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a. Inspection of rail ends
b. Rail cutting and set the required gap
c. Loosening of rail fastenings
d. Rail end preparation and alignment
e. Preheating and welding
f. Finishing and alignment
g. Weld testing
h. Replacement of defective welds
i. Records of thermit welding
Each procedure shall be in accordance with the AREA Manual for Railway
Engineering, the products or welding kit specifications itself and other
applicable standards.
13.1.3.10.2 Quality Assurance
This section shall conform to requirement in 2.1.3.1.1 Quality Assurance
Program.
13.1.3.10.3 Weld Testing
All weld testing and submittals shall be performed by a duly accredited
independent testing laboratory in accordance with quality control requirements
and applicable standards. In order to qualify the welding kits, welding crews,
and production welds; the following test shall be carried out:
a. Radiographic testing
b. Ultrasonic testing
c. Slow bend testing
d. Hardness test
e. Rolling load test
f. Magnetic particle test
g. Visual test
13.1.3.10.4 Tolerances
All alumino-thermic welds will be in the suspended portion of rail between
supports. The weld shall not encroach 150mm from tie ends or baseplate
support. Finished weld using 1 meter straight edge shall have the following
tolerances:
a. Rail head surface +0.3 / 0.0 mm
b. Rail gauge face +0.3 / 0.0 mm
13.1.3.10.5 Submittals
The Contractor shall submit the following:
a. Detailed specifications, proposed materials, methods and procedures to
be used for the thermit welding process,
b. Certification from the supplier or manufacturer that the materials
delivered to site conforms to the specifications,
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c. Welding supervisor qualifications with a minimum 3 years thermit
welding experience. The welding supervisor shall be replaced only
with the Engineer’s prior approval,
d. Schedule of CWR lengths and CWR string Designation system,
e. All material testing and weld test results,
f. Test equipment certificate and calibration,
g. And all submittals shall be in accordance with 2.1.3.1.2 Submittals.
13.1.3.11 Grade/Road Crossing
This section specifies the requirements for the supply and installation of materials
required for the construction of grade/road crossings at MRT3 Depot.
The contractor shall perform the work in accordance to applicable standards and
approved methods, procedures and materials by the Engineer. The Contractor
shall take all necessary safety measures for an organized construction work and to
avoid interruption to depot train movement and maintenance work.
13.1.3.11.1 Bituminous Material Installation It shall conform to Item 307 of DPWH Standard Specifications
13.1.3.11.2 Submittals
a. Shop drawings for the crossing showing details and arrangement of the
rail support and anchoring system including dimensions and tolerances
b. Grade/road crossings installation procedures
c. Approved job mix formula of the bituminous materials to be use
d. And all other required documents to necessary to complete the work
TABLE 1
TRACK CONSTRUCTION TOLERANCES
Notes:
Variation is measured between the designed and actual alignment at any point in the
track
Horizontal alignment is measured in mm by 10m chord placed at the gauge line of the
rail running face.
Vertical alignment is measured in mm by 10m chord at the head of the datum rail.
Rail cant may vary between 1 in 18 and 1 in 22
Type of Track Gauge
Variation
Cant / Cross
Level
Horizontal
Alignment
Vertical
Alignment
Mainline
Ballasted
Track
N/A
N/A
N/A
N/A
Depot
Ballasted
Track
-2, +3 mm
±3 mm
±4 mm
0, +5 mm
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Maximum twist is 1 in 1000
14. DEPOT EQUIPMENT/FACILITIES
14.1 INTRODUCTION
Under the capacity expansion project additional trains are to be provided to increase
capacity. Upgrading of existing maintenance facilities and additional workshop
equipments are necessary to support the project.
The overhaul area in MRT3 depot was utilized fully whilst conducting general
overhauling and at times also when carrying out car body repairs. It was necessary for
some parts to be fork lifted in order to transfer to the bogie hoisting area. To
complement the present bogie hoisting area, it is necessary to provide a service track
and turntables for bogies to link the two areas. Please refer to MRT3 Workshop
Improvement Lay-out.
14.2 WORKSHOP IMPROVEMENT (Infrastructure)
14.2.1 General
All works under this section shall be carried out in accordance with all the governing
codes and regulations that are hereby made part of these specifications. The plans and
these specifications are complementary and what is called for in one shall be as if
called for in both.
Applicable Standards
The following are the main reference standard comprises the technical requirements
and the condition to be adopted for the execution of the works.
