Professional Documents
Culture Documents
VOLUME 4 PART 3 OF 3
Clause Page
GENERAL .................................................................................................................................................. 1
801.01 SCOPE...................................................................................................................................... 1
801.02 REFERENCES ......................................................................................................................... 1
OPERATIONS ........................................................................................................................................... 1
801.03 CLEARING.............................................................................................................................. 1
801.04 SURVEY .................................................................................................................................. 1
801.05 EXCAVATION IN GENERAL ............................................................................................... 2
801.06 NOT USED .............................................................................................................................. 2
801.07 FOOTINGS ON SOIL.............................................................................................................. 2
801.08 DEWATERING ....................................................................................................................... 3
801.09 ACCEPTANCE OF FOUNDATION SURFACE.................................................................... 4
801.10 BLINDING CONCRETE......................................................................................................... 4
801.11 BACKFILL .............................................................................................................................. 4
GENERAL
801.01 SCOPE
801.02 REFERENCES
Australian Standards
OPERATIONS
801.03 CLEARING
801.04 SURVEY
1. Survey shall be undertaken in accordance with the Survey Control requirements Survey
of Specification 100 GENERAL MANAGEMENT REQUIREMENTS.
2. Prior to excavation, a survey of the existing ground surface shall be carried HOLD POINT
out and approved.
3. Prior to excavation in rock, a survey of the rock surface shall be carried out HOLD POINT
and approved.
6. In general, the actual dimensions for excavation shall be no more than Dimensions
that required for the placement of protective works if necessary and any working space
required.
7. Unless otherwise specified, all surplus excavated material shall become Disposal of
the property of the Contractor and shall be disposed off site to the Contractor’s spoil Surplus
sites or other authorised waste disposal sites. Excavation
2. The Contractor shall compact the bottom of the excavation to 99% of Compaction
maximum dry density.
3. When foundations in Perth sands have been excavated the Contractor Perth Sands
shall compact the bearing surface and test the compaction with a standard Perth falling
weight penetrometer in accordance with AS 1289, F3.3. The minimum acceptable blow
count is 10 blows per 300 mm for the whole of the first 750 mm depth for all footings.
1. Where excavation for foundations is at or below insitu water table levels Water Table
the excavation shall be dewatered by pumping or well point dewatering prior to Level
commencing construction of any foundations and shall be kept free from water until
foundation work has been completed or sufficiently set or protected and the
construction and backfilling around the structure is far enough advanced to permit
dewatering operations to be discontinued.
5. Discharge of water from excavations into sanitary sewers will not be WRC Licence
permitted. Silt traps shall be installed to reduce the discharge of silt into existing
drainage systems. To discharge water from excavations into watercourses in
“Proclaimed Areas” requires the Contractor to have a licence obtained from the Waters
and Rivers Commission under the ‘Rights in Waters & Irrigation Act 19 14’
6. The Contractor shall provide for disposal of all water pumped from
excavations or any part of the Works in such a manner that at no time shall waste water
interfere in any way whatsoever with the use of adjacent land by the public or other
persons. Where the Contractor’s method of disposal requires drains to cross existing
roads, the cost of installation and removal of such drains including the resurfacing and
sealing of all affected sections of road shall be met by the Contractor.
8. Prior to the shutdown of any dewatering system the Contractor shall HOLD POINT
provide to the Superintendent details of the proposed shutdown procedure.
10. If waste water from dewatering plant is discharged into existing water
courses, traps shall be provided to prevent any silt entering these systems. All Water Courses
discharge shall comply with the requirements of all relevant authorities.
801.11 BACKFILL
1. The Contractor shall backfill around piers, abutments, retaining walls Backfill in
including footings to the levels shown on the drawings using selected granular fill General
material.
2. All fill shall be placed in continuous horizontal layers of not more than
300 mm uncompacted thickness.
3. Selected granular fill shall be supplied by the Contractor and shall be Fill Material
cohesionless sand or sandy limestone complying with the following requirements:-
a) Particle Size distribution WA 115.1
37.5 100
19.0 80 – 100
9.5 60 – 100
4.75 45 – 100
2.36 30 – 100
1.18 20 – 100
0.425 5 – 100
0.150 3 – 30
0.075 1 – 10
NOTE: The portion of the total sample retained on the 37.5 mm sieve shall not exceed 15% of the
total sample.
TABLE 801.01 PARTICLE SIZE DISTRIBUTION (GRANULAR FILL)
The portion of the sample which passes the 0.425 mm sieve (soil
mortar) shall have a linear shrinkage not exceeding 1.0%.
c) Oversize Material
5. All fill shall be placed in continuous horizontal layers of not more than
300 mm uncompacted thicknesses.
6. Backfill shall be placed on all sides of piers, abutment and retaining wall
footings so as not to damage the concrete.
7. All fill including embankment fill material shall be selected fill Compaction
compacted to 96% of maximum dry density or greater.
8. Within three (3) metres of structural members including abutment walls, Hand Operated
piers, retaining walls and footings only hand operated vibratory compacting equipment Equipment
shall be used.
MECHANICALLY STABILISED
EARTH WALLS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
802.01 SCOPE...................................................................................................................................... 1
802.02 REFERENCES ......................................................................................................................... 1
802.03 SUBMISSION.......................................................................................................................... 1
DESIGN ...................................................................................................................................................... 2
802.04 DESIGN ................................................................................................................................... 2
802.05 DOCUMENTATION ............................................................................................................... 2
802.06 VERIFICATION ...................................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
802.07 COMPONENT MATERIALS ................................................................................................. 2
802.08 NOT USED .............................................................................................................................. 2
OPERATIONS ........................................................................................................................................... 2
802.09 COMMENCEMENT................................................................................................................ 2
802.10 INSTALLATION ..................................................................................................................... 2
GENERAL
802.01 SCOPE
802.02 REFERENCES
Australian Standards
Other Publications
802.03 SUBMISSION
1. The Contractor shall submit sufficient details of the proposed MSE Submission
System to enable a full technical and aesthetic assessment to be made of its suitability.
In particular this should address:
802.04 DESIGN
1. The MSE System shall be designed to support the loads from the
abutment sill beam as shown in Drawings and in accordance with the requirements of
the Australian Bridge Design Code and AS 4678 Earth Retaining Structures. Borehole
information is contained in Information for Tenderers.
802.05 DOCUMENTATION
1. The Contractor shall be responsible for the design and preparation of Design
detailed specifications and Drawings for the manufacture and construction of the MSE
structure.
802.06 VERIFICATION
MATERIALS
OPERATIONS
802.09 COMMENCEMENT
1. At least 4 weeks prior to carrying out any work on the MSE HOLD POINT
abutments or walls the Contractor shall supply to the Superintendent full details
of the proposed system, including four copies of all Drawings and specifications
and certification that the design has been checked by an independent geotechnical
engineer experienced in this form of construction.
802.10 INSTALLATION
Clause Page
GENERAL .................................................................................................................................................. 1
812.01 SCOPE...................................................................................................................................... 1
812.02 REFERENCES ......................................................................................................................... 1
OPERATIONS ........................................................................................................................................... 1
812.03 BORING AND TEMPORARY CASING................................................................................ 1
812.04 PROTECTION OF ADJACENT PILES.................................................................................. 2
812.05 INSPECTION OF PILE EXCAVATION ................................................................................ 2
812.06 CASTING PILES ..................................................................................................................... 3
812.07 TOLERANCES ........................................................................................................................ 4
GENERAL
812.01 SCOPE
1. This section covers the requirements for the construction of reinforced Scope
concrete piles which are bored and cast-in-place without the use of permanent casing.
812.02 REFERENCES
Australian Standards
OPERATIONS
1. Each pile shall be bored to allow the construction of the pile to the size,
position and level shown on the drawings.
2. All excavated material shall be removed from the site and disposed of as
soon as practicable, so that the site of the works is kept in a clean and tidy condition.
3. If excavations are to be left open, the Contractor shall ensure that they are
made safe with appropriate fall protection measures such as guardrails with a footplate
around the full perimeter of the pile hole, a sleeve extending at least 1 metre above
ground level or a secure pile hole cover. Fall protection shall be provided at all times
during excavation and after excavation is completed. The Contractor shall provide
effective measures to protect each pile hole from site run-off and from loose material
falling in.
7. The toes of the steel casings shall be driven into solid rock where
specified on the drawings or suitable alternative material as required to seal them
sufficiently to prevent soil and water entering from outside the casing.
8. The type and thickness of the steel plate used in the temporary casing
shall be selected by the Contractor who shall be fully responsible for its structural
adequacy. The type and thickness of the temporary casings shall be certified by an
Engineer who has qualifications admitting to Corporate Membership of the Institution
of Engineers, Australia as being suitable for its intended purpose which may include
providing safe access for personnel, resisting all superimposed loads from driving,
extraction, earth and water pressures and the effects of any distortion which is likely to
occur to the casing.
1. The Contractor shall ensure that the pile construction process does not
result in damage to adjacent newly cast piles due to ground vibration. The following
minimum requirements shall also be met.
(b) piles more than 2.5 m clear distance from a newly cast pile may be
installed by boring at any time providing there is no likelihood of
damage to the newly cast piles;
1. Prior to inspection, the pile excavation shall be de-watered and the walls
and base of the pile cleaned out, including the internal surface of the casing, to remove
all mud, loose or foreign material.
2. The temporary casing (where used) shall not be removed, nor shall HOLD POINT
reinforcement and/or concrete be placed until the pile walls and base have been
inspected by the Contractor’s geotechnical representative.
5. In the event that the Contractor is unable to de-water the pile hole for
inspection, full details of the proposed method of cleaning out the pile and the pile
inspection shall be submitted to the Superintendent for review.
1. General
(a) The materials used, and the methods of proportioning, mixing and
handling concrete shall comply with the relevant provisions of
Specification 820 Concrete for Structures.
(c) Concrete shall be placed in the dry and shall be compacted with
immersion type, high frequency vibrators.
(d) Concrete shall be placed through a tremie tube and shall not be
dropped from a height greater than 2 m through air. Concrete which
is being discharged from a tremie shall be positively guided away
from the pile reinforcement so that segregation is not caused by the
flow of concrete impinging on the reinforcement.
(e) Alternative methods for placing concrete in the dry from those
specified in this clause may be used subject to a review by the
Superintendent.
(g) Care shall be taken to prevent earth and rock dislodging from the
side of the hole and contaminating the concrete forming the
minimum cover to the reinforcement.
(h) The minimum height of concrete within the casing shall be adjusted
to ensure that water is not permitted to enter from outside the casing,
and that the soil pressure at the toe of the casing is balanced by the
mass of the concrete within the casing. The free surface of the
concrete shall be at least 1.5 m above the bottom of the casing.
(i) If after driving the casing, it is found not possible to seal the
excavated pile from the inflow of water, mud, loose rock or similar
materials, the reinforcement and concrete may be placed under
water, subject to a review by the Superintendent and the
requirements of Clause 812.06(2) of this specification.
(j) Reinforcement and/or concrete shall not be placed until the HOLD POINT
proposed method of removing mud, loose rock or similar
materials, and the method of placement of concrete under water
has been reviewed by the Superintendent.
(a) Concreting using tremie methods shall not commence until the pile
hole is filled with such head of water as to equalise the external
water pressure from the surrounding ground.
(b) Where a tremie is used, the hopper and pipe of the tremie shall be
steel, smooth bore, clean and water tight throughout. The tremie
pipe shall be sealed with a plate taped to its outlet, to prevent direct
contact between the first discharge of concrete in the pipe of the
tremie and the water. The tremie pipe shall extend to the base of the
pile hole before the tremie is charged with concrete.
(d) Concreting shall not commence until the tremie pipe or pump
discharge hose are fully charged. During concreting the outlet of the
tremie pipe or pump discharge hose shall be kept a minimum of 2 m
below the top surface of the concrete at all times and the Contractor
shall continuously monitor and record the depth of embedment. The
method used for concrete placement shall be such that a continuous
supply of concrete is available at the top of the tremie tube or pump
hopper during the entire process of placing concrete. Concreting
shall be continued until sound concrete appears a minimum of
400 mm above the required cut off level. The pile concrete shall not
be cut back to its required level until a minimum of 24 hours after
completion of placement of concrete.
812.07 TOLERANCES
(a) pile head shall finish within 75 mm of the specified plan position;
(b) variation from the vertical or the specified batter/rake shall not be
more than 1 in 100;
(c) for piles which develop a curve, the offset from the theoretical
straight pile line shall not exceed 150 mm over a length of 15 metres
or proportionally for greater or shorter lengths.
FALSEWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
819.01 SCOPE...................................................................................................................................... 1
819.02 REFERENCES ......................................................................................................................... 1
819.03 DEFINITION ........................................................................................................................... 1
819.04 - 819.10 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
819.11 GENERAL ............................................................................................................................... 1
819.12 PROPRIETARY FALSEWORK ............................................................................................. 1
819.13 - 819.20 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 2
819.21 GENERAL REQUIREMENTS................................................................................................ 2
819.22 SAFETY................................................................................................................................... 2
819.23 DESIGN ................................................................................................................................... 2
819.24 LOAD TESTING ..................................................................................................................... 3
819.25 REMOVAL .............................................................................................................................. 3
819.26 - 819.79 NOT USED ................................................................................................................ 3
SPECIAL REQUIREMENTS................................................................................................................... 3
819.80 SPECIAL REQUIREMENTS FOR STEEL BEAM BRIDGES.............................................. 3
FALSEWORK
GENERAL
819.01 SCOPE
1. The work to be executed under this Specification is the design and erection
of falsework required for the proper construction of the permanent Works and after
completion of these Works the dismantling and removal of falsework.
819.02 REFERENCES
Australian Standards
819.03 DEFINITION
1. Falsework comprises all temporary supports of any nature that are required
for the construction of the permanent structure.
MATERIALS
819.11 GENERAL
1. Footings shall comprise concrete bases or timber bed logs or other types of Footings
suitable materials and shall be of a size that will satisfactorily distribute the bearing
pressures under each footing.
2. All standards shall be securely fastened to sole plates and shall be Bracing
adequately braced in every direction necessary to provide rigid and stable support to the Standards
permanent Work. Where standards are used with extending ends the length of unbraced
extensions shall be limited in accordance with the manufacturer's recommendations.
OPERATIONS
1. Falsework shall be designed and constructed so that on completion of the Allow for
permanent Works the concrete levels are as shown on the Drawings. To achieve this the Settlement
levels of the falsework shall be set to allow for any settlement and deflection
accompanying casting of the concrete.
2. In the event that falsework settles under load to such an extent that the
allowable tolerances on the finished concrete work are exceeded then the concrete shall be
removed and the falsework modified so that the finished work is in accordance with the
Drawings. The cost of such remedial works shall be borne by the Contractor.
819.22 SAFETY
1. All falsework shall comply with the requirements of the Occupational Worksafe
Safety and Health Regulations 1996.
819.23 DESIGN
1. The design of all falsework shall be in accordance with AS 3610 - and be Design by
adequate in every way for the loads it is required to support and to meet the General Contractor
Requirements.
3. Falsework shall be designed and erected in such a manner that the loads are
accepted in accordance with the loading assumptions made. All permanent structures
such as piers and abutments which are adjacent to or surrounded by falsework shall be
adequately protected to ensure that they are not damaged during the Contract.
6. At least two weeks prior to the installation of sheet piling the HOLD
Contractor shall supply to the Superintendent the proposed process description for POINT
installation and removal.
819.24.01 GENERAL
1. When directed by the Superintendent the Contractor shall carry out load Testing When
tests on representatives areas of the completed soffit formwork. Directed
3. The purpose of the tests will be to prove the structural adequacy of the
falsework/formwork system under overload.
1. The load shall be applied using kentledge. The load shall be equivalent to Kentledge
1.25 times the actual weight of the concrete plus a construction live load of 0.75 kN per
square metre.
1. The full test load shall be applied for at least twenty four hours during Tolerances
which time the Contractor will determine the displacement of the falsework resulting from
the application of the test load. The acceptance of the system shall be subject to it
sustaining no structural damage under the test load and it being adequate such that the
profile of the soffit surface after pouring the concrete shall be in accordance with the
Drawings and the Formwork Tolerances.
819.24.04 NONCONFORMANCE
1. If any section of the falsework under the test load displaces such that the Retesting at
profile of the cast concrete soffit will not be within the tolerances specified or if the Contractor’s
falsework under the test load shows signs of structural distress then the Contractor shall Cost
make the necessary modifications to the falsework tested and to all other areas which
would be similarly defective. The Contractor shall then carry out a further test load on an
area of the modified falsework in accordance with this Specification. The costs of all
retesting shall be borne by the Contractor.
819.25 REMOVAL
1. After completion of the permanent works the Contractor shall dismantle all
falsework and remove it from the site.
SPECIAL REQUIREMENTS
1. Steel beams shall be supported on the bearings before casting the deck
elements. The bottom flanges of beams shall be set parallel to the top surface of the
bearings.
2. The Contractor shall provide adequate temporary bracing for the beams to
prevent rotation, lateral and longitudinal movements due to superimposed loads and
3. Beams may require pulling into line to conform with the construction
tolerances specified.
GENERAL .................................................................................................................................................. 1
820.01 SCOPE.................................................................................................................................. 1
820.02 REFERENCES ..................................................................................................................... 1
820.03 DEFINITIONS ..................................................................................................................... 2
820.04 SPECIAL PROCESSES ....................................................................................................... 2
820.05 ADDITIONAL QUALITY SYSTEM REQUIREMENTS .................................................. 2
820.06 - 820.10 NOT USED ............................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
820.11 GENERAL ........................................................................................................................... 2
820.12 CEMENT.............................................................................................................................. 3
820.13 AGGREGATE...................................................................................................................... 3
820.14 WATER................................................................................................................................ 4
820.15 ADMIXTURES.................................................................................................................... 4
820.16 ALKALI-REACTIVE MATERIALS & SOLUBLE SALTS .............................................. 4
820.17 - 820.20 NOT USED ............................................................................................................... 4
DESIGN OF CONCRETE MIXES .......................................................................................................... 4
820.21 GENERAL ........................................................................................................................... 4
820.22 DURABILITY...................................................................................................................... 4
820.23 CLASS OF CONCRETE FOR MIX DESIGN .................................................................... 5
820.24 - 820.26 NOT USED ............................................................................................................... 6
820.27 TRIAL MIXES..................................................................................................................... 6
820.28 - 820.30 NOT USED ............................................................................................................... 7
SUPPLY AND DELIVERY OF CONCRETE......................................................................................... 7
820.31 CONCRETING PLANT ...................................................................................................... 7
820.32 BATCHING AND MIXING................................................................................................ 7
820.33 TRANSPORT....................................................................................................................... 7
820.34 TEMPERATURE AT POINT OF DELIVERY ................................................................... 7
820.35 MIX CONSISTENCY.......................................................................................................... 8
820.36 ADDITION OF WATER TO THE MIX AFTER MIXING ................................................ 8
820.37 SAMPLING OF CONCRETE FOR STRENGTH ............................................................... 8
820.38 STRENGTH OF CONCRETE DELIVERED...................................................................... 8
820.39 NOT USED .......................................................................................................................... 9
OPERATIONS ........................................................................................................................................... 9
820.40 GENERAL ........................................................................................................................... 9
820.41 PLACING CONCRETE....................................................................................................... 9
820.42 CONSTRUCTION JOINTS ............................................................................................... 10
820.43 COMPACTION.................................................................................................................. 10
820.44 FINISHING OF UNFORMED SURFACES ..................................................................... 11
820.45 CURING OF CONCRETE................................................................................................. 11
820.46 STEAM CURING .............................................................................................................. 12
820.47 PROTECTION OF CONCRETE SURFACES .................................................................. 14
ANNEXURE 820A ................................................................................................................................... 15
CLASS OF CONCRETE ....................................................................................................................... 15
GENERAL
820.01 SCOPE
1. The work to be executed under this Specification consists of the mix Scope
design, the supply and delivery, placing, compaction, finishing, curing and protection of
concrete for the following structures:
(a) Bridgeworks
(c) Major structural works involving the use of high strength concrete,
including retaining walls
820.02 REFERENCES
Australian Standards
Test Methods
1. The placing, compacting, finishing and curing of concrete are identified Special
as SPECIAL PROCESSES in accordance with Specification 201 QUALITY Processes
SYSTEMS.
MATERIALS
820.11 GENERAL
2. In its finished state concrete shall be sound and dense and durable and
free from honeycombing and shall have the strength and other properties specified.
820.12 CEMENT
1. All cement used in the Works shall comply with the requirements of Type Testing
GP cement as specified in AS 3972. The Contractor shall provide manufacturer's test
certificates showing all cement has been sampled and tested and conforms in all
respects with the above standard.
820.13 AGGREGATE
1. Fine aggregates for concrete shall be natural sand and shall comply with Testing
the requirements of AS 2758.1. The maximum amount of water absorption for fine
aggregates shall not exceed 1.5 percent.
4. In addition all aggregates proposed for use in the Works shall comply
with the requirements of the "Alkali-Reactive Materials" clause of AS 2758.1. The
Contractor shall also demonstrate that measures have been taken to prevent latent Alkali
Reactivity which is not identified by these tests. (See also Clause 820.16 of this
Specification).
1. Water used in concrete manufacture and curing shall be clean and potable
and free from amounts of suspended material or organic matter or alkali salts or any
other impurities which may adversely affect the properties of the concrete or have
harmful effects on any reinforcement or other fixture embedded therein.
2. Water for concrete shall have a total soluble salts content of not greater Testing
than 1 500 milligrams per litre when tested in accordance with MRWA Test Method
WA 910.1.
3. The Contractor shall arrange that a suitable supply of water is available at Contractor to
the batching plant. Supply
820.15 ADMIXTURES
1. The total mass of reactive alkali in the concrete, including any Testing
admixtures, shall not exceed 2.5 kg/m³. The method of determining the alkali content
shall be in accordance with Part 2 of Report No. TR3 by the Cement & Concrete
Association of New Zealand.
820.21 GENERAL
1. The Contractor shall design a mix for each class of concrete specified and
shown in the Drawings. The locations for these classes are summarised in Annexure
820A.
820.22 DURABILITY
1. All concrete for the Works shall be as specified in Table 820.1 except
that blinding concrete shall be Class N20 in accordance with AS 1379.
3. The combined grading shall be within the limits given in Figure 820.1
and Figure 820.2 after making allowance for the permissible tolerances on individual
aggregate gradings specified in Clause 820.13.
Target strength for mix design 42 MPa 42 MPa 48 MPa 58 MPa 58 MPa
Minimum Cement Content 350 kg/m3 350 kg/m3 400 kg/m3 420 kg/m³ 420 kg/m3
TABLE 820.1
NOTE: Concrete Class S35/10 is to be used in the Manufacture of Precast Parapet Panels only and
concrete class S50/10 is to be used in the concrete restraint blocks only.
P 100
E
R
C
80
E
N
T 65
A 60
G
E
. 42
40 45
P 35
A 31
S 24 30
S 20 23
I 12 16
N 9
2 2
G 0 2
SIEVE SIZE mm
S
S 20
14 20
I 16
N 5 12
G 0 4
SIEVE SIZE mm
1. The Contractor shall prepare a trial mix for each class of concrete to be
used in the Works. Each mix shall use such aggregates that have been tested and
approved by the Superintendent. The mixes shall be made using the plant and degree of
quality control proposed for the Works.
3. The Contractor shall measure the slump of the trial mix in accordance Slump Test
with AS 1012.3 and the value of the slump shall be agreed by the Superintendent.
