP

As defined on the Survey Method Statement ( ref. 6.2.3. ),The finish rail levels and chainages will be marked on the tunnel wall in the same intervals with marker pen. For straight, a single value will be marked on the wall whereas for curves, the left rail level and right rail level will be marked on the respective left and right walls.

6.5.2. Position of walkway

Once the track lifting is lifted lateral and vertical position, surveyors and/or survey assistants will mark the walkway support position at the rail foot on the field side area. This marking will only serve as a guide for the preliminary installation group. Minor vertical and horizontal adjustment will be done once the track final survey has been established.

6.5.3. Transportation and distribution of High level walkway components

6.5.4. DURING TRACK PANEL LAYING

The high-level walkway support will be loaded and delivered to the site and unloaded by hiab crane.6.5.5. installation of the temporary support jig and positioning of walkway support

The walkway support installation teaml perform their work in behind the track adjustment team.

The walkway will be adjusted on its approximate level with the aid of the finish rail level marking by survey. The walkway support will be lifted

and positioned to its approximate position by using a purposely-made Frame or equivalent ( see figure 2 )

Sequence of installation;

1. The walkway support jig will be slotted-in and the front support props bracket shall be positioned in place.

2. The 22mm diameter long rod shall be inserted through the front support props bracket to the holes provided at the center of the walkway support.

3. The rod will be secured with flat washernut at the other end, thus, this will also secure the front support props bracket installed in front.

4. The adjustable coupling shall be inserted at the end of the rod near the tunnel wall.

5. The walkway support jig with lifting plate will be hooked to the Frame or equivalent and hoist the walkway supports into position.

While sequence no. 5 is being performed, preparation is being done on the other walkway supports by following sequence nos. 1, 2, 3 & 4.

Once the track has been lifted to its approximate position;

6. By the aid of an approved Alignment and Level Jig (see fig. 2), the walkway support will be vertically adjusted and positioned parallel to the running track.

The same sequence will apply on the remaining walkway support.

6.5.6. POSITIONING AND installation OF LEVELING SCREWS AND SUPPORT BRACKET

7. After the walkway support has been lifted to its approximate position, the levelling screws will be inserted to the nut sleeves. They will be adjusted up to the extent that they carry the load of the walkway support. Once it is stable, the A Frame or equivalent shall be transferred to the next walkway support.

Once the track has been lifted to its approximate position;

8. The rear props (bracing) will be inserted to the rod end and adjusted against the tunnel wall. A timber wedge shall be provided between the metal and tunnel wall to avoid damage to the tunnel lining.

9. The other end of the pipe shall be positioned to fit in the front support props bracket. The threaded rod with the adjustable coupling will be inserted to the front support props bracket. The other end of the support pipe will be inserted to the threaded rod and the V shape end of the

support pipe shall be inserted to the foot of the rail. The adjustable coupling (side props) shall then be adjusted to suit the required distance until it is reasonably stable.

This sequence will apply on all remaining walkway support being adjusted.

6.5.7. FINAL ADJUSTMENT OF HIGH LEVEL WALKWAY SUPPORTS

During the final survey and track adjustment, the walkway final installation group will follow behind. The final vertical checking and adjustment will be done using the top of rail as a reference (260mm 10mm). With the aid of the approved Alignment and Level Jig, the walkway support will be adjusted by turning the levelling screws to the required level. At the same time, during the same process, the longitudinal dimension (1011.5mm 10mm from gauge side to face of support) will be checked and adjusted.

Final adjustment of the walkway support verticality towards the track at the canted section will be done by adjusting the levelling screws located on both sides of the Alignment and Levelling Jig in line with the rail head. Adjustment of levelling screws will always be at the low rail. The walkway support is on its vertical position once the bubble on the attached spirit level is at the centre.

Prior to concreting, a final check and inspection on the walkway integrity, stability, horizontal and vertical alignments will be done. The results will be recorded and submitted to CCLP when required.