AASHTO - American Association of State Highway and Transportation Office
ACI - American Concrete Institute
PCI - Prestressed Concrete Institute
ANSI - American National Standard Institute
ASTM - American Society for Testing and Materials
AWS - American Welding Society
PNS - Philippine National Standards DPWH Standard Specification
PEC - Philippine Electrical Code
NEMA - National Electrical Manufacturer’s Association
Work in General
The work shall consist of providing all items, materials, operations or methods listed,
implied, mentioned or scheduled on the drawings and/or herein, including all labor,
supervision and equipment necessary to the proper completion and execution of the
works except those portions of the work that are clearly stated to be done by others.
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Work Included
The work to be done under this section shall include the furnishing of all tools, labor,
supervision, equipment, fixtures and all necessary materials, each complete and
proper working condition unless one or other is specifically excluded or stated
otherwise in this specifications but not limited to the works below:
Relocation, removal and demolition, re-installation of existing equipment and other
works as required in carrying out removal, demolition and modifications to existing
lighting, fixtures, pneumatic lines and branch circuits. Such necessary improvements
and modifications to the electrical and mechanical works because of structural and
architectural changes shall form part of the scope of this section even if not
specifically identified.
Visit to Site
The Contractor is advised to visit and satisfy himself as to the local conditions and
facilities that may affect his work. He will be deemed to have fully completed this
study before preparing his proposal and no subsequent claim on the grounds of
inadequate or insufficient information shall be entertained.
14.2.1.1 CONVERSION OF LEVELED TRACK TO
MAINTENANCE PIT TRACK
A portion of Tracks 19 and 20 shall be converted to a maintenance pit (40 M each) so
that bogies can be dismounted from the car using the mobile lifting jacks. All
compressed air supply complete with quick connect coupling, valves and fittings shall
be provided with the same materials used as of the existing pit including other
associated utilities (electrical/ mechanical) inside the pit. The depth of the pit shall be
1.2 M from top of rail. Please refer to MRT3 Workshop Improvement Lay-out.
14.2.1.2 SERVICE TRACK FROM TRACK 17 TO BOGIE
WASH TRACK
A service track from track 17, 18, 19 and 20 to bogie wash track shall be provided to
be connected by means of bogie turn tables for easy access to cleaning in the bogie
wash room during dismounting. Please refer to MRT3 Workshop Improvement Lay-
out.
14.2.2 WORKSHOP EQUIPMENT (Additional)
14.2.2.1 DESCRIPTION
The scope of this section is to provide specification for the supply, installation, testing
and commissioning and subsequent training of operators in relation to additional
Depot Equipment.
Warranty The supplier shall provide the MRT3 with a two (2) year period of warranty coverage
for the equipment issued that will commence upon written confirmation of final
acceptance. Refurbished equipment shall also be guaranteed for not less than 2 years.
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Submittals
Supplier shall provide written instruction in English language pertaining to the
operation, servicing and maintenance of the equipment.
The O & M manuals shall be provided from the delivery of equipment. It shall
describe the method and theory of the operation, equipment characteristics and
specifications, as well as maintenance and troubleshooting procedures. Complete
parts list, troubleshooting flowcharts and guidelines and safety precautions shall be
included.
Supplier shall provide shop drawings in A1 size including “As Built” drawing.
Reliability, Availability, Maintainability and Safety
The supplier shall provide the equipment’s reliability, availability, maintainability and
safety criteria based on EN 50126 or acceptable equivalent Standard. It shall be based
or compatible with the existing installed equipment or even better.
Training
Supplier shall provide training in the proper and safe use of the equipment proposed
and shall describe/facilitate the proposed training program. The supplier shall provide
all training materials, training tools and venues.
Spare Parts
The supplier shall be responsible for the availability and supply (shall provide) of all
initial spares at site during installation, commissioning and the warranty period.
Consumable spares comprising those items which are required for routine
replacement or usage to meet the manufacturer’s recommended servicing and
maintenance programs shall also be provided for use during the warranty period and
for one (1) year service after the warranty period. Included in this supply shall be
those items which are expected to fail during the specified period based on the
manufacturer’s known or predicted failure rate.
The contractor shall ensure the availability of these spare parts for at least 4-four
years.