4. Once a mix design for a specific class of concrete is adopted the slump of
the trial mix shall be deemed to be the slump for that class of concrete and all concrete
of this class supplied to the Works shall have the same slump, within a tolerance of +
15 mm.
6. The Contractor shall cast not less than nine and not more than twenty-one
compressive strength test specimens from the trial mix which shall be tested to
determine that the strength requirements of this Specification are met.
1. The Contractor shall provide and maintain and operate the batching
equipment so as to accurately determine and control the amount of each separate
ingredient entering the concrete to the tolerances specified in AS 1379. The amounts of
cement and sand and each size of aggregate entering each batch of concrete shall be
determined by weighing and the amount of water shall be determined by weighing or by
volumetric measurement.
820.33 TRANSPORT
2. In continuous pours the maximum time lag between truck loads on site
shall not exceed 20 minutes.
OR
(c) The ambient shade temperature is less than 38°C and rising, but
placement can be completed before the ambient temperature exceeds
38°C.
3. When the ambient shade temperature is greater than 32oC suitable means
shall be provided by the Contractor to avoid premature stiffening of concrete placed in
contact with hot dry surfaces. Where necessary the surfaces against which concrete is
to be placed including reinforcement and formwork shall be sprayed with water to
prevent excessive absorption of water from the fresh concrete.
1. The Contractor shall check the consistency of all concrete by Slump Test
measurement of the slump in accordance with AS 1012.3. A minimum of one full set
of Slump Testing equipment shall be supplied by the Contractor for this purpose for the
period of the Contract. In general, slump tests shall be carried out close to the concrete
discharge point.
1. Excessive over-mixing shall not be permitted and any concrete which has
been retained in the mixer so long that it requires additional water to permit satisfactory
placing shall be rejected.
2. The Contractor shall have available not less than fifteen steel moulds for
making concrete compression test specimens. For the period of large concrete pours the
Contractor shall supply adequate extra moulds to meet the increased frequency of
sampling required.
1. Concrete from any class shall be deemed to conform with the strength
requirements of this Specification if:
2. Consecutive samples for the same class of concrete are not restricted to a
single pour.
4. If at any time during the progress of the Works any mix is found to be
unsatisfactory or it becomes necessary to use materials differing from those originally
approved then the Contractor shall prepare revised mix designs and prepare trial mixes
for testing in accordance with Clause 820.27 prior to their use being approved.
Otherwise for any particular class of concrete the Contractor shall not vary the
properties of the materials used or their relative proportions from those of the approved
trial mix.
OPERATIONS
820.40 GENERAL
2. Where chutes are used to convey concrete their slopes shall be such as to
avoid segregation. Concrete shall not be allowed to fall freely more than 2.0 m unless
suitable chutes or baffles or other devices are provided to prevent segregation.
5. All concrete in a batch shall be placed in its final position and compacted
within 90 minutes of adding water to the mix.
6. Prior to the placement of any concrete, the Contractor shall certify to HOLD POINT
the Superintendent that all falsework, formwork, reinforcement and other
embedded items, levels, placement procedures and curing procedures to be
employed comply with the requirements of the Specification.
2. Immediately before fresh concrete is cast against the joint the hardened
concrete surface shall be thoroughly wetted.
820.43 COMPACTION
820.43.02 OPERATION
820.44.01 GENERAL
1. The type of finish and surface texture required in each part of the Works
shall be as shown on the Drawings.
1. Freshly placed concrete shall be protected from the sun, wind and rain
and prevented from drying out too quickly.
2. Curing shall commence immediately after the concrete has achieved its
final set.
3. The minimum curing period for structural concrete shall be 7 days. The
minimum curing period for any other concrete incorporating ground granulated blast
furnace slag, silica fume or fly ash shall be 14 days.
7. The Contractor shall ensure that the method of curing shall not result in
any staining of exposed surfaces of concrete.
820.46.01 GENERAL
2. The method of control and the proposed curing cycle to achieve the
specified concrete compressive strength are the responsibility of the Contractor, but
shall be in accordance with this Specification.
3. The Contractor shall take measures to allow for the potential lower 28
day compressive strength obtained from test cylinders cured initially under in-situ
conditions, as compared to those cured in accordance with the requirements of
AS 1012.
1. To prevent drying out, steam covers shall be placed over the units
immediately following the casting and screeding operations in such a manner as to
ensure free circulation of the steam around the concrete mass.
1. After an initial "maturity " of 40°C hours, but not less than two hours
after batching the last batch of concrete for the units, steam shall be admitted to the
steam covers at such a controlled rate that the maximum average temperature rise shall
not exceed 24°C per hour and the temperature rise in any one fifteen minute period
shall not exceed 6°C. (Note: The initial "maturity" period is calculated by dividing
40°C hours by the concrete temperature of the last batch of concrete placed in the unit.
The concrete temperature is as measured on an indicating thermometer).
2. If the admission of steam to the steam covers is delayed by more than the
initial specified "maturity" of 40°C hours after the completion of placing of concrete,
water curing, shall be applied until steaming commences.
4. After the elapse of sufficient time at the maximum temperature for the
required concrete properties to have been reached, steam shall be completely shut
down. Steam covers shall not be removed nor any part of the concrete units and test
cylinders disturbed in any way until the temperature under the steam covers has fallen
to within 30°C of the ambient temperature. The rate of loss of temperature under the
steam covers after shutting off steam shall not exceed 24°C per hour.
3. Charts shall not be removed from any recording thermometers, nor the
recording thermometers disturbed or moved in any way until after the removal of the
steam covers.
2. Sufficient steam jets or steam entry points shall be provided to ensure that
a substantially uniform temperature is maintained under the steam covers such that the
difference in temperature between any two points adjacent to the concrete units is not
more than 10°C.
2. Test cylinders shall remain in position under the steam covers until the
steam curing cycle is complete. Test cylinders shall be suitably covered in such a way
as to minimise moisture and temperature losses between the time of removal from the
steam covers and the time of forwarding to an accredited laboratory for testing.
Cylinders shall be transported in moisture proof containers.
1. The Contractor shall protect all completed surfaces from damage and
staining from any source including rain water and concrete spillage and grout spillage
and contact with hardwoods and ferrous metals. Where a delay is likely prior to casting
the next concrete pour such that reinforcement bars protruding from completed sections
may cause staining to exposed parts of the finished Works, then the bars shall be
suitably treated to prevent rusting.
CLASS OF CONCRETE
FORMWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
821.01 SCOPE...................................................................................................................................... 1
821.02 REFERENCES ......................................................................................................................... 1
821.03 - 821.10 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
821.11 GENERAL ............................................................................................................................... 1
821.12 OFF-FORM CONCRETE FINISHES...................................................................................... 1
821.13 TIMBER FORMWORK .......................................................................................................... 2
821.14 OTHER TEMPORARY FORMWORK................................................................................... 2
821.15 - 821.20 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 2
821.21 FORMWORK DESIGN........................................................................................................... 2
821.22 FORMWORK CONSTRUCTION........................................................................................... 2
821.23 REMOVAL OF FORMWORK................................................................................................ 3
821.24 - 820.29 NOT USED ................................................................................................................ 4
821.30 TOLERANCES FOR CONCRETE CONSTRUCTION.......................................................... 4
FORMWORK
GENERAL
821.01 SCOPE
821.02 REFERENCES
Australian Standards
MATERIALS
821.11 GENERAL
3. All formwork made up from separate panels shall be so designed that the Panel
pattern of exposed panel joints complements the overall geometry of the structure and Arrangement
does not detract from the final appearance of the structure. The Contractor shall detail
proposed soffit and side formwork panel arrangements on the formwork Drawings.
4. In order to minimise the number of joints, formwork panels shall be Panels Plywood
supplied in the maximum practicable width and length. Plywood when used shall be
placed with the grain of the outer plys in the direction of the span.
1. Timber for formwork shall be well seasoned and free from loose knots Timber
and other defects. Timber which has become warped or unsuitable for use shall be
replaced at the Contractor's expense.
2. Plywood used in formwork lining shall comply with the relevant Plywood
provisions of AS 2271.
1. Forms made from materials other than plywood will be permitted Steel Forms
provided that the requirements for strength and rigidity and tightness are met and that
all bolts and rivet heads are countersunk and the finished concrete appearance is not
inferior to that obtained with good quality plywood. Steel forms shall be suitably
treated to prevent rusting of the face to be in contact with the concrete. The minimum
thickness required for steel formwork is 4 mm.
OPERATIONS
3. Where concrete is poured in more than one operation the Contractor shall Construction
take all necessary precautions to hold the formwork tight against the previous pour to Joints
avoid any discontinuities in the finished off form surface.
4. At least two weeks prior to commencing formwork construction the HOLD POINT
Contractor shall supply to the Superintendent design details and Drawings
checked and certified by a qualified structural engineer that the formwork
complies with the Specification.
1. Forms shall be built true to line and level and braced in a substantial and
unyielding manner to maintain correct position and shape.
3. Forms shall be mortar tight and the edges of all joints shall be sealed with a Sealing
suitable type of sealant. Forms subject to external water pressure shall be watertight.
4. Forms shall be held in correct alignment and spacing by bolt and rod Bolt and Rod
assemblies designed so that when the forms are removed no metal shall be closer to the Assemblies
surface of the concrete than the minimum cover specified on the Drawings. The rods
shall be held in place by devices capable of developing the strength of the rod attached
to the walings. Bolt and rod assemblies shall be arranged so that cavities caused by
their removal shall form a regular pattern appropriate to the area being formed. All
such cavities shall be wetted and carefully packed with colour matched mortars and
brought to an even surface.
5. The use of wires and/or bolts extending to the surface of the concrete Cover
shall not be permitted except where shown on the Drawings. Wires or bolts or
fastenings for forms or fixing reinforcement shall have the same concrete cover as
specified for reinforcement.
6. All handrail and guardrail sockets and hole formers and all other fittings Fittings
shall be accurately located. Bolts, pipes and bars used to form holes in the structure
shall be well greased and arranged so that they may be removed from the concrete
without excessive jarring or hammering before removal of forms.
7. Form lubricants shall be of the non-staining type which do not adversely Lubricant
affect the surface of the concrete. Lubricants shall be used after the fabrication of
forms and prior to the placing of any reinforcing steel or other embedded item. The
lubricant shall be uniformly applied in a thin film and any surplus shall be removed
prior to placing concrete. Care shall be taken that such coatings do not soil the surface
of reinforcement.
8. Where the bottom of a panel is inaccessible from within then access Access Panels
panels shall be provided to permit thorough removal of rubbish before placing concrete.
9. Prior to concreting all forms shall be clean and free from sand and Cleaning
shavings and tie wire ends and other debris. Surplus water shall be drained and any
temporary openings closed in a proper manner.
10. Forms for re-entrant angles shall be chamfered and forms for corners Chamfers &
shall be filleted. The bevel in each case shall have a width of 20 mm on each side Fillets
unless otherwise shown on the Drawings.
2. Formwork support and formwork to reinforced concrete deck soffits and Timing
pier cap beams shall not be removed until a minimum of 7 days has elapsed and the
concrete has achieved a cylinder strength of 30MPa.
3. Not Used.
4. For other parts of the structure other than the deck formwork shall not be Timing
removed until a minimum of 48 hours has elapsed and the concrete has attained a
cylinder strength of 20 MPa.
1. The materials for forms and form arrangements shall be such as to result
in finished concrete work complying with the tolerances shown in Table 821.1
Bridge Superstructures:
STEEL REINFORCEMENT
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
822.01 SCOPE...................................................................................................................................... 1
822.02 REFERENCES ......................................................................................................................... 1
822.03 CLEAR COVER REQUIREMENT ......................................................................................... 1
822.04 - 822.09 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
822.10 STANDARDS .......................................................................................................................... 1
822.11 BENDING AND CUTTING.................................................................................................... 1
822.12 STORAGE................................................................................................................................ 2
822.13 CLEANING.............................................................................................................................. 2
822.14 MECHANICAL SPLICES ....................................................................................................... 2
822.15 - 822.19 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 3
822.20 FIXING .................................................................................................................................... 3
822.21 WELDING ............................................................................................................................... 3
822.22 LAP SPLICES .......................................................................................................................... 3
822.23 TOLERANCES FOR FIXING................................................................................................. 4
STEEL REINFORCEMENT
GENERAL
822.01 SCOPE
822.02 REFERENCES
Australian Standards
1. The minimum cover measured from the surface of the concrete to the face
of any reinforcing steel shall be as shown on the Drawings.
MATERIALS
822.10 STANDARDS
Reinforcement Specification
1. The Contractor shall prepare reinforcement bending schedules from the Schedule
North Quay: Construction of a Rail 1 Series 800
Loop, Rail Bridge, Rail terminal and Specification 822
Associated Roadworks Steel Reinforcement
Drawings.
a) The steel shall be heated uniformly for at least 100 mm each side of
the portion to be bent.
b) For grade 500 steel the heating shall be controlled such that the
temperature does not exceed 450°C and shall be measured with
temperature indicating crayons. Steel heated beyond 450°C shall be
rejected.
5. Prior to heating any reinforcement the Contractor shall supply to the HOLD POINT
Superintendent full details of the proposed heating procedure.
822.12 STORAGE
822.13 CLEANING
1. Reinforcement placed in the Works shall be clean and free from all loose
rust and mill-scale and all dirt and grease and other foreign substances which might
impair the bond between steel and concrete. After being placed in position all
reinforcement shall be maintained in a clean condition until it is embedded in the
concrete.
822.20 FIXING
4. All reinforcing steel supported off formwork where the resulting concrete
surface will be exposed, shall be supported on approved special purpose cement bar
spacers.
822.21 WELDING
2. Prior to welding any reinforcement, the Contractor shall supply to HOLD POINT
the Superintendent documentation showing that welders to be employed on the
Works are suitably qualified and that the qualification of welding procedures has
been verified by testing in accordance with the requirements of AS 1554.3
3. Welded steel wire fabric shall be lapped as detailed on the Drawings and
where not detailed shall overlap by at least one complete mesh on all sides such that the
end cross wire of one sheet overlaps with the second end wire of the adjacent sheet.
Loose bars shall not be used in conjunction with fabric reinforcement except where
shown on the Drawings. Loose small pieces of fabric shall only be used where they are
essential for fitting into small confined parts of the Works.
1 2 3 4
Nominal length Nominal size Tolerance
Condition or Dimension or Diameter of (mm)
L (mm) Bar (mm)
On each overall dimension, or on the overall dimension
of each straight portion, or on that offset dimension,
controlled by concrete cover at both ends for bars
other than fitments. Up to 600 Up to 20 +0 -20
Up to 600 Over 20 +0 -30
Over 600 Up to 20 +0 -40
Over 600 Over 20 +0 -50
Up to 600 Up to 20 -0 +20
Up to 600 Over 20 -0 +30
Over 600 Up to 20 -0 +40
Over 600 Over 20 -0 +50
Up to 600 Up to 12 +0 -10
Up to 600 16 to 20 +0 -15
Over 600 Up to 20 +0 -20
Any Length Over 20 +0 -30
Up to 600 Up to 12 - 0 +10
Up to 600 16 to 20 -0 +15
Over 600 Up to 20 -0 +20
Any Length Over 20 -0 +30
On the deviation from square measured in relation to Any bar 24 and over
the end 300mm of the sawn or machined end of a length. ∝=2°
a straight bar intended for use as an end bearing
Length Allowance (mm) 120 140 160 180 220 260 300 340 380
(assumed pin diameter, 5 db)
TABLE 822.4 HOOK AND COG ALLOWANCES FOR BENT BARS AND FITMENTS
2 Where cover is not 2a. At the end of reinforcement. Tolerance on Dimension 'L'.
controlling. ± 50
(see Case 1)
2b. At the outside edge of Tolerances on Dimension 'E'
reinforcement including ±10
fitments.
The tolerances given above are the maximum permissable, but it should be noted that
in some circumstances, where reinforcement is fabricated to maximum tolerance,
they may not be fully available.
Clause Page
GENERAL .................................................................................................................................................. 1
827.01 SCOPE...................................................................................................................................... 1
827.02 REFERENCES ......................................................................................................................... 1
827.03 MANUFACTURE.................................................................................................................... 1
827.04 FORMWORK .......................................................................................................................... 1
827.05 REINFORCEMENT................................................................................................................. 2
827.06 CONCRETE ............................................................................................................................. 2
827.07 MEMBER TOLERANCES...................................................................................................... 2
827.08 MARKING OF MEMBERS .................................................................................................... 2
827.09 STANDARD OF FINISH ........................................................................................................ 3
827.10 HANDLING AND STORAGE................................................................................................ 3
827.11 ERECTION OF NOISE WALLS............................................................................................. 4
GENERAL
827.01 SCOPE
827.02 REFERENCES
827.03 MANUFACTURE
827.03.01 GENERAL
The external faces of the wall panels and posts will be exposed surfaces in the
completed works and shall have a finish as described on the drawings. Casting methods
shall be designed to ensure that no damage occurs to the units. The ends of all units
shall be free from any grout loss or honeycombing or cracking or spalling. Units with
defects of this nature shall be rejected.
3. Protect all completed surfaces from damage and staining from any source
including rainwater and concrete spillage.
827.04 FORMWORK
(a) The formwork used for the units shall be rigid formwork to achieve
a surface finish of Class 2.
827.05 REINFORCEMENT
827.06 CONCRETE
(b) Where steam curing is proposed to be used then it shall be low Curing
pressure wet steaming and in accordance with Clause 820.28. Any
other form of accelerated curing will not be permitted. Steaming
shall not commence until at least two hours after the last batch of
concrete has been placed. Subsequent curing shall be in accordance
with Clause 820.27.
(a) The precast units shall conform to the dimensions shown on the
drawings and to the Codes specified.
4. No production units shall be produced until the sample panel has been
approved by the Superintendent.
827.10.01 GENERAL
827.10.02 LIFTING
1. Leave precast units in forms until the concrete has attained sufficient
strength and durability to be handled without damage, either structurally or to corners
and surfaces. Damaged units will be rejected.
2. No unit is to carry its own weight or any load until it has gained sufficient
strength to do so. If removed prior to this stage adequately support it and carefully
handle it.
5. Ensure precast wall panels are lifted and transported in a vertical upright
position.
827.10.03 TRANSPORT
1. The units shall be transported to the Site in a manner that does not
damage the units. Units shall not be transported until they are at least 7 days old and
the concrete shall have reached its 28 day nominated strength.
2. Wall panels shall be kept in an upright position at all times and shall only
be lifted from the lifting points specified by the Precast Contractor.
1. Handle all precast units with due care to avoid bumping and impact. In
the event of any member sustaining damage in the way of cracking or spalling, set aside
the member and no further work done on it until it has been inspected by the
Superintendent and determined whether the member can be repaired or is to be rejected.
2. Do not lift or support units at other than the designated lifting points. All
wall panels shall be delivered in a vertical position.
4. Carry out the erection of the precast units in accordance with the lines
and levels shown on the drawings and to the tolerances specified below.
5. Ensure that the posts are adequately braced in position, levelled, aligned
and plumbed prior to concreting the post socket. Provide adequate protection during
post installation and concrete backfilling to prevent side collapse of the hole walls.
Where necessary, provide a temporary steel lining.
PRECAST CONCRETE
MEMBERS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
828.01 SCOPE...................................................................................................................................... 1
828.02 REFERENCES ......................................................................................................................... 1
828.03 – 828.11 NOT USED ............................................................................................................... 1
828.12 MANUFACTURE.................................................................................................................... 1
828.13 NOT USED .............................................................................................................................. 2
828.14 HANDLING AND STORAGE................................................................................................ 2
828.15 – 828.19 NOT USED ............................................................................................................... 3
828.20 ERECTION AND CONSTRUCTION..................................................................................... 3
828.21 – 828.22 NOT USED ............................................................................................................... 3
828.23 DECK CONCRETE OVERLAY ............................................................................................. 3
GENERAL
828.01 SCOPE
828.02 REFERENCES
Australian Standards
828.12 MANUFACTURE
828.12.01 GENERAL
828.12.02 FORMWORK
828.12.04 CONCRETE
(a) If the Contractor proposes to use external type vibrators for concrete Compaction
compaction then he shall provide evidence to show that the same
level of compaction can be achieved.
(b) Where steam curing is proposed to be used then it shall be low Curing
pressure wet steaming and in accordance with Clause 820.46. Any
other form of accelerated curing will not be permitted. Steaming
shall not commence until at least two hours after the last batch of
concrete has been placed. Subsequent curing shall be in accordance
with Clause 820.45.
828.14.01 GENERAL
828.14.02 LIFTING
1. Units shall be kept in the upright position at all times and shall only be
lifted from the specified lifting points. Units shall be lifted using either a full length
steel lifting beam or two cranes to ensure the force at the lifting points is purely vertical.
828.14.03 TRANSPORT
1. The units shall be transported to the Site in a manner which does not
damage the units. Units shall not be transported until they are at least 7 days old and the
concrete shall have reached its 28 day nominated strength.
1. Before the deck concrete overlay is placed the top surface of the precast
units shall be thoroughly cleaned with a water jet to remove dust and chips and any
other foreign matter.
STRUCTURAL STEELWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 3
830.01 SCOPE...................................................................................................................................... 3
830.02 REFERENCES ......................................................................................................................... 3
830.03 WORKMANSHIP.................................................................................................................... 4
830.04 PROVISION FOR AUDIT INSPECTION .............................................................................. 4
830.05 DEFINITIONS ......................................................................................................................... 4
830.06 QUALITY ASSURANCE........................................................................................................ 4
830.07 - 830.09 NOT USED ................................................................................................................ 5
MATERIALS.............................................................................................................................................. 5
830.10 NOT USED .............................................................................................................................. 5
830.11 SPECIFICATIONS FOR STEEL............................................................................................. 5
830.12 TEST CERTIFICATES AND IDENTIFICATION OF MATERIAL...................................... 6
830.13 TESTING OF STEEL .............................................................................................................. 6
830.14 IDENTIFICATION MARKS................................................................................................... 7
830.15 STORAGE................................................................................................................................ 7
830.16 HANDLING AND STACKING .............................................................................................. 7
FABRICATION ......................................................................................................................................... 7
830.17 GENERAL ............................................................................................................................... 7
830.18 SHOP DRAWINGS ................................................................................................................. 7
830.19 PRECAMBER AND DISTORTIONS ..................................................................................... 8
830.20 STRAIGHTENING AND CORRECTION OF DISTORTIONS............................................. 8
830.21 CUTTING AND EDGE TREATMENT .................................................................................. 8
830.22 NOT USED .............................................................................................................................. 9
830.23 HOLES FOR BOLTING.......................................................................................................... 9
830.24 WELDING ............................................................................................................................... 9
830.25 STUD SHEAR CONNECTORS ............................................................................................ 13
830.26 BOLTING .............................................................................................................................. 14
830.27 HOLDING DOWN BOLTS................................................................................................... 14
830.28 - 830.29 NOT USED .............................................................................................................. 14
830.30 CERTIFICATION OF FABRICATION ................................................................................ 14
830.31 - 830.39 NOT USED .............................................................................................................. 15
830.40 ERECTION ............................................................................................................................ 15
830.41 - 830.49 NOT USED .............................................................................................................. 15
830.50 BOLTED JOINTS .................................................................................................................. 15
830.51 - 830.59 NOT USED .............................................................................................................. 15
830.60 CONSTRUCTION TOLERANCES ...................................................................................... 15
830.61 - 830.79 NOT USED .............................................................................................................. 16
SPECIAL REQUIREMENTS................................................................................................................. 16
830.80 - 830.89 NOT USED .............................................................................................................. 16
STRUCTURAL STEELWORKS
GENERAL
830.01 SCOPE
830.02 REFERENCES
1. All metal fabrication and welding shall comply with the current edition of
the relevant Standard or Code of Practice (including amendments)
specified in the Contract Specification or nominated on Contract
Drawings.