Walkway supports will be embedded after the second stage concreting of the mainline track slab. The walkway concrete will be done by the shuttle

6.5.8. REMOVAL OF LEVELLING SCREWS AFTER CONCRETING

24 hours after concreting, the levelling screws will be removed by using a mechanical ratchet or pneumatic impact wrench. The levelling screws will be cleaned and transferred to the next concreting section. Holes left the levelling screws will be filled with non-shrink grout of 30N/mm strength with the same method as the concrete sleeper holes.

6.5.9. INSTALLATION OF STEP UNITS

24 hours after the installation of walkway supports, step units will be installed manually with a maximum 10mm gap in between the two units.

A dia. 8mm X 100mm hot-dipped galvanised dowel will be inserted on holes provided at the pre-cast support unit.

The step unit vertical level will be checked in reference to the top of rail, which is 20mm nominal.

A levelling nut will be installed and adjusted to the correct level and height of the step unit.

The step unit will then be installed within the correct position and tolerance, both vertical and longitudinal (818.5 10mm from gauge side to the face of the step).

If required, a temporary support will be installed underneath the step unit.

Apply the 30N/mm-strength non-shrink grout as per suppliers recommendation and ensure that it is full.

Double-check the accuracy of the step unit vertical and horizontal position.

Finally, fill in the holes at the step units with not-shrink grout and apply necessary finishing touches.

The step unit shall not be disturbed until it gains the required strength recommended by the supplier.

For details about the rod, please refer to technical specification High level walkway reference 83001-07-D210-MTI+0123.

6.5.10. DELIVERY OF WALKWAY COVERs (COPING SLAB) AND CHEQUERED PLATE HINGED COVERs

After the cable installation has been done, the walkway covers and chequered plate hinged covers will be delivered to the site.

The walkway covers and chequered hinged covers will be loaded as per agreed loading schedule and procedure, to the delivery wagon with mounted crane through the shaft or any other access provided. (ref. Works train operating procedure 6.4.)

WALKWAY COVER (COPING SLAB)

The walkway cover will be individually off-loaded by the crane mounted on the wagon, on top of the walkway support approximately on its correct position by using the bottom edge of the chamfer as guide. A purposely-made (DEHA) lifting device designed to hook into the anchoring system will be used. (see fig. 3). The walkway cover will be temporarily secured by -M12 bolt.

CHEQUERED PLATE HINGED COVER

As required, there will be a 22KV cable joint connections every 500m length of track and/or as prescribed on the design. A maximum of 7 numbers of 1.990m (13.930m length) chequered plate hinged covers will be off-loaded in this area.The crane mounted on the wagon will handle the walkway cover. A purposely made lifting eye which is half threaded shall be inserted to the holes provided at the cover and secure by oval head nut at the bottom. (see fig. 4). The walkway cover will be temporarily secured by M12 bolt.

6.5.11. installation of walkway covers (COPING SLAB )

By the aid of the Alignment and Level Jig, walkway cover will be installed, checked and fitted to the support assembly. The walkway cover will be adjusted to its correct position and level by using a purposely-made A Frame or equivalent.

Maximum gap between two-walkway covers will be 10mm and minimum-seating width of walkway cover on walkway support will be 100mm.If the required level can not be obtain a rubber pad or equivalent with various thicknesses will be used as a shim, while maintaining the nominal 10mm gap in between cover as per design. The top surface of the support will be cleaned prior to application of the adhesive glue. The required timing of installation to acquire proper bonding between concrete and rubber pad or between two rubber pads shall be as per suppliers recommendation.

The final level between adjacent walkway concrete cover and chequered plate hinged cover will be within 3mm.

Once the walkway cover is on the correct position and level, the two M12 x 200mm hot dipped galvanised bolt will be inserted and fixed to the M12 x 80mm anchor provided at the walkway support. Grease will be applied on the M12 bolt & nut prior to filling of the hole with a low strength non-shrink grout.Final check on alignment and position will be carried out with the Alignment and Level Jig (see fig. 5) and the rate of change in alignment shall be 5mm per 1000mm spacing.

