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