Australian Standards
830.03 WORKMANSHIP
830.05 DEFINITIONS
MATERIALS
1. All materials supplied by the Contractor shall be new and shall conform New Steel
to the Standards specified below.
2. Unless otherwise specified, steel plate used in box girders shall meet the Standards
requirement of Grade 250LO in accordance with AS 3678.
a. All bolts, nuts, screws and washers will conform with the relevant
Australian Standards listed in Clause 9.2;
b. High strength bolts, with associated nuts and washers, will comply
with AS4100. The length of the bolt will be as shown on the
Drawings, or, if no length is shown, will be in accordance with
AS4100;
c. All screw threads will conform to the ISO coarse pitch series thread
in accordance with AS1275;
d. Unless shown on the Drawings, nuts other than those for high
strength bolts will be “normal” size. The strength grade of normal
nuts to be associated with each strength grade of the bolt, U-bolt,
screw, stud or other threaded component will be as follows:
4.6 5
5.8 5
8.8 8
10.9 10
6. The strength grade required for precision bolts and screws will be as
shown on the Drawings.
7. Where stainless steel bolts are shown on the Drawings the stainless steel
used in the manufacture of non high strength bolts, nuts and dowels will
conform to AS2837 Grade 316L for welded components or Grade 316
otherwise. The stainless steel used in the manufacture of high strength
bolts and nuts will conform to SS2343 (American Iron and Steel Institute
Grade 316 Mo+) and have a minimum ultimate tensile strength of 800
Mpa.
c. With stainless steel bolts – stainless steel washers Grade 316, normal
series.
10. Washers are generally not required under socket head cap screws.
2. The Contractor shall ensure that all materials or parts conform with the
tests required by the Standards and with other tests specified in this Part
of the Specification.
3. Test certificates showing the results of mechanical tests and chemical Certificates
analysis (where applicable) of the material or parts used in the Works
shall be retained by the Contractor, and shall form part of the MDR.
4. All materials or parts used in the Works shall be traceable to the Test
Certificates. The Contractor shall establish and maintain a
comprehensive system of identification records. Copies of all these
records shall be forwarded to the Superintendent on request, and shall
form part of the MDR.
3. A written report on each line tested shall be forwarded direct from the
NATA registered testing laboratory to the Superintendent within 24 hours
of completion of the test. The location and extent of inclusions and/or
laminations shall be detailed and sketched in the report.
1. Each item of structural steelwork shall have its own item mark number Identification
which shall be used on all related schedules and documents. This mark
shall be clearly indicated on all members by durable identification marks
to enable accurate identification on site.
830.15 STORAGE
1. All steel, whether fabricated or not, shall be stored in such a manner that
corrosion is minimised. Generally, storage at least 200 mm above the
ground on timber gluts under cover will be satisfactory. Rusted or bent
or damaged steel will be rejected.
1. Before and after fabrication and during transit and on the Site all Identification
structural steelwork shall be handled and stacked in such a way that it is
not damaged.
2. All bolts and nuts and washers and plates under 300 mm maximum
dimension and small articles generally shall be packed separately in
watertight containers.
FABRICATION
830.17 GENERAL
1. The Contractor shall prepare shop Drawings for the fabrication of all
members.
2. Shop Drawings shall show details of fabrication which are not explicit in
the Contract Drawings. Details required include dimensions, angles and
weld preparation details.
3. The details shown on the shop Drawings shall be consistent with the
Contract Drawings and shall comply with the following:-
a) The marking plan shall show the location of each part in the
structure.
1. All plates shall be flattened and all sections shall be straightened and
made free from twist before any work is done on them to ensure that
when assembled surfaces shall be flat within specified tolerances and
adjacent surfaces shall be in close contact throughout. The methods
adopted for such flattening and straightening shall be such as not to
damage or mark the material. Heating of plates and all sections will not
be permitted unless written approval is obtained from the Superintendent.
3. Ends of web stiffener plates shall be cut and finished to fit snugly and
uniformly to girder flanges unless otherwise shown on the Drawings.
5. Unless shown otherwise on the Drawings, all corners on cut edges shall
be rounded to a radius of approximately 1.5 mm, except where such
edges are subsequently to be welded. Rolled edges need not be rounded
provided the corners have a similar radius.
1. All bolt holes shall be drilled to a diameter 2 mm larger than the diameter
of the bolt unless otherwise shown on the Drawings.
830.24 WELDING
830.24.01 General
830.24.02.01 Welder
1. Welding shall only be carried out by welders meeting the requirements of
Clause 4.11.2 of AS 1554.1
2. Not less than ten (10) working days prior to planned commencement of
welding, the following information on each welder shall be provided to
the Superintendent:
2. Not less than ten (10) working days prior to commencement of welding,
the WSP shall identify the Welding Supervisor who will be responsible
for the coordination of all operations in respect of the welding work. The
WSP shall provide details of the Welding Supervisor’s qualifications,
certification and experience to the Superintendent. The Welding
Supervisor shall have delegated authority to deal directly with the
Superintendent on all issues relating to the welding work, including:
2. Not less than ten (10) working days prior to commencement of welding,
the WSP shall identify the Welding Inspector who will be responsible for
the inspection of the welding work. The WSP shall provide details of the
Welding Inspector’s qualifications, certification and experience to the
Superintendent.
830.24.03 EQUIPMENT
1. Welding procedures for all fillet and butt welds, or any combination of
either, shall be proven qualified by the WSP, who shall submit to the
Superintendent a schedule of all proposed welding procedure
qualifications, not less than ten (10) working days prior to the planned
commencement of welding work to which the procedures will apply.
2. When the essential variables vary outside the limits specified in Table
4.11(A) of AS1554.1, new procedures shall be qualified by the WSP.
These shall be submitted to the Superintendent for review and release of
the hold point.
3. Suitable run-on and run-off tabs shall be used for all butt welds. The tabs
shall have the same thickness and preparation as the parts to be joined.
Each weld pass shall terminate at least 20 mm beyond the edges of the
parts to be joined. Welds shall be continuous for the full length.
4. All welding for the work shall be shown in a detailed Welding Procedure
Sheet in accordance with AS 1554.1. Each welding procedure shall be
qualified by way of test pieces and/or assemblies in accordance with AS
1554.1.
5. Test pieces and/or assemblies shall represent the actual conditions in the
work in regard to location, weather environment, geometric arrangement,
plate thickness, joint preparation and equipment and be of a minimum
size recommended by AS 1554.1, but of adequate size to carry out all
testing.
7. The WSP shall obtain any test and/or Inspection Certificates from a
laboratory with appropriate NATA registration, with all relevant results
shown and a statement that the results comply with AS 1554.1.
1. All run-on and run-off tabs shall be removed after the joint has cooled
and the ends of the welds shall be finished smooth and flush with the
faces of the abutting parts.
2. Slag shall be removed from completed welds. The weld and adjacent
base material shall be cleaned by brushing or other suitable means to
remove spatter and foreign material. Welded joints shall not be painted
until after the welds have been inspected and approved.
3. Where butt welds form part of a faying or contact surface, the surfaces of
the butt welds shall be dressed in accordance with Clause 5.12 of AS
1554.1.
2. The WSP shall ensure that testing of all welds is carried out in
accordance with AS 1554.1. Test Certificates issued by a NATA
registered laboratory shall be available to the Superintendent and shall be
part of the MDR. The testing procedures to be used are:
i) Visual Scanning;
d) For all other butt welds test 10% of the length of all welds longer
than 1 m and one in twenty of all welds which are less than 1 m long
using a combination of procedures (iii) and (iv).
4. The Contractor shall allow for all labour and plant required to lay out and
arrange items for inspection and testing and carry out any necessary weld
preparation including allowance for lost production time.
5. All repaired welds shall be retested and for welds tested under (d) above
two extra samples of either 10% or one in twenty shall be tested as
appropriate. All costs associated with repairing and retesting defective
welds and additional testing shall be borne by the Contractor.
2. The cost of repairing or correcting defective welds and the cost of any
additional work or material required to repair defective welds shall be
borne by the WSP.
830.25.01 GENERAL
1. Stud shear connectors and stud welding shall comply with the
requirements of AS 1554.2 except as varied by this Specification.
830.25.03 WELDING
1. After stud welding, all beams shall comply with the tolerances given in Distortion
Clause 830.60 "Construction Tolerances". Quality control for all stud
welding shall be maintained in accordance with Section 3 of AS1554.2
and shall be at the expense of the WSP.
830.25.04 TESTING
830.26 BOLTING
1. Generally:
− where 8.8 bolts are designated, the washers and nuts shall also
be hardened as for the bolt.
− Where 8.8X bolts are designated, keep the thread portion of the
bolt outside the shear plane of the parts being joined.
3. Tightening of Bolts:
1. All holding down bolts will, wherever applicable, be welded into a cage
to ensure accurate placement. Bolts, nuts, washers and cage assemblies
will be hot-dip galvanised to give a coating of zinc of not less than 85
microns thickness.
830.40 ERECTION
830.50.01 General
1. Unless otherwise shown on the Drawings, all bolts and nuts for field
joints shall be High Strength Friction Grip Bolts, complying with AS
1252 Grade 8.8.
2. The Contractor shall allow in the fabrication of the girders for all weld
distortion so that on completion of erection the dimensions of the
fabricated members shall be correct within the tolerances specified in AS
4100 and in addition shall not exceed the following:
e) Not Used.
SPECIAL REQUIREMENTS
Clause Page
GENERAL .................................................................................................................................................. 1
831.01 SCOPE...................................................................................................................................... 1
831.02 REFERENCES ......................................................................................................................... 1
831.03 WORKMANSHIP.................................................................................................................... 1
831.04 - 831.09 NOT USED ................................................................................................................ 2
MATERIALS.............................................................................................................................................. 2
831.10 NOT USED .............................................................................................................................. 2
831.11 STRUCTURAL STEEL FOR PLATES, BARS AND SECTIONS......................................... 2
831.12 BOLTS, NUTS, SCREWS AND WASHERS ......................................................................... 2
831.13 TESTING AND IDENTIFICATION OF MATERIAL ........................................................... 3
831.14 DAMAGED STEEL................................................................................................................. 3
831.15 STORAGE OF MATERIALS.................................................................................................. 3
831.16 ASSEMBLY PROCEDURES.................................................................................................. 3
831.17 ACCEPTANCE OF PROTOTYPE COMPONENTS.............................................................. 4
831.18 IDENTIFICATION MARKS................................................................................................... 4
831.19 - 831.20 NOT USED ................................................................................................................ 4
FABRICATION ......................................................................................................................................... 4
831.21 CUTTING AND EDGE TREATMENT .................................................................................. 4
831.22 SPLICES .................................................................................................................................. 5
831.23 HOLES FOR BOLTING.......................................................................................................... 5
831.24 WELDING ............................................................................................................................... 5
831.25 STUD SHEAR CONNECTORS .............................................................................................. 5
831.26 - 831.29 NOT USED ................................................................................................................ 6
831.30 CERTIFICATION OF FABRICATION .................................................................................. 6
831.31 - 831.34 NOT USED ................................................................................................................ 6
831.35 PROTECTIVE TREATMENT................................................................................................. 6
831.36 TRANSPORT, HANDLING AND STORAGE....................................................................... 6
GENERAL
831.01 SCOPE
831.02 REFERENCES
Australian Standards
831.03 WORKMANSHIP
1. All work shall be carried out by capable personnel under the supervision of
experienced and competent supervisors to fully satisfy the requirements of this Part of the
Specification.
MATERIALS
1. Structural steel for plates, bars and sections shall conform to the
requirements of AS/NZS 3678, Grade 250, and AS/NZS 3679 Grade 250 unless noted
otherwise on the Drawings or the Specification.
1. All bolts, nuts, screws and washers shall conform with the relevant
Australian Standards listed in Clause 831.02.
3. All screw threads shall conform to the ISO coarse pitch series thread in
accordance with AS 1275.
4. Unless shown otherwise on the Drawings, nuts other than those for high
strength bolts shall be "normal" size. The strength grade of normal nuts to be associated
with each strength grade of the bolt, U-bolt, screw, stud or other threaded component shall
be as follows:
4.6 5
5.8 5
8.8 8
10.9 10
5. The strength grade required for precision bolts and screws shall be as
shown on the Drawings.
6. The stainless steel used in the manufacture of non high strength bolts,
nuts and dowels shall conform to AS 2837 Grade 316L for welded components or
Grade 316 otherwise. The stainless steel used in the manufacture of high strength bolts
and nuts shall conform to SS 2343 (American Iron and Steel Institute Grade 316 Mo+)
and have a minimum ultimate tensile strength of 800 MPa.
c) With stainless steel bolts - stainless steel washers Grade 316, normal
series.
9. Washers are generally not required under socket head cap screws.
1. The Contractor shall ensure that all materials or parts conform with the
tests required by the standards and with other tests specified in this Part of the
Specification.
3. All materials or parts used in the Works shall be identified with the tests.
The Contractor shall establish and maintain a comprehensive system of identification
records. Copies of all these records shall be forwarded to the Superintendent on
request.
1. All steel, whether fabricated or not, shall be stored in such a manner that
corrosion is minimised. Generally, storage at least 200 mm above the ground on
platforms, slabs, or other supports under cover will be satisfactory.
2. Bolts, nuts, screws and washers not promptly incorporated in the work
shall be stored in a waterproof shelter clear of the ground, and protected from damage.
1. Details of the procedures for assembly and fabrication shall be submitted Quality Plan
with the Contractor's Quality Plan. These procedures shall be comprehensive and shall
cover all aspects of the work. The procedures shall include, but not be limited to:-
b) Welding procedures
1. The Contractor shall give five working days' notice in writing before HOLD POINT
commencing work, and this shall be allowed for in its programme. For the first
item of any component fabricated the Contractor shall make a thorough
dimensional check. The Contractor shall submit to the Superintendent details of
this dimensional check, and certification that the dimensions are in conformity
with the requirement of the Drawings and the Specification. No further
fabrication work on similar items shall be carried out until submission of this
certification.
FABRICATION
3. Unless shown otherwise on the Drawings, all corners on cut edges shall
be rounded to a radius of approximately 1.5 mm, except where such edges are
subsequently to be welded. Rolled edges need not be rounded provided the corners
have a similar radius.
831.22 SPLICES
1. The diameters of the bolt holes shall be 2 mm greater than the diameters
of the bolts shown on the Drawings unless otherwise specified.
4. For sub-punched holes the diameter of the die shall not exceed the
diameter of the punch by more than 1 mm. Holes shall be clean cut, without torn or
ragged edges. Reamed or drilled holes shall be cylindrical and perpendicular to the face
of the member. Reaming and drilling shall be done by mechanical means.
831.24 WELDING
1. Stud shear connectors and stud welding shall comply with the
requirements of AS 1554.2 except as varied by this Specification.
831.35.01 GENERAL
1. All minor items of steelwork shall be hot dip galvanised unless otherwise Galvanise
specified.
2. Unless shown otherwise on the Drawings, all other bolts, U-bolts, screws,
nuts and washers shall be protected with the following protective treatment:-
Precision bolts and screws and If not shown otherwise on the Drawings,
associated nuts and washers & electroplated with zinc in conformity with
Prevailing torque locknuts the principles of AS 1897, or for sizes
over M16, of AS 1789 - Classification
Fe/Zn 12c Type C
Clause Page
GENERAL .................................................................................................................................................. 1
833.01 SCOPE...................................................................................................................................... 1
833.02 REFERENCES ......................................................................................................................... 1
833.03 - 833.09 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 2
833.10 NOT USED .............................................................................................................................. 2
833.11 SPECIFICATIONS FOR STEEL............................................................................................. 2
833.12 TEST CERTIFICATES............................................................................................................ 2
833.13 IDENTIFICATION RECORDS............................................................................................... 2
833.14 IDENTIFICATION MARKS................................................................................................... 2
833.15 STORAGE................................................................................................................................ 2
833.16 HANDLING AND STACKING .............................................................................................. 3
FABRICATION ......................................................................................................................................... 3
833.17 GENERAL ............................................................................................................................... 3
833.18 SHOP DRAWINGS ................................................................................................................. 3
833.19 VERTICALITY OF POSTS AND BALUSTERS ................................................................... 3
833.20 CURVING OF RAILS ............................................................................................................. 3
833.21 CUTTING AND EDGE TREATMENT .................................................................................. 3
833.22 SPLICES .................................................................................................................................. 4
833.23 BOLTING ................................................................................................................................ 4
833.24 WELDING ............................................................................................................................... 4
833.25 - 833.34 NOT USED ................................................................................................................ 4
833.35 PROTECTIVE TREATMENT................................................................................................. 4
833.36 - 833.39 NOT USED ................................................................................................................ 4
833.40 ERECTION .............................................................................................................................. 4
833.41 - 833.79 NOT USED ................................................................................................................ 5
SPECIAL REQUIREMENTS................................................................................................................... 5
833.80 – 833.82 NOT USED ............................................................................................................... 5
GENERAL
833.01 SCOPE
833.02 REFERENCES
Australian Standards
833.11.01 GENERAL
1. All materials supplied by the Contractor shall be new and shall conform New Steel
to the standards specified below.
2. Unless otherwise specified all structural steel sections shall be Grade 250 Standards
in accordance with AS 3679.
1. The Contractor shall ensure that all materials conform with the tests Certificates
required by the standards.
1. All materials used in the Works shall be identified with the test Identification
certificates. The Contractor shall establish and maintain a comprehensive system of
identification records. Copies of all these records shall be forwarded to the
Superintendent on request.
1. Each item of steelwork shall have its own item mark number which shall Identification
be used on all related schedules and documents. This mark shall be clearly indicated on
all members by durable identification marks to enable accurate identification on site.
833.15 STORAGE
1. All steel, whether fabricated or not, shall be stored in such a manner that
corrosion is minimised. Generally, storage at least 200 mm above the ground on
platforms, slabs, or other supports under cover will be satisfactory. Excessively rusted
or bent or damaged steel will be rejected.
1. Before and after fabrication and during transit and on the Site all
steelwork shall be handled and stacked in such a way that it is not damaged.
FABRICATION
833.17 GENERAL
2. The Contractor shall supply and fabricate and transport and erect all
railing to the deck and approaches of the bridge as shown on the Drawings. The railing
shall be fabricated from steel sections.
2. Each item shall be clearly identified with the identification marks shown
on the Drawings. Each type of component shall be further identified to readily
distinguish it from all other types.
1. All balusters and posts shall be vertical as shown on the Drawings. The
Contractor's attention is drawn to the need to detail individually angled brackets and
joints to ensure that this requirement is met.
1. Where the rails are shown on the Drawings to be curved, they shall be
curved to form that shape without excessive “springing” forces being applied to the
posts. The methods adopted for curving the rails shall be such as not to excessively
distort the section or damage the material.
2. Unless shown otherwise on the Drawings, all corners on cut edges shall
be rounded to a radius of approximately 1.5 mm, except where such edges are
833.22 SPLICES
2. The location of any splices required in the rails additional to those shown
on the Drawings shall be subject to approval by the Superintendent.
833.23 BOLTING
1. All bolt holes shall be drilled to a diameter 2 mm larger than the diameter
of the bolt unless otherwise shown on the Drawings.
1. Manufacture - Grade 4.6 bolts shall comply with AS 1111 and nuts shall
comply with AS 1112. Plain washers shall comply with AS 1237. Grade 8.8 bolts and
associated nuts and washers shall comply with AS 1252.
833.24 WELDING
2. All electrodes used for manual welding shall conform to AS 1553. Flux
cored electrodes used for semi-automatic welding shall conform to AS 2203.
833.40 ERECTION
833.40.01 GENERAL
2. After fabrication all weld splatter and slag shall be removed by suitable
833.40.02 TOLERANCES
1. The finished railing shall be erected to the tolerances set out below:
2. The final appearance of the bridge will depend very much on the profile
of the railings and therefore in addition to the above tolerances the Contractor shall take
every care to ensure that the railings are erected to smooth curves which reflect the
design profiles of the bridge. In particular the Contractor shall ensure that a smooth
profile is maintained in the top rail after all site connections have been completed.
SPECIAL REQUIREMENTS
PROTECTIVE TREATMENT
OF STEELWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
835.01 SCOPE.................................................................................................................................. 1
835.02 REFERENCES ..................................................................................................................... 1
835.03 DEFINITIONS ..................................................................................................................... 2
835.04 PROCEDURES .................................................................................................................... 2
835.05 SCHEDULE OF SURFACE TREATMENTS..................................................................... 2
835.06 - 835.09 NOT USED ............................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
835.10 COATING SYSTEMS ......................................................................................................... 2
835.11 GENERAL REQUIREMENTS AND INFORMATION TO BE PROVIDED BY
CONTRACTOR....................................................................................................................................... 4
835.12 - 835.19 NOT USED ............................................................................................................... 5
OPERATION.............................................................................................................................................. 5
835.20 SURFACE PREPARATION................................................................................................ 5
835.21 GALVANISING .................................................................................................................. 5
835.22 SHOP PRIMING .................................................................................................................. 6
835.23 INTERMEDIATE COATING ............................................................................................. 6
835.24 FINISHING COATS ............................................................................................................ 7
835.25 FINISH COLOUR................................................................................................................ 7
835.26 APPLICATION.................................................................................................................... 7
835.27 ACCEPTANCE TESTING .................................................................................................. 8
835.28 PROTECTION ..................................................................................................................... 9
835.29 SITE REPAIRS .................................................................................................................... 9
835.30 - 835.79 NOT USED ............................................................................................................. 10
SPECIAL REQUIREMENTS................................................................................................................. 10
835.80 - 835.89 NOT USED ............................................................................................................. 10
ANNEXURE 835A ................................................................................................................................... 11
SCHEDULE OF SURFACE TREATMENTS....................................................................................... 11
GENERAL
835.01 SCOPE
835.02 REFERENCES
Australian Standards
Other Publications
835.04 PROCEDURES
1. Annexure 835A lists the approved surface treatments for use in this
contract.
MATERIALS
835.10.01 GALVANISING
2. At least 7 days prior to the application of the galvanised coating, the HOLD POINT
Contractor shall submit details of procedures which eliminate the
above coating deficiencies.
2. The Contractor shall also carry out protective treatment on site using
epoxy rich zinc primer conforming to AS 3750.9 for areas of steel
members which have been site welded. Refer also Clause 835.29.
a) Galvanised Members
b) Painted Members
3. Hollow Members
The treatment of hollow members shall be as follows:
a) Galvanised Members
b) Painted Members
3. The Contractor shall submit proposed details of work to be carried HOLD POINT
out by shop treatment and that to be carried out by field treatment.
4. The details shall include a program of the work covering the following:
835.11.02 PAINT
2. At least fourteen days before commencing the protective treatment of HOLD POINT
steelwork, the Contractor shall submit the following details for the
Superintendent's approval:-
835.11.03 TESTING
1. The Contractor shall record details of the paints used on the Works. The
records shall include, but not be limited to, the following:-
OPERATION
1. The surface treatment for all steel surfaces except those shown on the
Drawings to be left unpainted or to be galvanised shall be abrasive blast
cleaned followed by shop priming with inorganic zinc silicate paint.
Surfaces which are to be left unpainted shall be thoroughly wire brushed
and solvent cleaned where necessary to remove loose rust and mill scale
and surface contamination.