6.5.12. INSTALLATION OF CHEQUERED PLATE HINGED COVER

By the aid of the Alignment and Level Jig, chequered plate hinged cover will be installed, checked and fitted to the support assembly. The walkway cover will be adjusted to its correct position and level by using a purposely-made Frame or equivalent.

Maximum gap between two chequered plate hinged covers (2.000m) will be 10mm and minimum seating width of chequered plate hinged cover on walkway support will be 100mm.

If the required level can not be obtain a rubber pad or equivalent with various thicknesses will be used as a shim, while maintaining the 2 x 10mm nominal gap in between cover as per design. The final level between adjacent walkway concrete cover and chequered plate hinged cover will be within 3mm.

Once the walkway cover is on the correct position and level, the two M12 x 120mm hot dipped galvanised bolts will be inserted and fixed to the M12 x 80mm anchor provided at the walkway support.

Final check on alignment and position will be carried out with the Alignment and Level jig (see fig. above) and the rate of change in alignment shall be 5mm per 1000mm spacing.

6.5.13. INSTALLATION OF cross passage ramp and walkway ramp at turnout

Walkway ramps vary in length depending on its location and track alignment. Following each specific design shall do installation. The specified method of installation below is for general use.

To ensure that the pre-cast steps are centrally located to the concrete sleepers and cross passage, the centre line of the cross passage shall be taken into consideration during tracklaying and adjustment, prior to concreting

The Cross-Passage Ramp will be realised in situ following the sequence below.

Survey will set the correct position of the beginning and end of the walkway ramp. An offset gradient mark will be established at the tunnel lining to serve as a reference in the installation and counter checking of the walkway ramp.

Lay the bottom reinforcement (D13 reinforcing mesh).

Lay the 150mm conduits on top of the mesh considering the required cover.

Drive nails on both sides of the 150mm conduit at a reasonable space and put a tie wire over the conduit to secure it. This will prevent the 150mm conduit from floating during placement of concrete.

Extra re-bar will be installed if the height of the nail is not sufficient enough to hold the 150mm conduit at the slope section.

Apply cement mortar to maintain the concrete cover and slope going to the extremity on both ends of the ramp. It will also prevent the 150mm conduits from floating during placement of concrete.

Install and secure formwork on both ends of the ramp and provide holes for the 150mm conduits.

Erect, align and support the remaining formworks against movement.

If required, a form tie will be installed by drilling at the tunnel linings dimpled area.

Install 20mm chamfer.

Install and tie the top pre-bend D13 reinforcing mesh. Secure mesh with concrete blocks.

Concrete cover shall be 30mm minimum.

After final adjustment, survey team shall check the alignment and height of the ramp prior to in-situ concreting.

Pouring of concrete in situ according to Method Statements Mainline Track Concreting.

Apply curing compound after concreting by means of sprayer equipment.

Remove formworks the day after.

Cut the protruding form tie and re-touch/patch or repair the voids with cement mortar.

Continue concrete curing for 3 days.

Survey will conduct the final check (as built and 3D) on alignment and position of the cross passage ramp.

The walkway ramp going to the turnout area shall be constructed on the following sequence;

The 150mm conduit for 22 KV cables shall be positioned, connected to the cable pulling pit and secured from any movement by cement mortar. The required slope will be observed during this process.

The protruding 150mm conduits on the finish concrete surface during the second stage concreting of the track slab will be secured by tie wire to the side props (bracing).

A key shall be provided during the second stage track slab concreting to avoid featheredge at the ramp end.

For the walkway ramp (second concreting operation), lay the D13 reinforcing mesh with provision for the 150mm conduits.

The protruding 150mm conduits shall be positioned and secured from any movement by cement mortar. The required slope will be observed during this process.

Install and secure formwork at the end of the ramp and provide holes for the 150mm conduits.

Erect, align and support the remaining formworks against movement.

If required, a form tie will be installed by drilling at the tunnel linings dimpled area.

