Quality In The Construction of

Turnouts

Trackwork Services Alliance

Charles Vuong & David Nguyen

22 - 23/05/14

Quality In the Construction Of Turnouts

Agenda

1. TSA – Who we are? What do we do?

2. How is quality ultimately achieved in construction through:

• Design

• Procurement/Manufacturing

• Prebuild

• Construction

3. Case study – Lithgow

4. Conclusion

TSA – Who We Are?

TSA – What we do?

Objectives:

1. Service delivery of turnout renewals

2. Rail industry objectives

Construction Methods

How Quality Is Achieved in Construction

Work Methodology

Increased efficiency

Quality Assurance

Culture and

Behaviours

How Quality Is Achieved in Construction

Quality of the end product will be influenced by:

Fix it here

How Quality Is Achieved in Construction

Design:

• Design for constructability

• Design for manufacturability

How?

• Constructor input / feedback at design stage

• Greater accessibility between constructors and

designers

• Collaborative design

How Quality Is Achieved

Manufacturing:

• Suitability of ordered components to site

• Manufacturing tolerances and design requirements are

met

• Compliance to design

How?

Site inspections before procurement

Manufacturing quality inspections

How Quality Is Achieved

Manufacturing:

• Procurement of materials to suit site requirements

Turnout to be

renewed

End of stockrail

(Aluminothermic weld)

Existing joint (flash butt)

600mm from end of stockrail

Plain line track not

to be renewed

Glued Insulated Joint

Cost:• Closure

• Weld

• Time

Impact on Quality

(additional weld in

track)

How Quality Is Achieved

Cost:• Truck Costs: $1400

• Modification of plates: $5750

• Safe Working: $1000

• Site Supervisor: $1300

• Labour: $1500

Total Cost = ~$11,000

Manufacturing:

• Ensuring No Manufacturing Defects through Inspections

How Quality Is Achieved

Prebuild

Case Study: Lithgow 77A/B, 78A/B, 79 &

81A/B Turnout Renewal

Quality In DesignCase Study: Lithgow 77A/B, 78A/B, 79 & 81A/B

Quality In Design

Quality In Manufacturing

Manufacturing inspection conducted:

1. Victoria

2. New South Wales

3. Queensland

Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B

Quality In Manufacturing

Customised Inspection Checksheet:

• Actual measurements recorded

• Acceptance only once manufacturing

tolerances and design requirements met

• Rectification list provided to manufacturer’s

post inspection

Quality In PrebuildPrebuild on level surface

• Entire shift prior to prebuild used to level surface

Quality In Prebuild

Self performing team

Quality In PrebuildPrebuild 16th – 24th January, 6 weeks & prebuild inspections: prior to welding

Quality In Construction

Lithgow 77A/B, 78A/B, 79 & 81A/B Points Renewal

Quality In Construction

Track Scope of Works

• Renewal of 7 point ends

• Full depth recondition

• Installation with PEM LEM’s

• Welding

• Resurfacing

Quality In Construction

Signalling Scope of Works

• Replace existing points motors

• Replace existing ESML with EOL

• Circuit modifications

• Relocation of signals

Quality In Construction

OHW Scope of Works

• Major OHW adjustments to

suit new track arrangement

• Installation 22off OHW

footings

• Erection 11off new OHW

structures

• Removal 6off redundant

OHW structures

Quality In Construction

• Safe & reliable product at end of possession

• No late possession handback

Quality In ConstructionQuality During Construction:

• Prior testing of material

• Allowing for contingency

• Customised ITP’s

• Live Survey

• NCR tracking

• PEM LEM

Quality In Construction

Quality In the Construction Of Turnouts

Outcomes

– Reduction in number of defects

– Reduced the risk of late possession handback

– Reduction in the cost of rework

– Increased scope deliverables

THANK YOU