835.21 GALVANISING
1. All hot dip galvanising shall conform with the requirements of AS 4680
and shall be clean and smooth and continuous and free from acid spots
and cracks and laminations and runs and drips. The coating shall have a
minimum thickness of 85 microns for thickness of steel member 6 mm
and greater. The coating thickness shall be in accordance with AS 4680
for all structural member less than 6 mm thick.
2. The primer shall be applied as soon as possible after blast cleaning before
deterioration has taken place and in any case within four hours.
1. Not more than eight hours prior to application of a finishing coat the
surface shall be washed with fresh clean water to remove any salt, sand,
dust, grit, grease and cement or other contaminants and allowed to dry
thoroughly. If necessary suitable solvents shall be used to remove
contaminants that are not water soluble and the areas concerned re-
washed with water.
3. The final finishing coat shall be applied on site after the erection of the
steelwork, placing of in situ concrete, removal of falsework and all site
repairs have been completed.
1. The finish colour for all steelwork shall be "Bottle Green" (G11) as
defined by AS 2700.
835.26 APPLICATION
1. Painting shall not be carried out under the following climatic conditions:
d) When the steel temperature is less than 3oC above the dew point
(see Section 8 of AS 2312).
1. Tie and finishing coats may be applied by spray brush or roller except
that the following conditions shall apply:
a) On site application of paint by spray can be carried out only after the
Contractor has taken every precaution to ensure that there is no
danger of overspray damaging property or passing traffic.
835.27.01 INTRODUCTION
1. The Contractor shall measure the dry film thickness using a non-
destructive type film thickness gauge. The gauge shall be either:
835.27.04 PROCEDURE
1. In order to determine the dry film thickness of each coating the following
procedure shall be adopted:
(a) Dry film thickness gauges shall be calibrated using shims of known
thickness set on the blast reference sample. The calibration
procedure shall consist of taking not less than 30 readings on the
shim on the reference blast sample and from these determining the
mean reading. This mean reading shall be subtracted from the
known shim thickness to produce a correction factor which shall be
added algebraically to all subsequent readings of dry film paint
thickness in order to obtain the true "above peaks" value.
(b) Readings shall subsequently be taken of the total dry film thickness
after the application of each type of coating.
(c) At each stage the Contractor shall use the average reading for that
surface.
(d) The dry film thickness for any coating is the difference between the
values obtained for this coating and the average total dry film
thickness at the completion of the preceding coating.
(i) For large flat surfaces like the webs and flanges of beams the
number shall be one per square metre.
(ii) For hand railing panels the number shall be six per linear metre.
2. For assessing the compliance of a coating with the thickness requirement
of this Specification all measured values of the dry film thickness on each
surface shall equal or exceed the specified minimum dry film thickness
for that coating. Surfaces not meeting this requirement shall receive
further coats of primer or finishing coat as appropriate to build up the
paint thickness required.
835.28 PROTECTION
1. The paint system shall be fully cured before any components are handled.
It shall be properly protected during all transport and erection procedures
to maintain it in a clean and undamaged condition. In particular proper
precautions are to be taken during lifting operations to ensure a minimum
of damage is caused by slinging or guying or supporting or similar
operations.
2. Areas of paintwork which have been damaged and areas of site welded
connections shall be cleaned by power wire brush to AS 1627 Part 2
Class 3 followed by abrasive paper to provide a surface profile. In
addition the edge of the surrounding undamaged paint shall be feathered
with abrasive paper.
3. In areas of site welded connections all weld splatter and slag shall be
removed by mechanical means and all sharp edges and rough welds shall
be rounded off before cleaning.
4. The damaged areas and areas of site welded connections shall then be
painted as laid down in Clauses 835.22 to 835.24 except that the primer
shall be an approved two pack epoxy-zinc-rich coating conforming to
Type 2 of AS 3750.9. The paint used shall be a product approved by the
Australian Paint Approval Scheme and shall be to Specification APAS
2916. The new paint shall overlap the existing paint by at least 50 mm all
SPECIAL REQUIREMENTS
2. Not Used.
BRIDGE BEARINGS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
860.01 SCOPE.................................................................................................................................. 1
860.02 REFERENCES ..................................................................................................................... 1
860.03 - 860.12 NOT USED ............................................................................................................... 1
DESIGN AND MANUFACTURE ............................................................................................................ 1
860.13 GENERAL ........................................................................................................................... 1
860.14 PHYSICAL DIMENSIONS AND TOLERANCES OF ELASTOMERIC BEARINGS..... 1
860.15 ACCEPTANCE TESTS FOR ELASTOMERIC BEARINGS............................................. 2
860.16 – 860.17 NOT USED ............................................................................................................... 3
860.18 REJECTION......................................................................................................................... 3
860.19 TRANSPORT AND DELIVERY ........................................................................................ 3
INSTALLATION OF BEARINGS ........................................................................................................... 4
860.20 LOCATION AND FIXING OF ELASTOMERIC BEARINGS.......................................... 4
860.21 – 860.22 NOT USED ............................................................................................................... 4
860.23 INSTALLATION OF ELASTOMERIC BEARINGS ......................................................... 4
860.24 NOT USED .......................................................................................................................... 4
820.25 TOLERANCES FOR INSTALLATION ............................................................................. 4
BRIDGE BEARINGS
GENERAL
860.01 SCOPE
860.02 REFERENCES
Australian Standards
Other Publications
860.13 GENERAL
860.15.01 GENERAL
4. Test loads shall be applied slowly and at a uniform rate. When the
specified loading has been attained it shall be maintained steady sufficiently long for a
physical examination of the bearing or for two minutes whichever is the greater before
unloading. If any damage occurs, then the load and time at which any damage begins to
occur shall be recorded.
1. All bearings shall be loaded individually to 1.5 times the rated load at
zero rotation and zero shear given on the Drawings or in the relevant table of the
Australian Bridge Design Code.
1. 50% of bearings of the same capacity and type shall be loaded in pairs
under the rated load at zero shear.
3. In case of bearings which are circular in plan one bearing shall be rotated
with respect to the other for a series of equal loads until an orientation producing
maximum lateral deflection is located. The bearings shall then be loaded under the
maximum rated load and the maximum radial lateral deflection measured. The bearings
shall be permanently marked and then reloaded with one bearing rotated through 180°
with respect to the other. The lateral radial deflection shall then be measured at the
same point on the non-rotated bearing and the lateral deflection for each bearing alone
shall be calculated.
4. Any bearing in which the lateral deflection in any direction under the test
1. The Contractor shall carry out the tests set out in Table 860.1 on one pair
of bearings of each type and capacity. The bearings shall be loaded in stacked pairs in
the test apparatus.
2. During the test described at (b) or (c) in Table.860.1, the net contact area
shall be not less than 80% of the unloaded bearing area.
(a) The rated load at zero rotation and maximum shear plus 1.5
x the maximum rated shear deflection.
(b) 1.5 x rated load at zero rotation and maximum shear plus 1.0
x the maximum rated shear deflection.
(c) 1.5 x the maximum rated shear deflection plus 0.5 x rated
load at zero rotation and maximum shear.
860.15.05 STIFFNESSES
860.18 REJECTION
1. Where a bearing is rejected the Contractor may elect to test all bearings of
the type represented and only bearings successfully passing the tests will be accepted.
In addition all replacement bearings shall be acceptance tested. The cost of all
additional testing shall be borne by the Contract.
2. Grout pads shall be well compacted and shall be constructed with formed
sides as detailed on the Drawings. Bearings may be used to set the levels of the pad but
shall be removed for inspection of the finished pad.
3. The pads shall consist of an approved non shrink cementitious grout with
a minimum of 28 days compressive strength of 30 MPa when tested using a 70 mm
cube. A minimum of two cubes shall be taken from each batch of mortar mixed.
MISCELLANEOUS
SPECIFICATION 901 – CONCRETE – GENERAL WORKS
SPECIFICATION 903 - FENCING
SPECIFICATION 908 - GRAFFITI
SPECIFICATION 909 – WATER RETICULATION
SPECIFICATION 910 – SEWER PRESSURE MAINS
S PECIFICATION 901
Clause Page
GENERAL .................................................................................................................................................. 1
901.01 SCOPE.................................................................................................................................. 1
901.02 REFERENCES ..................................................................................................................... 1
MATERIALS.............................................................................................................................................. 1
901.03 GENERAL ........................................................................................................................... 1
901.04 ADMIXTURES.................................................................................................................... 2
901.05 REINFORCEMENT............................................................................................................. 2
901.06 CLASS OF CONCRETE ..................................................................................................... 2
901.07 FORMWORK ...................................................................................................................... 2
901.08 - 901.29 NOT USED ............................................................................................................... 3
OPERATIONS ........................................................................................................................................... 3
901.30 MIXING OF CONCRETE ................................................................................................... 3
901.31 PLACING OF CONCRETE................................................................................................. 3
901.32 TESTING ............................................................................................................................. 4
901.33 CURING AND PROTECTION ........................................................................................... 4
901.34 CONCRETING IN HOT WEATHER ................................................................................. 4
901.35 CONCRETE SURFACES.................................................................................................... 5
901.36 CONFORMANCE AND NON-CONFORMANCE ............................................................ 5
901.37 - 901.79 NOT USED ............................................................................................................... 6
SPECIAL REQUIREMENTS................................................................................................................... 6
901.80 - 901.89 NOT USED ............................................................................................................... 6
GENERAL
901.01 SCOPE
1. The work to be executed under this Specification consists of the mix Scope
design, the supply and delivery, placing, compaction, finishing, curing and protection of
concrete for general non-structural works where normal (N) class concrete has been
specified.
901.02 REFERENCES
Australian Standards
MATERIALS
901.03 GENERAL
901.03.01 DEFINITIONS
1. Concrete in general shall consist of a mixture of cement and water and Constituents
coarse aggregate and fine aggregate.
1. In its finished state the concrete shall be sound, dense, durable, free from Finished State
honeycombing and shall have the strength and other properties specified.
2. The exposed surfaces shall be smooth and dust free and conform to the Exposed
shape tolerances specified. Surface
3. Concrete shall comply with AS 1379 except as varied by the requirements Concrete to
of this Specification. Comply
4. Aggregates shall meet the durability criteria for concrete exposure Aggregate
classification C of AS 2758.1 unless otherwise specified. Durability
901.04 ADMIXTURES
1. Admixtures may be used in concrete to modify workability but will not Admixtures
be permitted for the purpose of reducing cement content. However, the admixture shall Compliance
have no harmful effect whatsoever upon the quality of the concrete or upon any
reinforcement or other fixture embedded therein.
901.05 REINFORCEMENT
1. Reinforcement used in the Works shall comply with the relevant Reinforcement
requirements of AS 4671. to Comply
2. Steel for reinforcement shall be free from loose or thick rust, loose mill Storage
scale, all dirt, all grease and all other foreign substances which may impair the bond
between steel and concrete. Reinforcement steel shall be stored above ground level and
shall be protected from damage and deterioration due to exposure.
3. Reinforcing steel shall be accurately cut and bent to the dimensions and Cutting &
shapes shown in the Drawings. All bars shall be bent in accordance with AS 3600. Bending
4. Reinforcing steel shall be accurately placed in the positions shown on the Placement
Drawings and the maximum tolerance on all concrete cover dimensions shall be +5 mm Secured
and -0 mm. The reinforcement shall be secured in position so that it will not be
displaced during the placement of concrete and the Contractor shall ensure that there is
no disturbance of the reinforcement in concrete that has already been placed.
1. The Class of concrete shall be as specified on the Drawings or in the Concrete Class
relevant Specification.
901.07 FORMWORK
1. All formwork used to form and support the concrete shall conform to the
OPERATIONS
1. Production and delivery for the concrete shall be in accordance with the Batch Plant &
requirements of AS 1379 except that additional water shall not be introduced into a Transit Mixers
mixed batch of concrete and the period for completion of discharge from the
commencement of mixing shall not exceed ninety (90) minutes.
1. Prior to the placement of any concrete the Contractor must certify to HOLD POINT
the Superintendent that all falsework, formwork, reinforcement, levels, placement
procedures and curing procedures to be employed comply with the requirements
of the Technical Specification.
2. Before commencement of each concrete pour the Contractor must HOLD POINT
ensure that sufficient vibrators and spares are available and tested. The number of
working vibrators required must not be less that one for each 4 cubic metres of
concrete placed per hour. The number of standby vibrators must not be less than
25% of the number of working vibrators with a minimum of one.
3. Concrete shall be conveyed from on site mixers to its final position Transport &
without delay and by methods which will not permit segregation and/or loss of material. Placing
All the concrete shall be placed in its final position within ninety minutes of the
materials having been placed in the mixer.
5. Care shall be taken during placing to see that no foreign substances are Foreign
included in the concrete. Substances
901.32.01 GENERAL
2. The Contractor shall have available not less than six concrete moulds,
slump cone and tray, and rod.
1. Any batch of concrete shall be deemed to comply with the strength Compliance
requirements of this Specification if:
(a) Every concrete test specimen in the batch has a 28 day compressive
strength greater than 90% of the characteristic strength; and
All concrete surfaces shall be cured by one of the following methods for not less than
five (5) days:
The Contractor shall ensure that the method of curing shall not result in any staining of
exposed surfaces of concrete.
1. The requirements of AS 1379 for temperature of the concrete at the point Placement
of discharge shall be met for all concrete works undertaken in hot weather. In addition, Temperature
placement of concrete shall only be permitted providing:
b) the ambient shade temperature does not exceed 38°C and is falling, Shade
Temperature
c) the ambient shade temperature is less than 38°C and rising provided
that the placement can be completed before the ambient temperature
exceeds 38°C.
1. Surface finish of concrete shall conform to the following requirements: Surface Finish
(a) The quality of surface finish and tolerances for exposed formed Quality of
surfaces of concrete shall be as specified in Section 3 of AS 3610 for Finish
a Class 2 finish unless otherwise shown on the Drawings.
(b) The quality of surface finish and tolerances for concealed formed Concealed
surfaces of concrete shall be as specified in Section 3 of AS 3610 for Formed
a Class 3 finish unless otherwise shown on the Drawing. Surfaces
2. If at any time the concrete fails to meet any of the requirements of this Operations
Specification, concreting operations shall be suspended until corrective measures are Suspended
taken, at no cost to the Principal.
SPECIAL REQUIREMENTS
Clause Page
GENERAL .................................................................................................................................................. 1
903.01 SCOPE...................................................................................................................................... 1
903.02 REFERENCES ......................................................................................................................... 1
GROUNDWORK ....................................................................................................................................... 1
903.03 WORK NEAR TREES............................................................................................................. 1
903.04 PROTECTION OF TREES TO BE PRESERVED................................................................. 1
903.05 DAMAGE ............................................................................................................................... 1
903.06 WORK UNDER TREES.......................................................................................................... 2
903.07 CUTTING AND TREATING LARGE ROOTS...................................................................... 2
903.08 SITE CLEARING .................................................................................................................... 2
903.09 EXISTING SERVICES............................................................................................................ 2
903.10 FOOTINGS .............................................................................................................................. 2
MATERIALS & CONSTRUCTION........................................................................................................ 2
903.11 CONCRETE ............................................................................................................................. 2
903.12 METALWORK ........................................................................................................................ 3
903.13 BOUNDARY FENCES IN THE ELECTRIFIED AREA........................................................ 6
ANNEXURE 903A ..................................................................................................................................... 7
BOUNDARY FENCES IN THE ELECTRIFIED AREA ....................................................................... 7
REMOVAL AND REPLACEMENT OF A FENCE PANEL ................................................................. 7
NEW FENCES......................................................................................................................................... 8
GENERAL
903.01 SCOPE
1 This Specification details the fencing and gates to be installed on the Public
Transport Authority Railway Reserve of the Perth Urban Railway Network.
2 1800 mm high chain link fence with a triple row of barbed wire on cranked
posts applies to the fence along the rail easement, the ACS Section 15 Boundary and the
Intermodal Terminal area, and boundary between the Intermodal terminal and Port Beach
Road. Chain link fence is to be Black Powder Coated finish. A minimum offset of 1.0m
should be provided if used along cycle-paths as per Austroads Part 14 - Bicycles. This
fencing should be in accordance with the following Main Roads standard drawings with
the exception that posts are to be cranked:
• 9331-0385 Assembly Details
• 9331-0386 Gate and Post Details
3. The fence adjacent to the electrified areas of rail line should generally be
1800mm high chain mesh with 3 strands of barbed wire above (not cranked).
903.02 REFERENCES
GROUNDWORK
1. Trim, cut back or otherwise modify trees and shrubs on the Reserve
encroaching within one metre of the fence line, as approved by the Superintendent.
Protect trees that overhang or are not on Public Transport Authority property
1. Protect trees that are nominated for preservation by the Superintendent, with
high visibility tape.
903.05 DAMAGE
1. Remove topsoil from within the drip line of trees unless otherwise directed.
Excavations under tree canopies shall be dug by hand and filled in as quickly as possible
to minimise root damage.
1. Clear a strip generally 1 metre wide for fences, plus other specified
areas occupied by the works or shown on the Drawings.
903.10 FOOTINGS
903.11 CONCRETE
903.11.01 GENERAL
903.11.02 TESTING
b)Site Mixed
Use Type ‘A’ Portland cement, clean sharp sand, potable water and coarse
aggregate passing not less than 5 mm. and not greater than 20 mm. sieve
sizes. Mix in the ratio of not less than one part cement to two parts sand
and four parts coarse aggregate by volume (1:2:4 mix), with sufficient
water to provide a water/cement ratio by volume between 0.8 and 0.9.
If additional water is required for workability, the water/cement ratio shall
be maintained by adding a corresponding volume of cement.
903.11.04 PLACEMENT
1. Place concrete in layers not more than 200mm. deep, each layer being
tamped with a rod or vibrated with a poker vibrator to blend into the preceding layer.
2. Where formwork is required to support excavations, the formwork is not to
be removed without prior written approval of the Superintendent.
903.11.06 FINISHES
1. Concrete surfaces are to be wood float finished, flush with or above the
surrounding ground surface. Concrete splashes are to be cleaned off metal components
before initial setting.
903.12 METALWORK
1. All posts, fittings, threaded fasteners, cable wires, ties and mesh shall be
heavily zinc coated to a minimum coating mass of 200g./m2 in accordance with the
Standards in Table 1 that may supersede those referenced in the Standards above: -
903.12.02 POSTS
DIA DEPTH
INTERMEDIATE NB 40 4000 mm. 300 mm. 600 mm.
OD 48.3 mm. Maximum
WT 2.3 mm
END, CORNER NB 50 as required 300 mm. 750 mm.
OD 60.3 mm.
WT 3.6 mm
GATES NB 50 as required 300 mm. 900 mm.
UP TO 4 m. OD 59 mm.
OPENINGS WT 4.5mm.
GATES NB 80 as required 300 mm. 900 mm.
BETWEEN 4 m. OD 89 mm.
and 8 m. WT 4.5mm.
OPENINGS
BRACING NB 32 as required 300 mm. 600 mm.
OD 42.4 mm
WT 2.6 mm
Table 2 - Post Sizes, Spacings and Footing Details
903.12.04 CHAINMESH
1. Diagonal Braces:
Gooseneck Stays clamped to posts with steel
compression fittings and embedded in concrete footings.
2. Boxed Strainers
A 32NB horizontal brace fixed approximately 300 mm below top selvedge
of chain mesh with steel compression fittings and double twisted 3.15 mm. dia. wire and
turnbuckle for tensioning. Boxed Strainers are to be used where sandy soil prevails.
3. Back Stays -
To be fitted to gate posts at 45o to the vertical for gates with a leaf width
greater than 1.80m.
4. Horizontal Stays -
at each location of corner back stays.
1. The first cable wire shall be tied to the post, carried across the outside face
of the next post in line and then looped around the second post so that the wire leaves the
post on the outside face.
2. The second cable wire shall be tied to the first end post, looped around the
first post so that the wire leaves the post on the outside face, and is then carried across the
outside face of the second post.
3. This operation shall be continued along the fence, looping each cable wire
around alternate posts, finally tying each wire to the end or gatepost.
4. The two cable wires shall be twisted together at intervals between posts to
form a tight spiral pitch and so provide adequate tension to the cable wires.
1. The helicoil cable wire shall be looped twice around the first end post and
then twisted around itself four times. It shall then be passed along the outside of the line
posts and attached to other end, gate or strainer post in the same manner as for the first
post. Each run of cable wire shall be tensioned so as to support the weight of the chain
mesh, without sagging. Each run of cable wire shall be securely tied to each line post.
1. Lacing wire:
2.0 mm Dia. wire fully laced through each diamond at end, gate and corner
posts.
2. Tie wire:
2.0 mm Dia. wire with two full twists and neatly cut off. Chain mesh may
be fastened with Garrard Ring fasteners. (Or similar approved).
Three rows of two 3.15 mm dia, wire twisted together with four point barbs
at nominally 90 mm centres, heavy galvanised and attached to posts above chain mesh
fencing at 150 mm vertical spacing. Barbed wire shall be strained between all posts until
taut and secured with tie wire on to each post.
903.12.11 GATES.
2. Insulated panels are normally installed not more than 200 metres apart.
All fence panels in the electrified area are either bonded to or insulated from traction earth.The traction
return rail forms part of the traction earth.
Metallic items within 3 metres of the vertical plain formed by live 25 000 volt conductors are bonded to
the traction rail so that in the event of a fault a direct earth will be available for protection equipment to trip
the circuit breaker(s) feeding that section of overhead line. The ECO will usually reclose the circuit
breakers in an attempt to power the section up again. Even when the circuit breakers are open for an
electrical section the Overhead Line Equipment may still be charged due to induced voltage or residual
charge.
Fences and other metallic items are therefore bonded to the traction return rail to bleed off
voltages induced from the live overhead line.
A fence section should only be earthed at one point in order to prevent circulating current
between multiple earths.
Where a fence deviates away from the railway track and there is a distance of more than 3 metres from the
vertical plain formed by the live 25 000 volt conductors, an insulated fence panel is installed. This
insulated fence panel is at least 2.5 metres wide to ensure that a person cannot bridge across the panel and
make contact with a portion of a fence at traction earth and one that may be at Supply Authority earth.
In order to maintain electrically safe fences in the electrified area it is important that these insulated fence
panels are never electrically shorted with a jumper cable, temporary traction bond, cable etc and never
shortened in length.
An insulated fence panel is sometimes installed to give at least 2.5 metres separation between equipment at
traction earth and that at Supply Authority earth.
Example: a communications location case at Supply Authority earth may be located close to a fence at
traction earth. In order to make the situation electrically safe, an insulated fence panel may be installed
opposite the communications location case.
Insulated fence panels are also installed approximately every 100 or 200 metres along a fence that is at
traction earth, this is done to cut down the electrical length of the metal work that is parallel with live
overhead line equipment. This reduces the voltage induced into the fence.
Under fault conditions there may be up to 1000 volts difference between an item at traction earth and one
at Supply Authority earth in the vicinity .
Where there is a need to remove a fence panel, the installation must first be checked to see what type of
panel it is. Fence panels can be considered to be one of the following:
• NORMAL PANEL: Is neither insulated from nor bonded to traction earth and may be at Supply
Authority earth or close to equipment that is at Supply Authority earth.
• BONDED PANEL: A panel that is secured to a post that has a traction bond connected to it.
• SERIES PANEL: A fence panel that is bonded indirectly to traction earth via another bonded panel
• INSULATED PANEL:Has insulated fittings to electrically isolate two sections of bonded fence or
maintain a minimum of 2.5 metres separation from equipment at Supply Authority earth.
Renewal of a normal fence panel will require no special precautions other than to ensure that any adjacent
bonded or insulated panel is not disturbed.