Install 20mm chamfer.

Install and tie the top pre-bend D13 reinforcing mesh. Secure mesh with concrete blocks.

Concrete cover shall be 30mm minimum.

After final adjustment, survey team shall double-check the alignment and height of the ramp prior to in-situ concreting.

Pouring of concrete in situ according to Method Statements Mainline Track Concreting.

Apply curing compound after concreting by means of sprayer equipment.

Remove formworks the day after.

Cut the protruding form tie and re-touch/patch or repair the voids with cement mortar.

Continue concrete curing for 3 days.

Survey will conduct the final check (as built and 3D) on alignment and position of the cross passage ramp.

The work sequence introduced above shall be employed on the remaining walkway ramps.

6.5.14. Inspection method of walkway

Level position of high level walkway will be controlled with track level and survey points.

During high-level walkway final adjustment, an approved Alignment and Level Jig shall be used to verify the level and alignment For more technical details please refer to the technical specification High Level Walkway reference 83001-07-D210-MTI+0123.

6.6. Stress Equalisation (TEST TRACK) and homogenizing

Please refer to the method statement Track Stress Equalising , reference 83001-07-Y000-MTI+108.

6.7. Cleaning

During trackwork construction activity, the tracks should be frequently cleaned (after concreting phase) by the mean of water high pressure group or similar equipment installed on a wagon or lorry. Also wastes will be frequently evacuated from the site, using trucks or works trains.

6.8. Electrical Testing

Electrical testing is explained in the method statement Electrical testing reference 83001-07-Y000-MTI+124.

6.9. As built Survey

As built survey will be performed by survey team. As-built track shall be analyzed to ensure the conformity to design track alignment. The track analysis spreadsheet in softcopy and hardcopy shall be submitted to the Authority for acceptance within two days of concreting please refer to Survey method statement reference 83001-07-Y000-MTI+101.6.10. RecordsInformation which will appear on the record form are: Date of work,

Track and chainage,

Position of high level walkway / with respect to track (offset and level),

As built 3-D survey.

Electrical testing

3rd rail testing

7. Sequence of works

8. Y-Junction

Please ref: M.S: DAR/830/TRW/0088_B

1) Specially made temporary concrete sleepers track panels required with a spacing of 1.4m center/center (refer to figure 3) will be pre-fabricated at the staging area.

2) These panels will be delivered and installed by the main line track laying crew following the Tracklaying Method Statement. The panels will be laid from the chainage were the Y-Junction starts (refer to figure 1). Approximately 3 panels are required for this section.

3) The rails will be temporary fish plated.4) The activity of tracklaying will continue normally up to DBG station.8.1.1. Sequences of work of Y-Junction:

9. INSPECTION AND TESTING

9.1. Inspection method

Inspection methods will be the same as described in the different method statements for the main line. Please refer to these documents.

List of controls:

Survey inspections (refer to method statement Survey, reference 83001-07-Y000-MTI+101),

Track installation inspections (refer to method statement Pre-assembly panels and track laying, reference 83001-07-Y000-MTI+102),

Concreting inspections (refer to method statement Concreting, reference 83001-07-Y000-MTI+105),

Production Welds tests, ( refer to method statement Welds tests, reference 83001-07-Y000-MTI+100),

Turnouts installation inspection (refer to method statement Turnout pre-assembly & installation reference 83001-07-Y000-MTI+106),

Conductor rail inspections (refer to method statement Conductor rail installation, reference 83001-07-Y000-MTI+110),

(Test Track) Track stress equalising inspections (refer to method statement track stress equalising , reference 83001-07-Y000-MTI+108),

IRJ tests (refer to method statement IRJ, reference 83001-07-Y000-MTI+113),

Buffer stops inspections (refer to method statement Buffer stop, reference 83001-07-Y000-MTI+107),

Cable troughs and conduits inspections, (refer to method statement Cable trough & drainage installation, reference 83001-07-Y000-MTI+112).