Where a bonded post has to be removed, a temporary traction bond must be installed between the traction
return rail and the remaining fence panels prior to removing the permanent bond. The temporary traction
bond must be maintained until the fence has been fully restored and permanent bonding replaced.
Temporary traction bonds must not be coupled together. Prior to use, a temporary traction bond must be
inspected to ensure that the cable and fittings are in good order. Any faulty unit must not be used, but must
be forwarded to the Overhead Catenary Foreman for repair or replacement. An appropriate length
temporary traction bond must be used. A temporary traction bond must not be connected to anything other
than the traction return rail and the appropriate fence post per the job requirements.
NOTE: The traction return rail is generally the one closest to the masts. This rail is sometimes
transposed for signalling purposes. The web of the traction return rail is painted with a patch of light
blue paint opposite each mast.
A temporary jumper cable must be installed around a series fence panel prior to its removal. This jumper
cable must be left in place until the fence has been fully restored.
Jumper cables must not be coupled together, Prior to use, a jumper cable must be inspected to ensure that
the cable and fittings are in good order, Any faulty unit must not be used, but must be forwarded to the
Overhead Catenary Foreman for repair or replacement, An appropriate length jumper cable must be used,
A jumper cable must not be connected to anything other than the traction return rail and the appropriate
fence post or from one fence panel to another per the job requirements.
An insulated fence panel is only to be removed by Overhead Catenary Staff, An insulated fence panel must
not be bonded nor bridged.
After completing work on a bonded or series fence panel, the person in charge of the work must advise the
ECO that the work has been completed and the installation has been restored, The ECO will make
arrangements to have the installation electrically tested.
NEW FENCES
The Electrical Manager must be advised of any proposed new fence installations or replacements in the
electrified area, Any new fence must be assessed to determine bonding and insulating requirements.
GRAFFITI
CONTENTS
Clause Page
GENERAL .................................................................................................................................................... 1
908.01 SCOPE.................................................................................................................................... 1
908.02 REFERENCES ....................................................................................................................... 1
MATERIALS................................................................................................................................................ 2
908.03 GENERAL ............................................................................................................................. 2
908.04 ANTI-GRAFFITI COATINGS .............................................................................................. 2
908.05 GRAFFITI REMOVAL MATERIALS.................................................................................. 3
908.06 PAINT .................................................................................................................................... 4
908.07 - 908.10 NOT USED ................................................................................................................. 4
ANTI-GRAFFITI COATINGS ................................................................................................................... 4
908.11 SUBSTRATE SURFACE PREPARATION .......................................................................... 4
908.12 APPLICATION ...................................................................................................................... 5
908.13 ANTI-GRAFFITI COATING SYSTEMS.............................................................................. 5
908.14 - 908.20 NOT USED ................................................................................................................. 6
GRAFFITI REMOVAL............................................................................................................................... 6
908.21 GENERAL ............................................................................................................................. 6
908.22 GRAFFITI REMOVAL ......................................................................................................... 7
908.23 PAINTING OVER GRAFFITI............................................................................................... 7
908.24 - 908.30 NOT USED ................................................................................................................. 8
INSPECTION AND TESTING................................................................................................................... 8
908.31 EFFECTIVENESS OF ANTI-GRAFFITI COATINGS......................................................... 8
908.32 SURVEILLANCE OF CONSTRUCTION WORKS............................................................. 8
908.33 REPORTS............................................................................................................................... 9
908.34 - 908.40 NOT USED ................................................................................................................. 9
SPECIAL REQUIREMENTS ..................................................................................................................... 9
908.41 - 908.50 NOT USED ................................................................................................................. 9
ANNEXURE 908A ..................................................................................................................................... 10
APPROVED ANTI-GRAFFITI COATINGS .......................................................................................... 10
ANNEXURE 908B...................................................................................................................................... 11
GRAFFITI
GENERAL
908.01 SCOPE
1. The works to be executed under this specification consist of the provision Anti-Graffiti
of graffiti prevention measures by the application of anti-graffiti coatings to roadside Coatings
furniture and structures including bridges, noise walls, retaining walls, traffic controller
boxes, and similar features.
2. The scope also includes the removal of graffiti and/or the painting over of Graffiti
graffiti. Removal
3. The scope excludes the application of anti-graffiti coatings to the faces of Signs Excluded
traffic signs. The use of a protective overlay film for the protection of sign faces is
described in Specification 601 SIGNS.
908.02 REFERENCES
Australian Standards
Graffiti Removers
Non-Sacrificial Anti-Graffiti Coatings
Sacrificial Anti-Graffiti Coatings
Test Methods for Effectiveness of Graffiti Removers:
Non-Sacrificial Anti-Graffiti Coatings
Sacrificial Anti-Graffiti Coatings
Copies of the Materials Institute of WA specifications can be obtained from Graffiti
Program, Ministry of Premier and Cabinet, PO Box 877, BALCATTA, WA 6914, or
by Telephone on 08 9240 5555
908.03 GENERAL
2. Product Data Sheets and current Materials Safety Data Sheets HOLD POINT
detailing the properties of the proposed products shall be provided to the
Superintendent prior to the use of any materials on works within the Contract.
908.04.01 DEFINITIONS
908.04.02 GENERAL
2. The selected anti-graffiti coating system used shall carry a guaranteed Guaranteed
"Graffiti Removal" life of not less than ten years from the date of application. Life
4. The coatings shall be able to fulfil the claims of the manufacturer with
respect to coating properties for the particular surfaces on which it is designed to be
used.
0 No graffiti removed
7. The written request for the nominated coating shall include the
Manufacturer's Specification, Recommendations and Materials Safety Data Sheets and
the Materials Institute of Western Australia’s (MIWA) testing and approval for use on
public buildings.
8. The Contractor may be required to provide test samples or panels Test Samples
accompanied with NATA certification of colour, gloss, thickness and adhesion. The
panels shall be compressed cement sheet, and shall be used for testing in accordance
with MIWA assessment methods.
3. The remover shall be able to fulfil the claims of the manufacturer with
respect to removal properties for the particular surfaces on which it is designed to be
used.
0 No graffiti removed
908.06 PAINT
ANTI-GRAFFITI COATINGS
2. All dust, dirt, grease and oil contaminants, including remnants of curing
membranes, and other surface contaminants shall be removed by non-destructive means
followed by water washing.
5. Some of the smoother concrete surfaces may require whip blasting with a
fine grade garnet or surface etching with an approved acid wash followed by a water
wash in order to provide adequate adhesion of the coating system. Whip blasting
operations shall be carried out in accordance with the appropriate regulations.
908.12.01 GENERAL
(b) where wind borne debris may contaminate the uncured surface of the
freshly applied coating;
(e) when there is any chance of rain spatter, or run off, including leakage
through deck joints, contaminating the surface and adversely
effecting the adhesion to the substrate;
(f) where the surface temperature of the substrate is less than 3°C above
the dew point or exceeds 40°C;
2. Not Used.
1. The coating system shall be a non-sacrificial (except where the coating is Type of
to be installed on a limestone substrate) clear or pigmented coating to a specified colour. Coating
3. The coating system shall not affect the re-coat ability of the substrate
material.
7. The finished cured coating system shall have a minimum installed Dry Film
thickness of 175µm encompassing a minimum anti-graffiti coating dry film thickness Thickness
(DFT) of 100µm. The dry film thickness shall be measured in accordance with
ASTM D6132-97 using a digital coating thickness gauge suited for single or multiple
coating layers, which has been calibrated for use on concrete, steel and similar surfaces
to which the coatings are applied.
8. The installed coating system shall have an adhesion value to the substrate Adhesion
exceeding one (1) MPa in accordance with AS 1580.408.5. Value
GRAFFITI REMOVAL
908.21 GENERAL
2. Typical graffiti removal methods shall include but not be limited to:
908.22.01 GENERAL
1. Where the nature or composition of the graffiti is such that the HOLD POINT
Contractor's selected removal treatment may cause damage to the substrate, the
Contractor shall seek written authorisation from the Superintendent prior to
commencing the treatment.
3. For uncoated substrates the complete removal may not be possible due to
the absorbency of the substrate material. Under these circumstances the Superintendent
may allow some residual paint staining or shadowing to remain.
3. The paint shall be 100% acrylic. The colour and level of gloss shall be
specified by the Superintendent.
3. The frequency of adhesion testing shall be one (1) test per 25m2 of coated
area for each coating system layer.
4. The Contractor shall produce certification that the coating system has
been applied in accordance with the Manufacturer's published recommendations.
1. The Contractor shall systematically inspect road and bridge construction Inspections
Works for Graffiti at least on a weekly basis during the Contract period, including
immediately after weekends or public holidays. Particular attention shall be given to
obvious graffiti targets such as bridges and other major structures with a large surface
area.
908.33 REPORTS
1. The Contractor shall produce and submit a graffiti report upon completion Reporting
of each instance of graffiti removal. The report shall contain a comprehensive
photographic display of all graffiti supported with written detail as to the location,
description, area and treatment and removal cost of the graffiti.
3. The gauge shall be used in all photographs depicting graffiti and shall not
be permanently fixed or drawn on the defaced surface.
SPECIAL REQUIREMENTS
NOTE: Alternative anti-graffiti coatings will only be considered upon submission of a written request
to the Superintendent to vary the coating, together with supporting data and test panels, in accordance
with Clause 908.04.
WATER RETICULATION
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
909.01 SCOPE...................................................................................................................................... 1
909.02 INSPECTION........................................................................................................................... 1
909.03 HYGIENE ................................................................................................................................ 1
MATERIALS.............................................................................................................................................. 2
909.04 GENERAL ............................................................................................................................... 2
909.05 HANDLING OF MATERIALS ............................................................................................... 6
909.06 ALIGNMENT .......................................................................................................................... 6
9 6
9 7
909.09 EXCAVATION AND BEDDING ........................................................................................... 7
PIPE LAYING AND JOINTING ............................................................................................................. 9
909.10 PIPE LAYING AND JOINTING............................................................................................. 9
909.11 INSTALLATION OF VALVES, FITTINGS, HYDRANTS & FLUSHING POINTS ......... 11
909.12 THRUST BLOCKS................................................................................................................ 13
909.13 TESTING OF MAINS AND SERVICE CONNECTIONS ................................................... 13
909.14 BACKFILLING ..................................................................................................................... 13
INCIDENTAL WORKS .......................................................................................................................... 15
909.15 COVERS AND BOX ASSEMBLIES.................................................................................... 15
909.16 MARKER POSTS .................................................................................................................. 15
909.17 VALVES ................................................................................................................................ 15
909.18 CONNECTIONS TO EXISTING CORPORATION MAINS ............................................... 15
909.19 WATER RETICULATION MAINTENANCE ..................................................................... 15
COMPLETION ........................................................................................................................................ 16
909.20 PRACTICAL COMPLETEION............................................................................................. 16
909.21 FINAL CERTIFICATE.......................................................................................................... 16
WATER RETICULATION
GENERAL
909.01 SCOPE
The water reticulation works shall be constructed in accordance with the Drawings and
this Specification and will be subject to the inspection and approval of the Western
Australian Water Corporation who will be referred to as the “Corporation” for the
remainder of this specification.
909.02 INSPECTION
The Contractor shall ensure that all pipes, fittings and sluice valves supplied by the
Contractor have been manufactured, tested and inspected in accordance with the
relevant Australian Standard and the Corporation's requirements. The Superintendent
may be present at these tests. Certificates and test results shall be obtained from the
manufacturer by the Contractor and presented to the Superintendent upon request.
The Superintendent will inspect the constructed works and any faulty workmanship or
materials will be rejected and the work rectified in accordance with the Specification or
Drawings. All rejected materials shall be promptly removed from the site by the
Contractor.
The Contractor shall ensure that the Corporation's representative has full access to the
site at all times to inspect the work during the period of the contract. Any instruction
from the Corporation pertaining to the works will be issued to the Superintendent.
909.03 HYGIENE
The Contractor shall take every precaution to prevent contamination of the water supply
works. The Contractor shall also ensure a high standard of hygiene with respect to the
Contractors' employees and all materials, tools etc. used in the construction of the
works. In particular no materials, tools etc. previously used on live sewerage work
shall be used.
909.04 GENERAL
All materials used on the job shall be subject to the approval of the Corporation. The
Corporation may require from time to time manufacturers certificates, test results and
guarantees. Second hand pipes and fittings shall not be used. Materials shall be
handled and stored to avoid damage. Damaged materials shall not be used. All
materials, which will be in contact with the water supply, shall satisfy the Corporation
that the material is approved for use in contact with drinking water.
The specification of materials for construction shall be in accordance with Parts 2 & 3
of the Corporation’s Water Reticulation Manual, this specification and as defined in the
Drawings.
The Contractor shall obtain a certificate from the pipe manufacturer stating that all
pipes, joints and joint rings used in the works are covered by a guarantee identical to
that applying to pipes, joints and joint rings supplied under contract to the Corporation
at the time of manufacture. The certificate shall be passed to the Superintendent on
request.
No pipes, joints or joint rings shall be used in the works unless covered by the
guarantee.
a) General
The valves shall be manufactured generally in accordance with AS 2638 - 2002. They
shall also conform in all respects with the current Corporation specification for sluice
valves.
Double flanged;
Cement lined.
b) Variations
The Contractor shall be required to supply to the Corporation a full description together
with detailed drawings, specifications and weights of valves the Contractor proposes to
use, should the Contractor be proposing valves, which have not previously been
supplied to the Corporation under a Water Corporation Sluice Valve Supply Contract.
When the valves are ready for internal lining, the Contractor shall give the
Superintendent due notice in writing to this effect and nominate who will perform the
work so that the Superintendent may inspect the valves during the lining process.
The lining of the internal surface of valves shall be cement mortar in accordance with
AS 2544 - 1995 (heavy type). The lining shall be smooth and free from pinholes or
surface deposits. The internal surface of the body and bonnet of the sluice valve shall be
lined.
Before assembly, the various castings shall be coated externally with “Bitumastic
Super-Service” (black in colour) or similar approved protective coating. The surface
shall be sufficiently hard to resist damage from handling. Any valve imperfectly coated
or upon which the coating is damaged, will be rejected.
e) Testing
The valves shall be tested after completion of the internal lining in accordance with the
requirements of the “open end test” of AS 2638 - 2002 at a test head of 240 m. If the
valves are manufactured elsewhere than in the Perth metropolitan area, the
Superintendent will arrange for inspection, testing and branding of the valves under the
supervision of the inspector of the local Water Supply Corporation in the locality where
the valves are manufactured. All supervision charges incurred in such testing etc, will
be paid by the Principal for the Contract.
The Contractor shall supply to the Superintendent a certificate showing that the valves
have been duly inspected, checked for cement lining and tested as specified. No valve
will be accepted which has not passed the specified test.
e) Marking
The identification or marking required to be cast on the body of the valve is as follows:
909.04.03 HYDRANTS
Hydrants shall be 100 m nominal size cast iron of the screw down type, complete with
bayonet top for standard standpipe as approved by the Corporation. Where required
standard fire hydrant risers (sized to suit) shall be supplied and installed as required on
the Standard Drawings.
All items associated with the supply and construction of hydrants and associated
incidentals shall be to the Western Australian Fire Brigades Board standard requirement
and to the approval of the Superintendent.
Mechanical joints used shall be of the long body type either "Fergusons", "Gibaults",
"DNR's", "MFJ's" or other type approved by the Corporation. They shall be installed in
accordance with the manufacturer's specifications.
Stop taps shall be 20 mm nominal size, right angle pattern, ferrule type with female
BSP connections, manufactured from dezincification resistant brass and complying with
all relevant Australian Standards.
All covers to sluice valves, bronze gates valves, hydrants and flushing points shall be
cast iron and manufactured to the Corporation's standard patterns and Drawings (refer
Standard Drawings).
In addition all “sluice valve covers” (except those in a roadway or pathway) shall be
installed with a reinforced concrete “valve surround” to the dimensions shown on the
Standard Drawing.
All “valve liners” shall be of 150 mm diameter PVC pipe (or some other suitable
material) and length to suit.
All “hydrant boxes” shall be reinforced concrete to the dimensions shown on the
Standard Drawings.
All “bronze gate valve boxes” shall be of timber or reinforced concrete to the
dimensions shown on the Standard Drawings.
All “flushing point boxes” shall be of timber or reinforced concrete to the dimensions
shown on the Standard Drawings.
A petrolatum paste, “Denso 300”, “Taki” or similar approved product shall be used to
protect from corrosion all exposed nuts and bolts on all fittings, valves, hydrants,
mechanical joints, tapping bands etc.
909.04.08 TIMBER
Timber for bronze gate valve and flushing point boxes, marker posts and thrust blocks
shall be jarrah, and to the dimensions shown on the Standard Drawings.
909.04.09 CONCRETE
Concrete used for in-situ work shall conform to AS 3600 - 1994 and be provided by a
pre-mix concrete supplier conforming with AS 1379 - 1991 or mixed on site using
materials as specified and plant to the approval of the Superintendent.
Concrete for thrust blocks, hydrant boxes etc. shall have a minimum compressive
909.04.10 CEMENT
All cement used shall be Portland Cement Type A in accordance with AS 3972 - 1997
and obtained from an approved manufacturer.
Cement shall be delivered to the site fresh and in sealed bags and there stored in a
waterproof shed until such time as it is to be used. Any bag showing signs of
deterioration or setting is to be rejected.
909.04.11 AGGREGATE
Fine aggregate shall be well graded, clean sharp and free from clay and organic
impurities in accordance with AS 1141.0 - 1999 and AS 2758.1 - 1998.
Course aggregate shall be crushed granite or diorite, clean and free from all impurities
and dust in accordance with AS 1141.0 - 1999 and AS 2758.1 - 1998.
909.04.12 SAND
Sand for mortar shall be crushed stone or natural sand free from all deleterious
substances and have a uniform grading.
Sand for bedding or backfilling shall be clean sand free from roots, clay or any
deleterious matter.
Cement mortar for internal lining of fittings and sluice valves shall consist of one part
metal dust to one part cement.
Steel reinforcement fabric and steel reinforcing bars for concrete shall comply with the
requirements of AS 1302 - 1991, AS 1303 - 1991 and AS 1304 - 1991 and be free from
loose rust or matter likely to impair the bond with concrete.
909.04.15 WATER
Water from use in concrete and mortar shall be of potable quality free from any
impurities harmful to concrete, mortar or steel.
Water for filling constructed mains shall only be drawn from existing Corporation
mains at locations nominated by the Corporation's representative.
909.04.16 DISINFECTANT
The disinfectant used when filling constructed mains shall be Calcium Hypochlorite
(powder form) or Sodium Hypochlorite (liquid form).
All pipes, fittings, sluice valves, hydrants, mechanical joints etc. shall be loaded and
unloaded by lifting (by hand or hoist) or by skidding, in such a manner so as to avoid
shock or damage.
Likewise they shall be carefully lowered into the trench in such a manner as to prevent
damage to the materials and the protective coatings and linings. Under no
circumstances shall such materials be dropped, dumped or scraped along hard
pavements, which may cause scoring of the pipe.
Pipe handled on skid-ways shall not be skidded or rolled against pipe already on the
ground.
909.06 ALIGNMENT
All pipes and fittings shall be laid on an alignment of 2.1 m from the centre of the pipe
to the road reserve boundary.
Pipes and fittings shall be laid true to line and shall not deviate by more than 100 m
from their correct alignment, except where noted in this specification or where some
obstacle prevents access to the 2.1 m alignment. The Superintendent shall consult the
Corporation's representative for a direction on what action shall be adopted to remove
the obstacle or vary the alignment. Any such variation shall be fully documented on the
“As Constructed” Drawings.
In the case of mains constructed in Public Access Ways, Public Open Space and other
reserves, all pipes and fittings shall be laid parallel to and on an alignment of 2.1 m
from the side boundary. Where reserves are less than 4.2 m in width the main shall be
laid in the centre of the reserve.
Pipes and fittings shall be laid true to line and shall not deviate by more than 100 mm
from their correct alignment, except where noted in this specification or where some
obstacle prevents access to the alignment. The Superintendent shall consult the
Corporation's representative for a direction on what action shall be adopted to remove
the obstacle or vary the alignment. Any such variation shall be fully documented on the
“As Constructed” Drawings.
909.07 DEPTH
The depth of the pipe, including road crossings ducts shall be in accordance with the
Standard Drawings.
In the event of a conflict with the requirements of the Standard Drawings or the need to
avoid other utility services, the Corporation's representative shall be contacted for
instructions.
Where pipes cross or adjoin other existing or proposed services, the water main shall
North Quay: Construction of a Rail 6 Series 900
Loop, Rail Bridge, Rail terminal and Specification 909
Associated Roadworks Water Reticulation
have a minimum clearance of 100 mm.
Water service pipework shall have a minimum cover of 450 mm within the road reserve
and 500 mm within private property and shall have a maximum cover of 600 mm.
On completion of road reserve clearing and road earthworks, when finished levels are
achieved on lot boundaries, the Licensed Surveyor shall provide sufficient survey pegs
for the construction of the water reticulation, and that all ducts and service pipework
can be installed on the correct alignment. The Licensed Surveyor will also provide
sufficient temporary pegs on curved lot boundaries to enable the proper construction of
the water reticulation. All pegs shall be clearly marked with lot numbers (or other
means) so as to be clearly identifiable.
The Contractor shall ensure that all survey pegs installed for the water reticulation
works remain uncovered and undisturbed. If so directed by the Superintendent, the
Contractor shall uncover any pegs that are not visible, or pay the Licensed Surveyor to
reinstall any pegs that have been disturbed by the Contractor.
909.09.01 GENERAL
No excavation shall be commenced until the corresponding survey pegs are in position.
Excavation of road crossings shall not commence until the road levels have been
established and subgrade excavation completed. Trenches shall not be opened in
advance of the installation or road crossings and pipe laying more than is necessary to
enable the work to proceed without delay.
Trenches excavation shall normally commence after the completion of major site
earthworks but shall be carried out prior to pavement, footpath and final landscaping
operations.
The Contractor shall be responsible for carefully locating the position of all mains,
pipes, cables and other equipment belonging to Public Utility Authorities.
The Contractor shall provide, erect and maintain all temporary works necessary to
support exposed mains, pipes and cables to the satisfaction of the relevant Public Utility
Authority to ensure that the operation of such services is not interrupted in any way.
The Contractor shall be responsible for the cost of any repairs to such services arising
out of the Contractors' work.
Trenches shall be kept free of groundwater until each section of main has been
completed and tested. Groundwater shall not be permitted to enter pipes.
The trench width shall be as shown on the Standard Drawings. The depth shall be the
minimum required to achieve the correct cover on the pipe, as defined on the Standard
Drawings.
All trenches shall be neatly excavated to provide an even bed with a uniform grade.
Over-excavation of the bed of the trench shall be corrected with compacted bedding
material.
909.09.03 BEDDING
Bedding material shall be sand, gravel or other similar approved granular material.
Bedding material shall be free from all stones retained on a 6 mm sieve.
If the soil condition of the natural trench bed is non-granular or if the equivalent density
is less than 5 blows per 300 mm with a standard penetrometer (9 kg, 600 mm drop, 16
mm diameter rod), the trench shall be over excavated by at least 150 mm, backfilled
with bedding material (as defined) and compacted.
In all cases the trench bottom shall be hand trimmed immediately before placing the
pipe to enable the pipe to be supported evenly over the whole length of the pipe barrel
as shown on the Standard Drawings. Road crossings are to be true to line for their full
length with a maximum box of 100 mm in any duct crossings.
Under all trafficable pavements (roads, driveways, carparks etc.) the trench bottom will,
irrespective of natural soil condition, be levelled and compacted before hand trimming.
Holes shall be dug at each joint to allow the pipe to be supported on the barrel and to
enable the next joint to be properly made.
All pipes shall be carefully examined for cracks and other defects immediately before
being installed. Spigot ends shall be examined with particular care. Defective pipes
shall be rejected.
Care shall be taken to remove all sand and other material from the inside of the pipes
before they are lowered into the trench.
The inside of the pipe spigots shall again be carefully brushed immediately prior to
jointing to remove any sand that may have entered when the pipe was lowered into the
trench.
Immediately before jointing the outside of the pipe spigots, the inside of the socket and
the rubber joint rings shall all be carefully wiped clean to prevent scoring of the pipe
surface.
Elastomeric seal jointed steel pipes shall be installed in compliance with the
manufacturer’s instructions. Fittings shall be welded as for weld-jointed steel pipes.
Where steel pipes are weld-jointed, installation shall be in accordance with the Steel
Pipeline System Handling and Installation Manual and the following requirements:
• All pipe welding shall be in accordance with AS 4041 Pipework Class 2P,
Corporation Welding Specification WS-1 and the Drawings;
• Pipe flanges for valve connections shall be welded to pipes in accordance with
the Drawing AY58-15-1 of the Pipe Fittings Manual;
• Where the cement mortar lining of a pipe or fitting cannot be readily reinstated
at the welded joint, a convex band shall be welded over the joint. When the
band has cooled, it shall be fully injected with cement grout through a hole in
the bottom or side which is then sealed with a welded cap once the grout has
set;
• All cut ends and welded areas shall be protected as required by the sub-clause
909.10.04
PE pipes and pipe fittings and their jointing shall comply with the requirements of, and
including limitations in Table 2.1 of Part 2 of the Corporation’s Water Reticulation
Manual.
Where butt fusion weld jointing is expressly permitted, the pipes shall be prepared for
welding in accordance with pipe manufacturer’s recommendation.
Damaged pipe coating shall be primed, filled with butyl mastic and wrapped with a
2mm thick reinforced bitumen mastic with PVC backing (Densopol 80, Rockrap 4000
Tape System or approved equivalent), in accordance with the manufacturer’s
application specification.
All welded joints, bands, bends, tees, flanges, flange and valve body assembly bolts
shall be primed and wrapped with a butyl mastic tape and PVC overwrap system
(Denso or approved equivalent) in accordance with the manufacturer’s application
specification.
For pipes emerging from below ground, the tape wrapping shall extend to 100mm
above the finished ground level.
Where a protective coating system is used, pipeline and valve surfaces shall be prepared
so that rust and any other deleterious materials are removed in accordance with the
coating manufacturer’s requirements.
At the end of each day’s work or at any time when pipe laying is suspended, every open
end of each incomplete pipeline shall be plugged with a tapered stopper or an
acceptable end cap matching the pipe. No tools or any construction materials shall
remain in the pipes.
a) PE Pipeline System
Allowance shall be made for the likely pipe movement due to temperature changes
during installation and commissioning. A final service temperature of 20°±5°C may be
assumed unless otherwise specified in the Drawings. Pipe lengths and bend locations
shall be adjusted for changes in length that will occur when the temperature stabilises at
the final service temperature.
The trenches shall not be backfilled unless the ambient temperature is within ±5°C of
the final service temperature.
PE pipes within the trench may “snake” if the final “snaked” alignment at the final
stabilised service temperature is within 100mm of the correct alignment.
b) Railway Crossing
The pipes crossing shall not have elastomeric seal or mechanical joints and shall be in
conduit or sleeve only if required by the relevant authorities.
Minimum clearance between pipe and pipe sleeve shall be 100mm. The Corporation in
certain circumstances may require larger clearances.
The pipeline shall be supported within the pipe sleeve on saddles or support blocks
acceptable to the Corporation or on sand bedding installed after the pipeline has been
laid through the pipe sleeve.
A pipeline required to follow a long curve may be laid and jointed with deflections at
the joints. The maximum angular deflection at a pipe joint shall not exceed the pipe
manufacturer’s recommendations. Bending of pipes to achieve a curve for any other
purpose is prohibited, except for PE and CU pipes.
PE pipes may be laid in a curve of radius that is not less than the manufacturer’s
recommendations.
b) Bends
Where the required angle change exceeds the permissible joint deflection, standard
bend fittings shall be used.
Bends shall be installed opposite cadastral survey pegs unless otherwise shown on the
Drawings or accepted by the Corporation.
The Contractor shall be responsible for ascertaining by careful excavation, the precise
location of all existing Corporation mains and to lay at the correct depth and alignment
to ensure a simple connection. The Contractor shall take particular care not to disturb
the existing mains or thrust blocks.
The dead ends shall be within 4 m of the existing main and clear of any pavement.
Mains shall be plugged with a suitable end cap or blank flange and adequately anchored
to take the full test pressure.
Initial backfilling shall be done using selected fill, being defined as sand, gravel or
other approved granular material being free of all stones retained on a 25 mm sieve.
Initial backfilling at the sides and for 150 mm above the top of the pipe shall be hand
tool placed and compacted ensuring that no joints or pipes are disturbed or damaged.
Refer to Standard Drawings.
The joints shall be left fully exposed for inspection during testing.
909.11.01 GENERAL
All sluice valves, fittings and hydrants shall be carefully examined for cracks, damage
or defects immediately before being installed. Defective items shall be laid aside for
inspection by the Superintendent, who will prescribe corrective repairs or rejection.
Care shall be taken to brush clean the inside of all sluice valves, fittings and hydrants
immediately prior to installation. The outside of the spigot ends and the inside of the
North Quay: Construction of a Rail 11 Series 900
Loop, Rail Bridge, Rail terminal and Specification 909
Associated Roadworks Water Reticulation
collars and rubber rings shall likewise be carefully brushed clean before jointing.
a) Timber Bearers
Where the branch main from a 200 mm is a 100 mm or 150 mm main, the sluice valve
shall be bolted directly onto the flanged branch of the Tee piece.
All nuts and bolts shall be thoroughly smeared with a corrosion protection petrolatum
paste.
In all other cases, the sluice valve shall be installed opposite the truncation point.
If necessary a pipe shall be neatly cut to enable the sluice valve to be installed in the
correct position.
All nuts and bolts shall be thoroughly coated with a corrosion protection petrolatum
paste.
d) Valve Sizing
The nominal diameter of each valve shall be the same as the nominal diameter of the
pipe in which the valve is being installed.
e) Backfilling to Valve
The excavated trench within 1.0 m of the installed sluice valve shall be backfilled in
150 mm layers and firmly tamped.
Hydrant tees shall be installed in the main as near as possible to the centre of the lot or
according to the dimensions shown on the Detailed Drawings.
The excavated trench within 1.0 m of the hydrant shall be backfilled in 150 mm layers
and firmly hand tamped.
When the final verge level above the hydrant tee has been established, a double-flanged
hydrant riser of the appropriate length shall be bolted to the tee. The hydrant
installation shall then be completed in accordance with the Standard Drawings.
All nuts and bolts shall be thoroughly coated with a corrosion protection petrolatum
paste.
Flushing points shall be installed as shown in accordance with the Standard Drawings
on all copper mains, on all dead ends that for the purpose of this contract are considered
as permanent, or any location designated on the Detailed Drawings.
Thrust blocks shall be provided at all bends, tees and blank ends. A suitable temporary
thrust block shall be provided at temporary blank ends for pressure testing. Suitable
anchorage shall also be provided at reducers. Alternatively, bolted flanged reducers
and fittings may be used to rigidly connect reducers to the nearest suitably anchored
fitting.
Thrust blocks may be timber or concrete and as shown on the Standard Drawings.
Multiple bends shall be supported with concrete thrust blocks only, and as shown on the
Standard Drawings.
All bolts shall be protected with a corrosion protection paste prior to pouring of
concrete thrust blocks. All bolts shall be installed with the head facing away from the
concrete block. Bolts, nuts and flanges shall not be encased in the concrete.
Joints shall not be encased in the concrete blocks, but be protected by foam or similar
blockouts or other approved means.
A suitable bond breaker shall be provided between the fitting and the concrete (PVC
film or similar).
Thrust blocks shall not extend outside the 1.8 m to 2.4 m alignments. Where a conflict
exists the Corporation's representative shall be contacted for instructions.
Where buried steel pipes are used, thrust supports may be replaced by welded pipeline
sections installed on both sides of the fittings as indicated in Table 4-1 of the
Corporation’s Water Reticulation Manual.
909.13.01 GENERAL
After the mains have been laid to form a continuous main the main or any section as
selected by the Superintendent, shall be subjected to a hydraulic test.
All testing preparation, equipment and procedure shall be in accordance with Section
4.7 of the Corporation’s Water Reticulation Manual.
909.14 BACKFILLING
909.14.01 GENERAL
Final backfilling of pipe trenches shall not be carried out until mains have passed the
hydraulic test and measured by the Superintendent for as constructed purposes.
The fact of any such work being refilled does not relieve the Contractor in any way of
North Quay: Construction of a Rail 13 Series 900
Loop, Rail Bridge, Rail terminal and Specification 909
Associated Roadworks Water Reticulation
his responsibilities and the Contractor may be called upon to uncover and repair at the
Contractors' own cost, any main declared by the Superintendent as unsatisfactory at any
time until the end of the maintenance period. Any such repair work shall be subject to
retesting at the Contractor's expense.
909.14.02 MATERIAL
The material excavated from the trench may, subject to the approval of the
Superintendent, be used for ordinary backfill, provided it is free of rocks and vegetable
matter. Material in verge within 100 mm of water service pipework and in private
property shall be soil material with a maximum particle size of 10 mm. The remaining
backfill material in the verge comprising the excavated trench material shall be levelled
to the surrounding verge level and compacted.
Material in the pavement area shall be compacted granular material meeting the
specification for road construction.
The joint holes left open for the pressure testing, shall be carefully refilled and hand
compacted with selected fill up to the top level of the initial backfill material. Care
shall be taken not to damage or disturb the joints.
For trenches in verges, the ordinary backfill material shall then be placed, compacted
and neatly trimmed off to the final verge level.
Backfill under pavements shall be entirely of sand, free of clay, vegetable, petrol, diesel
fuel, lubricating oil, hydrocarbon products or foreign material, and compacted as shown
on the Standard Drawing. If the Superintendent deems the compaction to be
insufficient, the Contractor shall re-excavate the trench for a distance and depth as
determined by the Superintendent. The trench shall then be refilled and compacted as
specified.
The contractor shall place all sluice valve, hydrant, bronze gate valve and flushing point
cover and box assemblies, flush with their final surface level.
Marker posts shall be provided and installed to the details shown on the Standard
Drawing. They shall be used to indicate the position of valves, hydrants, flushing
points, bronze gate (fullway) valves and where otherwise directed on the Detailed
Drawings. Metal marker posts shall be used in preference to wood where termites are
prevalent.
Markings of “SV”, “H”, “FP” & “FW” shall be black painted letters approximately 150
mm high, on white background.
The marker posts, except where varied, shall be placed adjacent to the fittings, after
final verge trimming.
909.17 VALVES
All sluice valves and bronze gate section “fullway” valves shall be left open and all
hydrants, flushing points and tappings at temporary dead ends left shut.
Sluice valves will have extension spindles installed where required by the Standard
Drawings
The maintenance period shall be 12 months from the date of Practical Completion.
The Corporation will carry out operational maintenance in accordance with their normal
practice. The Corporation shall have full and unrestricted use of the works without
interference from the Contractor.
Any leaks or bursts in the works due to faulty workmanship or materials, shall be
repaired by the Corporation at full cost to the Contractor. The Contractor shall also be
responsible for any consequential damage arising from the leaks or bursts.
Any other defects due to faulty workmanship or materials but of a non urgent nature
and not affecting the supply to consumers may be rectified by the Contractor at the
discretion of the Corporation.
The Corporation may require the retesting of repaired sections and the cost shall be
borne by the Contractor.
The Contractor shall immediately reinstate any subsidence over trenches occurring at
any time during the maintenance period.
Tappings or service pipework found to be more than 200 mm from the standard or
agreed service location in the road reserve or 100 mm within a property shall be
North Quay: Construction of a Rail 15 Series 900
Loop, Rail Bridge, Rail terminal and Specification 909
Associated Roadworks Water Reticulation
deemed defective unless the Corporation decides that the tapping or service can be used
in the incorrect location without detriment to the Corporation of the owner of the
affected property.
COMPLETION
The Certificate of Practical Completion will not be issued by the Superintendent until
all mains and prelaid water services have been laid, tested and backfilled in accordance
with the Drawings and this Specification and to the satisfaction of the Superintendent
and the Corporation.
Not less than 14 days before the end of the Maintenance Period, a final inspection shall
be made by the Superintendent and the Contractor to determine any items of
maintenance work to be done by the Contractor, which should be carried out to make
the scheme acceptable.
The Final Certificate will not be issued until these items have been completed to the
satisfaction of the Superintendent and the Corporation.
Clause Page
GENERAL .................................................................................................................................................. 1
909.01 SCOPE...................................................................................................................................... 1
GENERAL
909.01 SCOPE
The sewer works shall be constructed in accordance with the Drawings and this
Specification and will be subject to the inspection and approval of the Western
Australian Water Corporation who will be referred to as the “Corporation” for the
remainder of this specification.
All works by the contractor shall be carried out in accordance with the most recent
version of the Corporation’s Wastewater Manual Volume One and the Sewage
Pumping Station Code of Australia.
RAIL WORKS
SPECIFICATION 1001 - SIGNALLING
SPECIFICATION 1002 - TRACKWORK
SPECIFICATION 1003 - OHLE
S PECIFICATION 1001
SIGNALLING
CONTENTS
Clause Page
GENERAL................................................................................................................................................... 1
1001.01 SCOPE.................................................................................................................................. 1
1001.02 REFERENCES ..................................................................................................................... 2
1001.03 AMENDMENTS TO STANDARDS................................................................................... 4
OPERATIONS ........................................................................................................................................... 4
1001.04 DESCRIPTION OF EXISTING SIGNALLING SYSTEM................................................. 4
CONSTRUCTION REQUIREMENTS & MATERIALS ...................................................................... 5
1001.05 WORKS INCLUDED .......................................................................................................... 5
1001.06 DESIGN AND DOCUMENTATION.................................................................................. 5
1001.07 INTERLOCKING ................................................................................................................ 6
1001.08 TRAIN CONTROL ROOM ................................................................................................. 6
1001.09 TRAIN CONTROL CONSOLE AND DIAGRAM ............................................................. 6
1001.10 TELEMETRY AND ROUTE SETTING SYSTEMS .......................................................... 7
1001.11 OPERATION UNDER FAILURE....................................................................................... 7
1001.12 LEVEL CROSSING PROTECTION................................................................................... 7
1001.13 EQUIPMENT HOUSINGS.................................................................................................. 7
1001.14 FIELD SIGNALLING EQUIPMENT.................................................................................. 7
1001.15 SIGNAL POWER DISTRIBUTION AND ALTERNATIVE SUPPLIES .......................... 9
1001.16 CABLE ROUTE................................................................................................................... 9
1001.17 CABLES............................................................................................................................... 9
1001.18 COMMUNICATIONS ......................................................................................................... 9
1001.19 LIMITS OF WORK ............................................................................................................. 9
1001.20 INTERFACE WORKS....................................................................................................... 10
1001.21 PRELIMINARY WORKS ................................................................................................. 10
1001.22 STAGE WORKS................................................................................................................ 10
1001.23 TESTING AND COMMISSIONING ................................................................................ 10
1001.24 REDUNDANT EQUIPMENT, MATERIAL AND CLEAN UP....................................... 11
1001.25 MAINTENANCE AND OPERATIONS MANUALS AND TRAINING......................... 11
1001.26 SPARES AND TEST EQUIPMENT ................................................................................. 11
1001.27 MATERIAL/EQUIPMENT TO BE SUPPLIED BY FREMANTLE PORTS AUTHORITY
11
1001.28 SIGNAL SIGHTING ......................................................................................................... 11
WORKS NOT INCLUDED..................................................................................................................... 12
1001.29 GENERAL ......................................................................................................................... 12
MAINTENANCE ..................................................................................................................................... 12
1001.30 WORKING LIFE & RELIABILITY ................................................................................. 12
ANNEXURE 1001A ................................................................................................................................. 13
BACKGROUND....................................................................................................................................... 13
1001A.01 GENERAL ..................................................................................................................... 13
EXISTING SIGNALLING ARRANGEMENTS................................................................................... 13
1001A.02 GENERAL ..................................................................................................................... 13
NEW SIGNALLING SYSTEM .............................................................................................................. 13
1001A.03 OVERVIEW................................................................................................................... 13
1001A.04 ASSUMPTIONS ............................................................................................................ 14
1001A.05 NEW AND ALTERED SIGNALS AND POINTS........................................................ 15
1001A.06 TRAIN OPERATIONS .................................................................................................. 16
North Quay: Construction of a Rail Series 1000
Loop, Rail Bridge, Rail terminal and Specification 1001
Associated Roadworks Signalling
1001A.07 LEVEL CROSSING....................................................................................................... 18
1001A.08 CONTROL CENTRE ALTERATIONS ........................................................................ 20
1001A.09 TESTING AND COMMISSIONING ............................................................................ 20
REFERENCES ......................................................................................................................................... 21
APPENDIX 1 .............................................................................................................................................. 1
STAGING DIAGRAMS .......................................................................................................................... 1
SIGNALLING
GENERAL
1001.01 SCOPE
2. The new signalling works proposed for the North Quay Rail loop shall be
controlled from PTA’s train control centre located on Level 4 of the Public Transport
Centre (PTC), West Parade, East Perth.
• track work
• level crossings;
• civil works including the new bridge over Tydeman Road;
• over head
• lighting and power
• Terminal paving, electrical and mechanical works
• Victoria Quay signalling works
1001.02 REFERENCES
1. The whole of the work covered by this specification and the material and
the equipment used shall, unless otherwise specified, be in accordance with the relevant
sections of the most recent issues of the following:
PTA Standards
• Equipment location case specification and earthing (PTA standard 750 or 1400 and
drawings ES-HE-887, ES-HE804 to ES-CE-810)
• Signal mast drawings ES-KE-404 to 406, ES-HE-619, ES-FE-943, ES-CE-910,
ES-CM-51
• Level crossing equipment - ES-KE-328&356, ES-FY-41 to 43
• Level crossing signage - ES-HE793 to 795
• Boom barrier equipment - ES-FY-27 to 29, ES-CE 909, ES-HE-779 to 881, ES-
FE-1726, ESHE-870, ES-FE-569, ES-CE-70, ES-HE-791, ES-KE-352, ES-KE-
359,ES-FE-655, ES-FE-637, ES-HE-793 to 795, ES-HE-84, ES-CE-1550, ES-HE-
779 to 881, ES-FE-1726, ES-HE-463, CE81663 Sheet 012, Technical instruction
No. 249E
CE81663 Sheets 001, to 013/3, ES-FE-1823, ES-FY-93 to 95, 99 & 100
• Point machines and fittings - ES-KE-403
• Track circuits - ES-HE-618, 638, 801, 873
OPERATIONS
1. Currently the line between Fremantle and North Fremantle is double track
fitted with unidirectional automatic colour light route signalling. Fremantle and North
Fremantle / Leighton yards located on either end of the automatic signalling section are
relay based interlockings.
4. The Fremantle line is fully track circuited using single rail AC immune
DC track relays.
1. The Contractor shall design, draft, check and supply all drawings and
documentation of the entire signalling system including:
• Site surveys;
• Data preparation and calculations;
• Control Tables;
• Software development or modification;
• Circuit books;
• Signalling scale plan and signalling diagram;
• Design, training and training manuals;
• Level crossing controls;
• Power supplies, earthing arrangements and calculations;
• Boundary interfaces;
• Stage and preliminary work;
• Amendment of all plans and documentation;
• Printing, compiling and issue of files and plans
1001.07 INTERLOCKING
1. The contractor shall design, check, supply, install and commission all
relay and / or Computer Based Interlocking (CBI) components necessary to ensure safe
operation of the signalling systems.
1. The contractor shall modify the wall mounted indication diagram and
associated equipment and wiring to include:
2. The Contractor shall modify the VDU based control console to allow
operation of the new points and signals including any route setting or software blocking
functions and remove any controls including changes to wiring, software and associated
equipment that will not be required as a result of the works.
1. The Contractor shall modify the existing PTA ICS telemetry system to
allow for:
2. The Contractor shall modify the ICS route setting equipment located in
the North Fremantle relay room:
a. To enable route setting into and out of the rail loop and freight
terminal, and
1. Under point failure conditions, the train driver or safe working person
will manually operate the point machines using the crank handles coded in accordance
with the signalling arrangements. When in manual operation all routes affected by that
point machine shall be set to stop.
1. The contractor shall install level crossing protection equipment at the new
Tydeman Road level crossing as indicated on plans R-01-Z-001 and R-01-Z-002
including:
3. The Contractor shall provide facilities for observing and determining the
status and condition of the level crossing equipment and associated field devices
remotely via the PTA Communications system.
1. The contractor shall design, supply, install and commission all field
equipment boxes located to minimise the extent of local wiring.
1. The Contractor shall design, supply, install and commission all field
signalling equipment including:
1. The contractor shall provide a local Western Power supply to the new
Tydeman Rd level crossing which shall be used to power the level crossing and
adjacent signalling.
1. The Contractor shall install a new cable route from the mainline cable
route to Signal 344 departing the North Quay Rail terminal. The new cable route shall
connect to the existing main line main cable route. Cables wherever possible shall be
direct buried. Where direct burial is not feasible the cables shall be installed in ground
level troughing or in conduits. Steel trunking may be used for attachments to bridge
structures and on walls as per the bridge drawings, in but shall not be used elsewhere
without the approval of Fremantle Ports Authority.
1001.17 CABLES
1. The Contractor shall supply, install, wire, terminate, join, test and
commission all local and through signalling, power and telecommunications cables.
1001.18 COMMUNICATIONS
1. The limits of work for the signalling are Signal No. 344 (20.014km) to
Signal No. 335 (19.211km) to Location case F177 (mainline) and via Points 874 to the
down end of the existing level crossing approach to existing Tydeman Road level
crossing including Leighton yard.
2. Outside of these limits the Contractor shall design, supply, install, test
and commission all the associated works to interface the new signalling system with the
adjoining systems in accordance with R-001-F001, R-001-F002 and R-001-F003 in
Appendix 1.
1. The Contractor shall design, supply, install, modify, test and commission
all interface equipment necessary to ensure the safe and correct operation of the
signalling system at and outside the contract boundaries defined by the Limit of Works.
1. The scope of works includes supply and installation of track work and
associated overhead works. Therefore, it may be necessary for the Contractor to stage
preliminary works to relocate, test and re-commission signalling and/ or
communications equipment obstructing implementation of new works.
• Signals;
• Location cases;
• Cabling;
• Communication pillars;
• Trunking;
• Conduits;
• Pits.
2. The Contractor shall allow for any stage works associated with
decommissioning of turnouts and their associated signalling infrastructure, also
equipment at the existing Tydeman Road level crossing. This work includes the
intermediate stage works associated with decommissioning Leighton Yard as indicated
on plan R-001-F-003 (Appendix 1) and any clipping or scotching of turnouts as
required by PTA-WA.
1. The Contractor shall test and commission the complete system including
all preliminary and stage works in accordance with the PTA’s testing and
commissioning procedure 8190-600-002.