9.2. records

Information, which will appear, on the different record documents will be the same as described in the different method statements for the main line. Please refer to these documents.

10. SAFETY

Safety and environment risks and preemptive actionswill be the same as described in the different method statements. Please refer to these documents.

List of safety and environment risks and preemptive actions:

RISKSPRE-CONTROL risk Rating SEVERITYControl MeasuresResidual risk rating SeverityRemarks

PSRPSR

Train movement within the depot over completed and uncompleted tracks

248 All works train movements will be in accordance with the traffic schedule established for each works.

A shunter will accompany the works trains.

144

Fire incident248 Dry powder fire extinguishers will be kept with the team and the relevant staff will be trained in their use.

Use of safety PPE

133

Rail cutting process

Rail drilling process

248 Workers will be provided with gloves, goggles, and ear plugs

During operation no worker in front of the cutting machine.

133

Loading and unloading: hit4312 Qualified personnel and Lifting Supervisor to control and co-ordinate the movement of the machines.

PPE (Personal Protective Equipment) including reflective vest must be worn at all times.

144

Curing: air quality for workers

326 Workers shall be equipped with breath protection (mask).

212

Cleaning of concrete pipes with air pressure: Injury by pipe accident.

248All workers shall evacuate the concrete pipe area during this phase.144

Removing welding mould and performing rail shearing

4416 Workers shall pay due care and attention, taking into consideration the extremely high temperatures of the materials

Workers will be provided with specific gloves

133

Hammers: hit

236 Protection associated will be given to workers

212

Solvent using

4312 Workers will be provided with specific safety equipment during solvent using.

122

Resin using

4312 Workers will be provided with safety equipment according to manufacturers specifications.

122

Shot blasting / blank grinding

4312 Workers will be provided with specific safety equipment during shot blasting / blank grinding.

122

Heating process

4312 Workers will be provided with specific safety equipment during heating process

.

122

Trapping feet or hand under rail

248Personnel protective equipment (PPE) must be worn at all times during the work122

Track installation

Concreting

Grouting

Grouting of inserts first and later the gap between the Vipa baseplates and slab.

Water Pump

Temp Sump Pit

Concreting

Concreting using concrete works train following mainline concreting Method statement.

Coring

Coring of the marked locations.

Survey Checks

Final Survey Checks

Figure 1 Please refer to Appendix A- section 1 for calculations regarding specific formworks

Track Concreting

Flashbutt Welding

Construction of temp.bundwall and sump pit

Mobilisation of TLG,Loco,Trolley

Temporary T/OUT @ DBG installation

Bund wall

Grouting

After 24 hours, removal of Jigs and clean Vipa baseplates. Preparation of Circle Line track to receive grout under Vipa baseplates. Grouting. commence.

Marking

During no works trains activity, removal of the rails and installation on the Future Line track for marking future position of the Vipa baseplates.

Setting up

On completion of coring, move the rails from the Circle Line on to the Future Line track, set and final adjust the track.

Setting up

Removal of sleepers at Y-Junction area. Installation of Jigs and Vipa baseplate assemblies.

Final Adjustment

Final adjustment of the Circle Line tracks. Preparation of area for concreting works including Future Line Track.

Intermediate Concrete @ DBG

Tunnel wall

Conductor rail components

Lifting Team

Reinstatement of Circle Line Track

Place back the rails on Circle Line, clean and wash tracks.

EMBED Word.Picture.8

Walkway Delivery and installation

Tracklaying

Tracklaying of specially made panels through the Y-junction area with tracklaying gantry.

Reinstatement of Circle Line Track

Upon setting of grout, works trains movements are allowed to pass over this section.

For installation and concreting

Reinstatement of Circle Line Track

After marking, rails will be moved back to Circle Line tracks.