1001.29 GENERAL
1. The following details the work excluded from this design and
construction specification and work supplied and/or provided by Fremantle Ports
Authority.
MAINTENANCE
BACKGROUND
1001A.01 GENERAL
3. The PTA of WA have advised that the down mainline will be resignalled
for bi-directional running as part of the Victoria Quay Freight Line Alterations project.
1001A.02 GENERAL
2. The main line is double track fitted with unidirectional colour light route
signalling.
1001A.03 OVERVIEW
3. Points 880 are provided to access the rail loop and catchpoints No. 884
provide runaway protection for the container terminal.
5. Semi-automatic shunt signal No. 344 is provided to ensure trains from the
terminal do not shunt towards the level crossing when a down train has been signalled
towards the terminal.
7. Signal No. 342 is interlocked with the control of the boom barriers,
flashing lights and pedestrian gates. Operation of the level crossing will be automatic.
10. In conjunction with commissioning the new terminal and rail loop,
Leighton Yard and the existing Tydeman Road level crossing will be abolished and the
associated signalling equipment shall be removed.
1001A.04 ASSUMPTIONS
b. The line speed for freight trains will be Fremantle to Terminal entry
30kph, Terminal speed 20kph;
g. Existing dual gauge trackwork on the west mainline north of the new
Points 880 will be converted to narrow gauge as part of this project.
This will preclude standard gauge access to Leighton Yard;
j. The new “phoenix” single train control system” will not control or
monitor the Fremantle Line before this project is commissioned.
route indicator.
2. Dual control facilities will be provided for all new motor points. (The
interlocking will detect that the points have been put in hand operation and prevent
operation of all routes affected by the points).
1. For a down freight train at Fremantle bound for the North Quay container
terminal the train controller will contact the North Quay yard controller by telephone or
radio and obtain permission to dispatch the train.
2. The Yard Controller will check that the train can be accommodated
directly in the terminal without fouling the Tydeman Road level crossing before giving
the train controller permission to dispatch the train. The Yard Controller will then
arrange the yard hand points to accept the train.
3. Down freight trains will be signalled from Signal No. 355 (DG Main) or
Signal No. 357 (NG Down) to the North Quay container terminal via signal No. 335.
For these routes Signal Nos. 355 and 357 will clear to a yellow aspect when Points 880
are reversed, the overlap is clear and Signal No. 335 has cleared to a proceed (shunt)
aspect with illuminated left hand “feather” indicator. When points 880 are reverse
Signal No. 335 will not be able to clear unless Signals 342 and 344 are at stop, there are
no opposing routes set and the section is clear between Signal 335 and Signal 344.
6. Points No. 880 will be released when a down train has cleared track
circuit FGH1T (880N) or FGH2T (880R) allowing Signals 355 and 357 to be cleared
for a mainline move towards Perth, regardless of the position of catchpoints 884
provided that there is a route in progress towards the terminal. Route 335(A) will prove
catchpoints 884 normal or 335(S) route in progress as an initial condition only.
8. When there is a yellow or green aspect on Signal Nos. 355 and 357, it
will not be possible to move points No. 880.
1. Signal No. 344 will normally be at proceed unless the signaller has set the
signal to stop to allow a down train to be signalled from Signal No. 335 to the terminal
or there are vehicles on the track between Signal No. 344 and 342.
2. For an up freight train ready to depart the North Quay container terminal,
the train driver will contact the train controller to request that the train be dispatched.
3. When the mainline and yard are clear of trains, the train controller will
ensure Signal 344 is at proceed, then reverse signal lever no. 342 which will reverse
Points No. 880 and catchpoints No. 884 and allow Signal no. 342 to clear.
1. PTA require unsignalled access to Leighton Yard for narrow gauge trains
for a period following the commissioning of the North Quay Rail Loop. And interim
decommissioning stage shall be provided based on the configuration shown in R-001-F-
003.
1. Where the new rail loop crosses Tydeman Road at grade a new level
crossing with Level 3 crossing protection (1/2 boom barriers, RX-5 flashing lights and
automatic pedestrian gates on both sides of the roadway) will be provided. The level
crossing layout plan is contained in drawing R-01-Z-001.
2. Signal No. 342 is interlocked with the control of the boom barriers,
flashing lights and pedestrian gates. Operation of the level crossing will be automatic.
b. When Signal No. 342 is set to proceed (and after catchpoints No. 884
have run reverse) and the train is not on the up approach track circuit
FGNT, the level crossing will operate automatically. The up warning
distance is fixed to allow a 39 second warning time at 23kph;
c. When Signal lever No. 342 is set to proceed (and after catchpoints
No. 884 have run reverse) and a train is on the up approach track
circuit FGNT, the level crossing protection will commence operating.
Signal 342 will clear after 25 seconds of warning time.
d. After the train passes the catchpoints they will self-normalise; and
f. Subtotal 36 seconds
3. Current controls and indications associated with 324, 322, 326, 325 and
331 Signals and 876A, 876B, 876BK and 874 Points will be removed from the signal
control workstation and the overview diagram. The limit of indications is shown on
drawings R-001-F001 & R-001-F002.
4. The works will include the following changes to allow the remote control
of the North Quay Rail Loop from the Public Transport Centre:
REFERENCES
MT 01 6407 R003 Proposed Intermodal Terminal at North Quay Train
Simulation HGM 5.09.02
STAGING DIAGRAMS
TRACKWORK
CONTENTS
Clause Page
GENERAL................................................................................................................................................... 1
1002.01 SCOPE OF WORK .............................................................................................................. 1
1002.02 DESCRIPTION OF THE WORKS...................................................................................... 1
1002.03 CO-ORDINATION OF THE WORKS................................................................................ 3
1002.04 LIMITS OF THE WORK..................................................................................................... 3
1002.05 INTERFACES TO RELATED WORKS ............................................................................. 3
1002.06 REFERENCES ..................................................................................................................... 3
TECHNICAL REQUIREMENTS ............................................................................................................ 4
1002.07 GENERAL ........................................................................................................................... 4
1002.08 MAINTENANCE................................................................................................................. 4
1002.09 DETAILED REQUIREMENTS........................................................................................... 5
1002.10 INTERFACES...................................................................................................................... 5
MATERIAL SUPPLY ............................................................................................................................... 5
1002.11 GENERAL ........................................................................................................................... 5
1002.12 PACKING, TRANSPORT, HANDLING AND STORAGE ............................................... 6
1002.13 TRACK SYSTEM................................................................................................................ 7
1002.14 RAILWAY SIGNS AND MARKERS................................................................................. 7
1002.15 SPARES, SPECIAL TOOLS AND TEST EQUIPMENT ................................................... 7
1002.16 BUFFER STOPS .................................................................................................................. 8
CONSTRUCTION ................................................................................................................................... 10
1002.17 GENERAL ......................................................................................................................... 10
1002.18 TRACK ALIGNMENT...................................................................................................... 10
1002.19 SLAB TRACK TOLERANCES ........................................................................................ 13
1002.20 INSTALLATION OF RAILS ............................................................................................ 14
1002.21 RAIL WELDING ............................................................................................................... 15
1002.22 ALUMINOTHERMIC WELDING.................................................................................... 19
1002.23 RAIL JOINTS .................................................................................................................... 19
1002.24 FINAL FASTENING DOWN OF RAILS ......................................................................... 20
1002.25 ELECTRICAL REQUIREMENTS IN TRACK CIRCUITED TRACK............................ 20
1002.26 INSTALLATION OF TURNOUTS................................................................................... 22
1002.27 INSTALLATION OF BALLASTED TRACK .................................................................. 23
1002.28 INSTALLATION OF SLAB TRACK ............................................................................... 25
1002.29 INSTALLATION OF BUFFER STOPS............................................................................ 25
1002.30 INSTALLATION OF RAILWAY SIGNS AND MARKERS........................................... 25
TESTING AND COMMISSIONING ..................................................................................................... 26
1002.31 GENERAL ......................................................................................................................... 26
1002.32 PLANNING........................................................................................................................ 26
1002.33 FACTORY ACCEPTANCE TEST (FAT)......................................................................... 27
1002.34 INSPECTION..................................................................................................................... 28
1002.35 SITE ACCEPTANCE TEST (SAT)................................................................................... 28
1002.36 COMMISSIONING ........................................................................................................... 28
ANNEXURE 1002A ................................................................................................................................... 1
EXTENT OF EXISTING TRACK REMOVAL...................................................................................... 1
TRACKWORK
GENERAL
1. The Contractor shall manufacture, procure, install, test and commission a Scope
complete, integrated permanent way system, comprising the rails and their support
structure above the top surface of the capping layer or structural slab, together with
other items generally associated with the permanent way (buffer stops, derailment
containment, signs & markers, etc.).
2. The scope of trackwork covers the track structure from the new See clause
connection on the Fremantle to Perth line to the end of the Stage 1 terminal layout. 1001.22 Clause
2.
3. The scope for removal of trackwork covers the existing rail, sleepers and
ballast from 20m north of the Tydeman Rd level crossing through Baguley’s site and
immediately south of Patrick new entrance to the new Rail Terminal as shown in
Annexure 1002A - SK022 “Existing Track Structure Removal”.
4. The connection to the Fremantle to Perth line and the chord to the
entrance to the terminal is to be in conventional ballasted track together with track 4 of
the freight terminal. The freight terminal lines are to be laid on a track slab.
1. The scope of works for civil works has been fully detailed with the
exception of:
a. The 1:16 turnout from the main line, 1:10 turnouts on the terminal
(types to be confirmed by PTA);
b. The design of the track slab in the terminal and associated transition
slab.
2. Those works listed in 1002.02.1 and any other works not specifically
detailed in the Principal’s detailed design which are necessary to fulfil the requirements
of the Principal’s project requirements is deemed to be concept design.
3. The scope of supply shall include, but not be limited to the following.
Detailed specifications are given in the Technical Requirements.
c. Rail end safety devices, including friction buffer stops, fixed buffer
stops, wheel stops, etc;
h. All plant, tools and Temporary Works necessary for the installation.
4. The works shall include, but not be limited to the following. Detailed
specifications for the Principal’s detailed design are given in the Technical
Requirements.
1. The Contractor shall ensure the entire works are carried out with due
consideration to the work within and between these parts:
c. Specification 1001
1. The limits of the WORKS for Trackwork are shown on the Site
Drawings.
1002.06 REFERENCES
Draft PTA Narrow Gauge Mainline Code of Practice – Track and Civil
Infrastructure (Draft Oct 1998)
AS 4292 all parts Railway Safety Management PTA Drawing for 1:10 turnout
PTA Drawing for a catchment
AS 1055 all parts Acoustics – Description and measurement of environmental noise
AS 1085 all parts Railway Permanent Way Material
AS 1141 all parts Methods for Sampling and Testing Aggregates
AS 1152 - 1993 Specification for Test Sieves
AS 1302 - 1991 Steel Reinforcing Bars for Concrete
North Quay: Construction of a Rail 3 Series 1000
Loop, Rail Bridge, Rail terminal and Specification 1002
Associated Roadworks Trackwork
AS 1303 - 1991 Steel Reinforcing Wire for Concrete
AS 1304 - 1991 Welded wire reinforcing fabric for Concrete
AS 1397 - 1997 Specification & Supply of Concrete
AS 2205 all parts Methods of destructive testing of welds in metal
AS 2734 - 1984 Asphalt (Hot Mixed) Paving – Guide to Good Practice
AS 2758.1 - 1998 Aggregates and rock for Engineering Purposes – Concrete
Aggregates
AS 2758.7 - 1996 Aggregates and rock for Engineering Purposes – Railway Ballast
AS 3972 - 1997 Portland & Blended Cements
AS 4100 - 1998 Steel Structures
AS 4680 - 1999 Hot Dipped Galvanised Coatings on Ferrous Articles
AS 4799 - 2000 Installation of underground utility services and pipelines within
railway boundaries.
ISO 9000 all parts Quality management and quality assurance standards
ISO 9001 - 2000 Quality management systems – requirements
2. The Contractor shall comply with the provisions of the following
documents as appropriate.
TECHNICAL REQUIREMENTS
1002.07 GENERAL
1. The operation of the terminal relies on the fact that safety, robustness,
reliability and minimal maintenance requirements are the over riding issues in the
permanent way design and the primary determinants in the selection of track structure
and component type and quality. The Contractor shall carry out all work under this
contract in accordance with the criteria specified, keeping these aims in mind, in order
to contribute to the provision of a completed project which meets all objectives and
expectations of the Principal and prospective railway users.
1002.08 MAINTENANCE
1002.10 INTERFACES
MATERIAL SUPPLY
1002.11 GENERAL
1. All materials and components to be used for the installation of the track
and construction of the track structure shall be new and as defined in these Principal’s
project requirements. They shall be free of damage, dirt and loose rust immediately
prior to being taken to the point of installation and at the time of fixing in position. Mill
scale shall be removed from rails in the weld areas and the heads during grinding.
Materials which are not to the required standards shall be removed from Site and
replaced by the Contractor.
2. The Contractor shall identify all known hazards associated with materials
and components and specify recommended safe methods of storage, use and disposal to
ensure the safety of staff and that the condition of the component remains suitable for
installation into the track after the storage period which may be long term. The
Contractor shall abide by the manufacturer’s instructions on health and safety and use
of their product.
2. The Contractor shall ensure that the packing and transport of the
materials will not induce undue stress, vibration, extremes of heat, corrosion nor impact
their properties. The Contractor shall ensure that components of similar physical type
but differing properties are packed and labelled clearly. Small components shall be
crated or palletised suitable for mechanical handling and where practical, vertical
stacking.
4. All normal and regulatory precautions against fire shall be taken during
both storage and use. Dangerous goods shall be handled and stored in accordance with
the relevant regulations and in accordance with the requirements of the relevant
Authorities. Aluminothermic weld portions shall be stored in a dry ventilated container
to the requirements of the FESA. Weld igniters are classified as dangerous goods. The
Contractor shall comply with all relevant regulations.
7. Stacks of sleepers shall consist of sleepers laid side by side but not
touching each other, in layers separated by two timbers laid along the length of the
stack in the rail seats. The timbers shall be of sufficient thickness to support the upper
layer of sleepers clear of the fastenings and components of the lower layer of sleepers.
9. Prepared ballast shall be handled in such a manner that is kept clean and
free from segregation and the accumulation of fines. Vehicles used for transportation of
ballast shall be clean and free from rubbish and substances, which may contaminate or
damage the ballast and must be in good condition to prevent leakage of waste material
during transportation.
2. The railway track shall be Dual Gauge, consisting of three rails forming
Narrow Gauge 1067mm (NG) and Standard gauge 1435mm (SG), with the geometric
design to conform with the plans, profiles and typical cross sections produced during
the concept design.
7. For details of track foundations over the bridge and at transition slabs,
refer to the contract drawings.
1. The Contractor shall obtain and store and prior to the issue of the
Practical Completion Certificate for the Works hand over to the Principal the spare
components. The components shall be identical to those provided in the Works.
2. The Contractor shall submit for Review by the Superintendent the storage
requirements and storage protection for the spare parts 6 weeks prior to the delivery.
The spare parts shall be manufactured, factory tested, suitably packed and identified for
prolonged storage, and delivered to Site within 30 days of the first Key Date for the
completion of trackwork. The Contractor shall deliver the spare parts to a location to
be identified by the Superintendent.
d. Overall dimensions and weight including packing (if any) for shelf
space purposes;
1002.17 GENERAL
a. Method statements for the installation of the track for the Section
inspection and test plans have been Reviewed without objection by
the Superintendent;
b. The results of the track base survey, together with proposals for
correcting out of tolerance aspects have been Reviewed without
objection by the Superintendent.
3. The Contractor shall not operate any rail mounted equipment over any
track until the track has been properly assembled and is safe for the passage of the rail
vehicles. Before any such operations take place, details of the proposed vehicles to be
used, dimensions and maximum axle load shall be submitted to the Superintendent for
Review. See clause 1002.19 for exceptions to this, associated with the installation of
the track slab.
2. The track gauge shall be measured 16 mm below the rail head and shall
conform to:
Track Gauge
TRACK HORIZONTAL TOLERANCE AT CONSTRUCTION TOLERANCE AT CONSTRUCTION
GEOMETRY (NARROW GAUGE) (STANDARDS GAUGE)
Tangent (horizontally straight) 1067.5mm (+1, -1) 1435mm (+2, -2)
track
Curved Track 1073.5 (+1, -1) 1441mm (+2, -2)
0 – 310 m radius [Note 1]
Curved Track 1070.5mm (+1, -1) 1435mm (+2, -2)
311 – 610 m radius [Note 2]
Curved Track 1067.5mm (+1, -1) 1435mm (+2, -2)
611 m radius or greater
Note 2 - On concrete sleepered track for curves between 311 and 610 m in radius the gauge dimension
shall be increased in one step from 1067.5 to 1070.5mm at a point halfway along the transition. On slab
track the gauge shall be increased uniformly along the length of the transition.
Gauge widening where required (in curves) shall be achieved by increasing the distance from the track
design centreline to the gauge face of the inside (low) rail. The distance from the design track centreline to
the gauge face of the outer (high) narrow gauge rail shall remain at 533.75 mm.
Horizontal Alignment
CRITERIA AT CONSTRUCTION
CONCRETE SLEEPERS CONCRETE SLAB
General Tolerance Design (+5 mm, -5 mm) Design (+3 mm, -3 mm)
Maximum Deviation in any +2 mm, -2 mm +2 mm, -2 mm
10 metres of track
DEFECTS LIABILITY TOLERANCES
CONCRETE SLEEPERS CONCRETE SLAB
General Tolerance Design (+5 mm, -5 mm) Design (+3 mm, -3 mm)
Maximum Deviation in any +5 mm, -5 mm +3 mm, -3 mm
10 metres of track
Superelevation
CRITERIA AT CONSTRUCTION
CONCRETE SLEEPERS CONCRETE SLAB
Maximum variation from design. +2 mm, -2 mm +2 mm, -2 mm
Maximum rate of change of variation +2 mm, -2 mm +2 mm, -2 mm
over any 10 metres of track
DEFECTS LIABILITY TOLERANCES
CONCRETE SLEEPERS CONCRETE SLAB
Maximum variation from design. +5 mm, -5 mm +3 mm, -3 mm
Maximum rate of change of variation +5 mm, -5 mm +3 mm, -3 mm
over any 10 metres of track
Cross Level
CRITERIA AT CONSTRUCTION
CONCRETE SLEEPERS CONCRETE SLAB
Tangent Track 0 mm (+2 mm, -2 0 mm (+1 mm, -1
mm) mm)
Maximum rate of change over any 10 +2 mm, -2 mm +2 mm, -2 mm
metres of track
DEFECTS LIABILITY TOLERANCES
CONCRETE SLEEPERS CONCRETE SLAB
Tangent Track 0 mm (+3 mm, -3 0 mm (+2 mm, -2
mm) mm)
Maximum rate of change over any 10 +5 mm, -5 mm +3 mm, -3 mm
metres of track
1. At the final rail alignment check of the slab track sections prior to
pouring the infill concrete, the rail alignment shall be checked using a self-propelled
track recording trolley, such as the Geismar ECG7 or similar testing procedure. Rails
are to be restrained to very tight tolerances to allow the passage of rail vehicle without
any movement, then be removed without movement and have restraints removed..
Final track testing should take place under track load in accordance with the following
section Testing and Commissioning.
4. The recorded data shall be used to produce for consecutive 200 metre
sections of track:
b. Track quality standard deviations of the filtered track top data; and
1. On main line tangent track and track of 400 metres radius and greater, the
running rail steel shall be as-rolled grade. On main line track with radius less than 400
metres, the running rail steel should be head hardened grade. Grades are as specified in
AS 1085.1.
2. Rails shall be moved from their storage location around the Site in a
manner that will not damage the rails. The Contractor shall submit to the
Superintendent full details of his proposed methods of handling, stacking, installing and
subsequent cleaning of the rails. Rails shall be moved longitudinally by a suitable
means that shall not cause damage to any part of the Works. The rails may be pulled by
winch or tractor provided they are on rollers.
3. Rails shall be unloaded without dropping and placed onto the concrete or
ballasted track with rollers, ramps or other devices, which shall prevent damage of any
kind to the rail, other components and the track structure.
6. Details of the proposed fixing and drilling to the rail shall be submitted to
the Superintendent for Review prior to procurement. All drilling of the rail shall be
centred on the rail neutral axis (except for fishplate and insulated joints). Holes 24 mm
diameter or less shall be drilled 1 mm smaller diameter than specified and reamed with
chamfer edges to the correct size or milled by rotary cutter. Holes larger than 24 mm
diameter shall be drilled 1mm smaller diameter than specified and cold expanded to the
correct diameter. The maximum diameter of hole shall not exceed 32 mm. The drilling
speed, coolant and rate of feed shall be controlled to prevent overheating.
1. All main line tracks, yards and turnouts shall be continuously welded
except at insulated rail joints and other specific locations indicated in the Principal’s
detailed design or at the instruction of the Superintendent. Wherever possible, all rails
shall be welded by the flash-butt welding process. Where geometric constraints within
turnouts prevent the use of flash-butt welding plant, the aluminothermic welding
process shall be used.
4. All welds shall be marked by such means that they can be identified for a
minimum of 5 years. The marking shall be a structured numbering system enabling
traceability to testing and weld parameters. The means of weld identification shall
permit traceability to the records and the information obtained at the time of production
of each and every weld. The means of weld identification shall be Reviewed by the
Superintendent.
5. Rail ends, which are to be joined by welding, shall not be holed. There
shall not be less than 9m between welds.
6. The straightness along the end 1.5m of the rail prior to welding shall be
measured as a chordal ordinate of a 1m straight edge and shall be;
Upwards 0.5mm
Downwards nil
7. The rail ends shall be cut in accordance with Clause 1002.21 if necessary
to remove any dipped or hogged rail ends.
8. Any step between the rails across the weld in the ‘as welded’ condition
shall not exceed the following:
d. 1.0mm horizontally on the rail foot where the weld falls on the rail
seat.
11. Profile finishing operations for vertical and lateral alignment shall be
carried out over the minimum length possible. The maximum length profiled shall not
exceed 450mm either side of a weld.
12. Any deviation from straight after any pressing and profiling operation has
been completed, measured relative to a 1.0 metre straight edge central to the weld, shall
not exceed the following, as shown below, regardless of cause:
a. 0.0mm to 0.3mm high vertically at the centre line of the rail head, no
dips allowed; and
14. The Contractor shall submit for Review the details of the flash-butt
welding machine The machine shall comply with the following:
16. All of the welds shall be visually inspected for welding, trimming, profile
finishing defects, which could affect the subsequent service performance.
17. All the welds submitted in the "as welded" condition shall be measured to
determine the step across the joint, which shall not exceed the limits specified above.
The weld upset on all the welds in the "as welded" condition shall be measured and
shall not exceed:
a. 1 mm on aligned faces of the head, on the foot tips and on the upper
and under sides of the foot; and
19. All of the welds submitted in the "as-welded" condition shall be subject
to Slow Bend Tests using the procedure described in Appendix D of AS 1085.15, using
test equipment Reviewed by the Superintendent. All welds shall withstand the
minimum load given in the table below. The test shall continue until each weld has
fractured or the recommended load limit is achieved, at which point the test shall be
terminated and the load and mid-span deflection recorded. If failure occurs down the
weld line, the fracture surfaces shall be inspected. The size and location of weld
features shall be recorded. If failure occurs remotely from the weld, the fracture
surfaces shall be inspected to ensure the absence of "die burn" defects.