For delivery

Temporary Track @ Shaft

Preparation works

Survey works and prefabrication of temporary panels

FIG. 2

Track Panel Laying

Track Adjustment

EMBED Excel.Sheet.8

Fig. 3

EMBED Excel.Sheet.8

Fig. 4

Walkway Concreting

Installation of clayware

Installation of 3rd Rail

Final Finishing ( Destressing / IRJ /Electrical Testing/ Welding / Washing )

First Stage concrete

SINGAPORE

Circle Line Title: C830 PMF Method Statement Submission - Group 41 Trackwork

Mainline Track Installation

Project Reference: SUBJECT \* MERGEFORMAT 83001-07-Y000-MTI-0001Rev: BDoc Status:ApprovedDate: 23/June/06

Internal Reference:DAR/830/TRW/0208/A KEYWORDS \* MERGEFORMAT Page: 6 /39

Property of issuing entities, cannot be distributed or reproduced without authorisation.Ref. Form: UM07031E.DOC

_1123654305.doc

half round

steel mould

Special Jigs at 1.4m spacing

third rail support block

screws

steel plate

turnbuckle

Future Line

Circle Line

_1182256743.doc

Angle Bracket

Turnbuckle prop

levelling screws

Formwork

Gauge Bar/track support jig

Timber wedge

_1186386543.bin

_1213182947.doc

_1132996528.xlsJIGS

380mm 10mm

50mm

180mm

260mm 10mm

Spirit Level

Spindle for vertical adjustment

UIC 60

tolerance 10mm

Spirit Level

Spindle for vertical adjustment

UIC 60

tolerance 10mm

Lifting Belt

Lifting Device

FRAMES

LIFTING PLATE

LIFTING PLATE

LIFTINGROD

Sheet3

1. INSTALL WALKWAY SUPPORT LEVELLING JIG

2. INSTALL FRONT SUPPORT PROPS (BRACING)

.

3. INSERT 30 mm DIA. LIFTING ROD.

4. INSERT WASHER, NUT AND SUPPORT PROPS (BRACING)ADJUSTER

5. LIFT WALKWAY SUPPORT TO ITS APPROXIMATE LEVEL.

.

6. INSERT LEVELLING SCREWS TO HOLD THE WALKWAY SUPPORT WEIGHT.

7. INSTALL REAR SUPPORT PROPS (BRACING)

.

8. INSTALL FRONT SUPPORT PROPS (BRACING)

9. ONCE THE TRACK IS ON ITS CORRECT LEVEL, CHECK WALKWAY LEVEL AND RE-ADJUST AS REQUIRED.

.

1

2

3

4

5

6

8

9

7

_1130076825.xlsJIGS

380mm 10mm

50mm

180mm

260mm 10mm

Spirit Level

Spindle for vertical adjustment

UIC 60

tolerance 10mm

Spirit Level

Spindle for vertical adjustment

UIC 60

tolerance 10mm

FRAMES

LIFTING PLATE

LIFTING PLATE

LIFTINGROD

Sheet3

1. INSTALL WALKWAY SUPPORT LEVELLING JIG

2. INSTALL FRONT SUPPORT PROPS (BRACING)

.

3. INSERT 30 mm DIA. LIFTING ROD.

4. INSERT WASHER, NUT AND SUPPORT PROPS (BRACING)ADJUSTER

5. LIFT WALKWAY SUPPORT TO ITS APPROXIMATE LEVEL.

.

6. INSERT LEVELLING SCREWS TO HOLD THE WALKWAY SUPPORT WEIGHT.

7. INSTALL REAR SUPPORT PROPS (BRACING)

.

8. INSTALL FRONT SUPPORT PROPS (BRACING)

9. ONCE THE TRACK IS ON ITS CORRECT LEVEL, CHECK WALKWAY LEVEL AND RE-ADJUST AS REQUIRED.

.

1

2

3

4

5

6

8

9

7

_1072674049.doc

Concrete mixer &

concrete pump

Locomotive

Service Wagon

_1090216841.doc

First concrete stage ( by others)

Second stage concrete

Self propelled Shuttle hopper

Concrete pipe

Vibrator

Concrete pump

concrete truck

Concrete work train

100 m

_1062830082.doc

_992161066.doc