20. The finished welds shall be measured to determine their alignment, which
shall not exceed the limits specified above. The finished welds shall be inspected using
full X-Ray inspection methods around the profiled finished area of the head, as well as
the web and foot. All welds in rails to be laid inside the slab are to be fully tested
before placement within the grooves. If any surface cracks, tears, inclusions, die burns
or other production defects are found, then the procedure shall be deemed unsuitable.
21. The variation in hardness shall be measured across the heat affected zone
of each of the two finished welds not more than 5.0mm below the running surface. The
Brinell Hardness test, carried out generally in accordance with AS 2205.6.1, shall be
used. The hardness variation across the samples shall comply with the following
requirements:
22. One of the finished welds shall be subjected to a fatigue test using the
procedure described in Appendix C of AS 1085.15, using test equipment Reviewed by
the Superintendent. On completion the weld shall be subject to a Slow Bend Test in
accordance with the requirements given above.
23. The welding parameters shall be determined during procedural trials and
prototype test welds and submitted for Review by the Superintendent. Once the
welding parameters have been ‘Reviewed without objection’ by the Superintendent, the
procedure shall not be changed without re-submission for Review by the
Superintendent. Welding shall be carried out, and parameters monitored and recorded,
in accordance with the list below. Records shall be referenced to the appropriate weld
and submitted to the Superintendent. The parameters to be recorded are:
a. Welding current;
c. Displacement;
d. Welding time;
24. The flash-butt weld operator shall be trained and certified by the flash-
butt welding machine supplier or other suitably qualified instructor. The Contractor
shall submit for review for Review to the Superintendent the course syllabus and
examination proforma. Prior to undertaking any welding on site, the operator shall
perform two welds inclusive of final profile grinding, in the presence of the
Superintendent, which shall meet the following tests and criteria:
a. Visual examination;
26. All of the finished flash butt welds shall be inspected using the magnetic
particle inspection method around the profiled finished area of the head, as well as the
web and foot. If any surface cracks, tears, inclusions, die burns or other production
defects are found, then the procedure shall be deemed unsuitable.
28. When using long welded rail, where internal string flash butt welds fall
on a rail seat, the sheared weld collar on the rail foot shall be dressed by hand grinding.
29. Rails to be installed in the slab section shall be welded into full length
strings before being positioned in the grooves. All welds must be flash-butt, no
aluminothermic welds are to be used in these sections.
1. All rail joints shall be installed in accordance with Paragraphs 3.12.7 and
3.12.9 of PTA Narrow Gauge Mainline Code of Practice - Track and Civil
Infrastructure.
1. The Contractor shall keep a complete record of the mean rail temperature
and air shade temperature at the time of finally fastening down all rails and provide a
copy to the Superintendent within seven days of fastening down. In the case of rails
which have been fastened down prior to welding, the time of final fastening shall be
taken to be the time the connecting weld is made.
3. The rails shall be finally fastened down at a neutral or stress free rail
temperature of 40oC ± 2 oC. Achieving the neutral temperature for final fastening
down of the rail shall be either by natural means or artificially by the use of hydraulic
rail tensors.
4. The final fastening down shall not be undertaken until the track is in the
design horizontal and vertical location, the full ballast profile has been formed and
consolidated and the method of working for final fastening down has been Reviewed
without objection by the Superintendent.
5. The minimum anchor length should be at least 90m if tensors are used to
obtain the stress free temperature. This should be increased to at least 135m at rail
movement joints. If this minimum anchor length cannot be achieved, then the absolute
minimum anchor length shall be calculated using a maximum creep resistance of 5
kN/fastener or as directed by the Superintendent.
10. When finally fastening down track running through a turnout by artificial
means, the length of turnout from the stock rail joint to the first switch heel block shall
be laid at the stress free temperature.
11. Rails may be laid outside the stress free range but shall be released and
refastened before the track is offered for final acceptance.
12. After final fastening down of the rails in accordance with the above
Paragraphs, no further adjustments of the rails shall be made, without prior Review by
the Superintendent.
c. Cast baseplates shall have plastic ferrule lined holes and LDPE
bedding shims; and
3. Tests to check these values shall be carried out after track assembly but
before bonding of the track.
Rr = VxL/A
7. The test shall be undertaken as shown below and the minimum resistance
shall be 20 ohms km of single track.
9. The following procedures shall be followed for the rail to rail resistance
test:
b. Rust and dirt shall be removed from all contact points; and
R = (Vf+Vr) x L ohm km
2A x 1000
1. The Contractor shall assemble and install the turnouts and layouts strictly
in accordance with the detailed working drawings, alignment and tolerances supplied
by the turnout supplier.
3. The switch toes shall be square across the through track. The switch rail
shall fit properly against the stock rail and bear evenly against the distance blocks.
When the switch blade or swing nose is in the open position, the minimum flangeway
clearance between the stock rail and the switch rail at the commencement of the rail
head planing shall be 50mm. The minimum movement of the switch rail at the switch
toe shall be 150mm.
6. The flangeway gap for common crossing check rails shall be set to the
design value.
7. Rail joints shall be of the type and at the locations indicated on the
supplier’s drawings and in accordance with Clause 1002.15.
9. As part of the trackwork completion works, the turnouts shall include all
the necessary operating mechanism to allow the manual operation of the switches by
Works Trains operators. Point motors shall be fitted and locked in motor operation
mode with a master key padlock. The key and lever for manual operation shall be
issued to the Principal.
11. The bolts and metal washers fastening switch and crossing units together
shall be removed, wire brushed, coated with a suitable oil based compound, replaced
and re-tightened to the correct torque. Only one bolt shall be removed at any one time
in the unit.
4. The Contractor's methods for installing and assembling the main ballasted
track shall be such as not to foul, disturb or cause any damage to manholes, catch-pits,
buried pipes and ducts, drains, safety fences, cables, or cable troughs etc. The
Contractor shall make allowance for the presence of partially constructed items such as
lighting posts, draw pits, concrete support structures, acoustic barriers, safety fences
etc. as indicated in the Principal’s detailed design.
5. Sleepers shall be laid normal to the centre line of the track and shall not
be more than 10mm out of square across the gauge lines. Sleeper spacing tolerance is
+20, - 20 with no less than 1410 and no more than 1450 sleepers in any one kilometre.
The seating on the sleepers and the underside of the rail foot shall be free of loose dirt
and foreign matter when the rail is fastened down. The sleepers shall be handled and
laid with appropriate equipment. They shall not be subjected to blows from a hammer
or any other tool or appliance whilst being handled, laid or aligned. Sleepers shall not
be dropped.
10. Each lift of ballast on plain track shall be thoroughly consolidated for a
length of 450mm each side of the rail. Both ends of the sleeper, inside and outside of
the rails, shall be tamped simultaneously. The ballast under the centre of the sleeper
shall not be consolidated.
11. When jacks are used to lift the track, they shall be placed close enough
together to prevent undue bending of the rail or strain on rail joints or distortion of
switch and crossing units. All rails shall be raised at one time and as uniformly as
possible.
12. Sleepers which have been moved out of position during lifting operations
shall be corrected. Rail and rail fastenings which become loose during lifting
operations shall be corrected.
13. When the track has been brought to the correct alignment and level and
the ballast under the sleepers is fully consolidated, the ballast between the sleepers and
within the ballast shoulders shall be consolidated and trimmed to profile.
1. Rails are to be fully welded and weld testing completed before placement
in prepared grooves.
a. Guage
b. Cant
d. Level
e. Versine on 5m chord.
8. The Contractor shall submit his proposals for the correction of any aspect
exceeding the permitted tolerances.
9. The Contractor shall submit his proposals for the correction of any aspect
exceeding the permitted tolerances.
1002.31 GENERAL
1002.32 PLANNING
1. The Contractor shall submit for Review by the Superintendent the Testing
and Commissioning Plan, one month before undertaking any tests. The plan shall
detail:
1. For any tests required on a major product; such as the rail, sleepers,
bearers, turnouts, baseplates, etc, no testing shall be carried out until the test
specification has been Reviewed without objection by the Superintendent. Test
specifications shall include sample test certificates which shall clearly indicate the
required values and tolerances adopted.
a. Resilient baseplates;
c. Turnouts;
d. Rail; and
b. Slab track components where applicable (e.g. LVT blocks, boots and
pads); and
c. All turnouts.
1002.34 INSPECTION
1. During the installation process, tests shall be undertaken to prove that the
Technical Requirements are being met. In addition to the standard quality control test
on the materials, a check on assembly and tolerances shall include:
a. Alignment test;
1002.36 COMMISSIONING
4. All switches shall be tested following the installation of the point motor
and detection equipment. The test shall include the following:
a. All switches shall be subject to a test for the force required to throw
the switch;
c. Should the force exceed the maximum permitted, the Contractor shall
identify and rectify the fault prior to repeating the test.
5. Following each pass of the test train, the Contractor shall check that the
trackwork has not deviated from its position as fixed, and that all fastenings and fittings
are tight and in their correct position.
a. That the level and alignment of all parts of the track when unladen
remain within the installation tolerances given in Clause 1002.18;
b. That the track has not moved laterally or vertically under the passage
of the test train by more than the normal elastic deflection of the
components. The extent of any vertical movement under traffic shall
be checked by the Contractor, and
7. Prior to the issue of the Certificate of Practical Completion for the Works
or a separable portion, the Contractor shall undertake a final adjustment and tightening
of all fixings of the Permanent Works. This shall include but not limited to:
b. Adjustment of switches;
8. The Contractor shall assist in the train trials and undertake the
Operational Maintenance Support as defined by the Principal.
1. All fences, masts, posts, structures and the like within 3m of the track
centreline shall be surveyed and clearance supplied to PTA-WA.
a. Turnouts;
2. The Operation and Maintenance Manuals shall include but not be limited
to, detailed description, procedures and materials for the following as appropriate:
e. Replacement;
f. Welding technique;
h. Safety; and
i. Spares inventory.
3. The manual shall include a full parts list, detailed down to nut and bolt
size, manufacturer, part number and the design torque for bolts.
6. The final copy shall be submitted 1 month after the Key Date for first
Practical Completion of a Separable Portion. The final document shall incorporate all
comments identified by the Superintendent and information gained during the Tests on
Completion.
7. In developing the O & M Manual, the Contractor shall consult with the
PTA permanent way maintenance manager and ensure compatibility of maintenance
methods, techniques, available and required plant and equipment. The Contractor shall
incorporate details and maintenance of all proprietary permanent way components.
1. Regular patrols shall be undertaken along the full length of the Works,
with a minimum visual inspection twice weekly for ballasted plain track and all turnouts
and weekly for non-ballasted plain track. Routine visual track inspections shall identify
defects which, if uncorrected, could affect the safety or reliable operation of the
railway. Particular attention must be paid to new defects and to developments of
existing defects.
m. Gauge widening;
2. Switches, in running lines, when secured out of use shall have their
scotches, locks etc specially inspected at intervals not exceeding two months. A record
shall be kept of each inspection.
4. An inspection shall be carried out after any flooding, when the water has
subsided, to check for collection of debris in flangeways, point openings, between
floating slab units and at track-mounted equipment, undermining due to ballast washout
and increased slurrying of formation.
5. Buffer stops shall be inspected every six months. The inspection shall
include general condition, any evidence of collision damage, warning lights and, in the
case of a sliding buffer, any need for it to be returned to its normal position, condition
of holding-down bolts, and cleanliness of the running rails behind the buffer. The
details of the inspection shall be recorded together with any repairs carried out.
10. Where the remedial work is determined as wear and tear due to rail traffic
or the movement or settlement of the track base, the Superintendent shall instruct the
necessary remedial works and the Contractor shall implement with due regard to
operational safety.
1. The Contractor shall carry out an initial rail grind prior to the start of
Timetable Operations. The timing of the operation shall be identified based on the
Works Program, following coordination with the Railway Systems works and subject to
Review by the Superintendent.
2. The Contractor shall make all arrangements for a rail grinding vehicle and
operators to be made available and delivered to the Works by road or using the existing
rail connections, subject to availability. The Contractor shall provide all resources in
the form of labour, plant and consumables to prepare the vehicle for operation.
3. The Contractor shall submit for review the details of the rail grinding vehicle. The
machine shall be manufactured and supplied by a specialist rail grinder manufacturer,
of a type and model certified for use on a Major Railway and suitable for all rail
sections and grades used in the Contract.
4. The rail grinding vehicle operator shall be trained and certified by the
supplier or other suitably qualified instructor. The Contractor shall submit for review to
the Superintendent the course syllabus and examination proforma. Prior to undertaking
any grinding on site, the operator shall perform a trial grind, in the presence of the
Superintendent.
5. The operation and maintenance of the vehicle, fuel, oil, lubricants and
grind stone replacement will be undertaken by the Contractor, including the provision
of all resources necessary for:
6. All main line trackwork shall have a nominal 0.1 mm surface grind. The
profile shall meet the standard rail head from 50 degrees gauge side to minus 10
degrees field side. The Contractor shall carry out a pre-grind inspection and submit his
grinding proposals for review by the Superintendent.
Clause Page
GENERAL .................................................................................................................................................. 1
1003.01 DESCRIPTION OF THE WORKS...................................................................................... 1
1003.02 WORK INCLUDED ............................................................................................................ 1
1003.03 TECHNICAL SPECIFICATIONS....................................................................................... 1
1003.04 RELEVANT PTA STANDARDS AND DRAWINGS. ...................................................... 2
1003.05 AUSTRALIAN STANDARDS ........................................................................................... 2
1003.06 PUBLIC TRANSPORT AUTHORITY STANDARDS AND CODES OF PRACTICE ... 2
1003.07 DEFINITIONS & TERMS.................................................................................................. 2
1003.08 PERFORMANCE ................................................................................................................ 3
1003.09 DOCUMENTATION........................................................................................................... 3
1003.10 EXISTING SYSTEMS......................................................................................................... 3
1003.11 INTERFACES...................................................................................................................... 4
CONSTRUCTION ..................................................................................................................................... 4
1003.12 DESCRIPTION OF OVERHEAD WIRING SYSTEM WORKS ....................................... 4
1003.13 ASSOCIATED WORKS...................................................................................................... 4
1003.14 CONSTRUCTION ............................................................................................................... 5
1003.15 CLEARANCES.................................................................................................................... 6
1003.16 EARTHING AND BONDING ............................................................................................ 6
1003.17 MAST FOOTINGS .............................................................................................................. 6
SUPPLY OF EQUIPMENT AND MATERIALS ................................................................................... 7
1003.18 GENERAL ........................................................................................................................... 7
1003.19 PACKING, TRANSPORT, HANDLING AND STORAGE............................................... 7
1003.20 PROTECTION FROM CORROSION................................................................................. 8
1003.21 STAGE WORKS.................................................................................................................. 8
1003.22 TRACK POSSESSIONS AND ISOLATIONS.................................................................... 8
1003.23 INSPECTION AND TEST PLANS..................................................................................... 9
1003.24 OCCUPATIONAL SAFETY REQUIREMENTS ............................................................... 9
TESTING AND COMMISSIONING....................................................................................................... 9
1003.25 TESING AND COMMISSIONING..................................................................................... 9
1003.26 TESTING AND COMMISSIONING DOCUMENTATION .............................................. 9
1003.27 HAND-OVER AND HAND-BACK.................................................................................. 10
ANNEXURE 1003A ................................................................................................................................. 11
OHLE DRAWINGS............................................................................................................................... 11
APNNEXURE 1003B ............................................................................................................................... 12
DOCUMENTS & STANDARDS .......................................................................................................... 12
ANNEXURE 1003C ................................................................................................................................. 13
PTA REFERENCE DRAWINGS .......................................................................................................... 13
ANNEXURE 1003D ................................................................................................................................. 15
OVERHEAD DATA SHEETS AND TENSION LAYOUT ................................................................. 15
OHLE
GENERAL
1. The North Quay Rail Loop project will require the installation of a
turnout from and a track slew of the existing Down Fremantle Line for approximately
245 metres.. The track alterations are described on drawing R-01-G-004. In addition
the new North Quay Loop track will foul 3 overhead masts adjacent the Down
Fremantle.
2. This document defines the scope of the OHW activities and relevant PTA
specifications for these modifications.
2. Based on concept design the installation of the North Quay Rail Loop
will typically require the following overhead wiring modifications:
b. 4 new pull off masts – note if the embankment is too steep to install
a heavily laden pull off on the outside of the curve, then push off
mast on inside of curve to be considered..
c. Install new Balance Weight assembly for wire run No. 150.
d. Adjust height and staggers as required.
1. All work that is to be completed by the Contractor shall comply fully with the
requirements of the most recent versions of the Standards, Specifications and Codes of
Practice listed below in the following precedence:
c. Australian Standards.
d. International Standards
1. All 25kV OHE design and installation must comply with the PTA (PTA)
Specifications and Procedures described in Annexure 1003B.
• Specification 228E Guidelines for Earthing and Bonding in 25kV a.c. Electrified
Areas
1. Wherever possible the masts, assemblies and fittings installed during the
alterations shall be identical to existing equipment. Where this is not possible the
Contractor shall inform the Superintendent for direction to proceed.
1003.09 DOCUMENTATION
1. The design must be independently verified, then submitted to the PTA for
approval. Following this the documentation must be submitted to the Superintendent at
least 30 days prior to work commencing.
b. Where redundant, the Contractor shall decommission and remove the existing
equipment.
c. All recovered reusable equipment shall be removed from site and stored in a
secure area. The equipment shall be cleaned and inspected for damage. The
satisfactory equipment shall be returned to the PTA.
CONSTRUCTION
a. Loop track.
3. To facilitate the North Quay track installation, new mast structures are to
be placed at the following locations:
1. The Contractor shall supply, install, test and commission all equipment
and materials necessary for construction / alterations of the overhead wiring system as
detailed in the detailed design contract documentation including, but not limited to all
masts, foundations and system components. The proposed works are depicted in
drawings listed in Annexure 1003A.
h. Any preformed wrap on wire fittings, dead ends or splices shall not
be reused in permanent installations after removal. Any such devices
provided or used by the Contractor shall be identified by indelibly
bright green paint;
i. All insulators installed in the system shall be cleaned and free from
any defects at the date of handover;
k. All fasteners and fixings shall be tightened securely and correctly and
the equipment erected using good engineering techniques. Torque
wrenches shall be used where necessary;
1003.15 CLEARANCES
1. At no time shall any part of any new structure, materials, fittings, plant
and equipment be positioned permanently or temporarily within the minimum electrical
clearances from live 25kV traction overhead equipment, as nominated in the PTAC’s
“Safety Instructions for the Electrified Area”, unless otherwise approved in writing by
the Superintendent.
1. The E&B design shall be compatible with the track signalling system
installed. E&B cable sizes shall be in accordance with PTA standards. This must be
PTA approved prior to submission to the Superintendent.
1. The Contractor shall be responsible for the design of mast footings. The
Contractor must provide to the Superintendent independently verified design of the
footings at least 14 days prior to masts installation.
1003.18 GENERAL
2. All materials and components to be used for the alterations, shall be new
and as defined in the Contract Drawings and within these Technical Requirements.
They shall be free of damage immediately prior to being taken to the point of
installation and at the time of fixing in position. Materials which are not to the required
standards shall be removed from Site and replaced by the Contractor.
2. The Contractor shall ensure that the packing and transport of the
materials will not induce undue stress, vibration, corrosion or impact their properties.
The Contractor shall ensure that components of similar physical type but differing
properties are packed and labelled clearly.
5. All normal and regulatory precautions against fire shall be taken during
both storage and use.
1003.20.01 GENERAL
1. The Contractor is responsible for the stage works for the OHW
installation of the North Quay Rail Loop Project.
2. The Contractor shall ensure that in addition to the staging for the OHW
alterations attention and co-ordination shall be carried out for all associated civil,
signalling and communication works required.
5. The Contractor shall submit a proposed staging plan with his tender
submission for approval. The plan shall indicate the proposed number of close downs
required and any other required isolation/possession requirements to complete the
alterations, testing and commissioning.
6. The Contractor shall endeavour to keep the total number of track closures
to a minimum.
2. The Contractor shall prepare method statements for the work proposed in
each possession.
1. Prior to mobilisation, the Contractor shall prepare full Inspection and Test
Plans, including Factory Acceptance Testing documentation for items listed in clause
1003.18.
1. The Contractor shall be aware that there are other gas and electricity
services located within the railway reserve.
3. The Contractor shall inspect the proposed foundation locations and carry
out all works in accordance with Specification 105.
1. The contractor shall produce an approved PTA Inspection and Test Plan
and submit to the Superintendant for approval for all works to be undertaken at least 30
days prior to work commencing.
1. The Contractor shall prepare a factory acceptance test plan for all
equipment that is required to be factory tested prior to site installation.
1003.26.02 INSPECTION
3. The inspections shall be carried out on completion of all work and will
signify the works have been completed in accordance with the technical requirements
and the OHW system is safe and suitable for operation. The Contractor’s nominated on
site representative shall be familiar with the PTA permit to work procedure.
2. The maintainer shall be liable for the maintenance of the new installation
once all significant defects are remedied.
OHLE DRAWINGS
Drawing No Description
R-01-G-001 Rail Loop Alignment
R-01-G-002 Rail Loop Alignment
R-01-G-003 Rail Loop Alignment
R-01-G-004 Main Line Realignment
R-01-X-001 Rail Loop Cross Sections Sheet 1
R-01-X-002 Rail Loop Cross Sections Sheet 2
R-01-E-001 Proposed OHW Layout drawing
F18950d Perth Urban Rail Overhead Data Sheet
F18944d Perth Urban Rail Overhead Data Sheet
F18994u Perth Urban Rail Overhead Data Sheet
F19034d Perth Urban Rail Overhead Data Sheet
F19034u Perth Urban Rail Overhead Data Sheet
F19069d Perth Urban Rail Overhead Data Sheet
F19069u Perth Urban Rail Overhead Data Sheet
F19086d Perth Urban Rail Overhead Data Sheet
F19102d Perth Urban Rail Overhead Data Sheet
F19103u Perth Urban Rail Overhead Data Sheet
F19122d Perth Urban Rail Overhead Data Sheet
F19142d Perth Urban Rail Overhead Data Sheet
F19142u Perth Urban Rail Overhead Data Sheet
F19162d Perth Urban Rail Overhead Data Sheet
F19180d Perth Urban Rail Overhead Data Sheet
F19182d Perth Urban Rail Overhead Data Sheet
F19182u Perth Urban Rail Overhead Data Sheet
F19202d Perth Urban Rail Overhead Data Sheet
F19221d Perth Urban Rail Overhead Data Sheet
F19221u Perth Urban Rail Overhead Data Sheet
F19223u Perth Urban Rail Overhead Data Sheet
F19223d Perth Urban Rail Overhead Data Sheet
F19265d Perth Urban Rail Overhead Data Sheet
F19267d Perth Urban Rail Overhead Data Sheet
F19267u Perth Urban Rail Overhead Data Sheet
F19286u Perth Urban Rail Overhead Data Sheet
F19306d Perth Urban Rail Overhead Data Sheet
F19306u Perth Urban Rail Overhead Data Sheet
ES-RHL-1065 Rev D Perth Urban Rail Overhead Line Equipment Layout
12. 10--H-25-0136 Suburban Electrification Overhead Line Equipment Return Conductor and Rail to
Return Current Busbar Connection
Drawing No Description
ES-HG-1002 Overhead Line Equipment Standard Spans for Sagged Contact Wire
Catenary Wires
ES-HG-1130 Overhead Line Equipment Concrete Portal Mast and Heavy Load
Cantilever mast
ES-HG-1135 Overhead Line Equipment 50kN Nominal Capacity Concrete Feeder Mast