Delivery, Storage and Handling Materials shall be delivered to the site in the original sealed containers or packages,
and shall bear the manufacturer’s name and brand designation. Where materials are
covered by a reference specification number, type and plan as applicable. Materials
shall be stored and handled in a manner to protect them from damage during the entire
construction period.
14.2.2.2 HAND ACTUATED TURNTABLE FOR BOGIES (5
Units)
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This equipment is designed for transfer of bogies from one track to another for repair
and overhaul and shall be mounted in a concrete pit. The top of the turntable shall be
at the same level of the workshop floor so as not to hinder trolley movement. The
turntable shall be manually operated; at least two-2 personnel could easily rotate the
table with a maximum load of 6 tons. Rail gauge to be used shall be the same as the
existing rail (Rail Gauge = 1,435 mm). The gap between the foundation and the turn
out table shall be less than 10mm. A stopper shall also be provided so that the table
will not move when at rest position. The supply shall include (for each turntable):
The turntable
The running platform
The peripheral joint ring
Each turntable shall consist of mechanical assembly bearing on a center pivot and
several carrier rollers running on circular platform.
14.2.2.3 MOBILE LIFTING JACKS (1 Set / 12 Units – 50 KN Capacity)
This equipment is used to jack-up LRV in simultaneous, synchronized and a safe
manner in order that items of running gear and some under frame mounted equipment,
such as bogies, can be removed and replacement items fitted. The design of the jacks
shall be such that personnel shall be able to work safely under an LRV being
supported by these jacks without the necessity of providing additional supports.
The jacks will be controlled from one control station which will be provided with a
means of enabling the maintainer to monitor the jacking process is proceeding safely
and synchronized. The number of jacks being controlled during jacking operations
will be variable.
Control and power cabling for the jacks that could be under hatches will be strong
enough to bear any likely imposed weight, for example fork lift trucks or another jack.
The intension is to keep this cabling to a minimum on the workshop floor. Connection
between jacks and the floor sockets will be via suitably robust connectors and cables.
It is required to have a set of mobile jacks arranged to be able to lift one single LRV.
RAM CRITERIA DIMENSION
Reliability No more than one failure per year
Availability
95% after breakdowns and maintenance
Maintainability
Equipment to be back in service at maximum tone half day after failure
RAM CRITERIA DIMENSION
Reliability No more than one failure per year Availability 95% after breakdowns and maintenance
Maintainability Equipment to be back in service at maximum two days after failure
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14.2.2.4 TRAVELLING LIFTING TABLES IN PIT (1 Unit –
20 KN Capacity)
This equipment is designed for removal of equipment fitted on the under frames of
LRV. It shall also be designed for carrying in the equipment after removal from the
LRV to the end of the pit for transfer to a hoist.
14.2.2.5 JIB CRANES (2 Units – 20 KN Capacity)
This equipment is mainly used in the overhaul workshop. They shall be used for the
movement of large assemblies/sub-assemblies in a single area.
15 TAFT POCKET TRACK
MRT3 presently has already approached the limit of practical capacity. Therefore, capacity
expansion and improvements become particularly timely and an important objective to be
implemented.
The present three-car trains shall be improved to four-car trains in the implementation of this
Capacity Expansion.
The present retaining wall, tracks and wayside equipment installed at Taft Pocket Track
(TPT) shall be modified and lengthened accordingly to accommodate 4-car trains.
Modification works should not in any way disrupt the current system operations.
The extension of the Pocket Track shall be completely interfaced and integrated with the
signaling system, power supply, catenary system and track works.
The works will require demolition and replacement of some length of the affected wall
structure. It requires redesign, relocation and replacement the cables relevant to signaling and
Overhead Catenary System (OCS).
The technical specifications relevant to each portion of the works are as follows, but not
limited to:
a. Part 1 – Civil Works
b. Part 2 – Track works
c. Part 3 – Overhead Catenary System
RAM CRITERIA DIMENSION
Reliability No more than one failure per year Availability 98% after breakdowns and maintenance
Maintainability Equipment to be back in service at maximum one half day after failure
RAM CRITERIA DIMENSION
Reliability No more than one failure per year Availability 97.5% after breakdowns and maintenance
Maintainability Equipment to be back in service at maximum one half day after failure
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d. Part 4 – Signaling System
The Signaling Upgrade shall not be included in this contract. The upgrade of the signaling
system shall be carried out by the Signaling Provider of the MRT3.
The contractor shall follow the design requirement and specification of the Signaling system
to make the Power & OCS system, Civil Works and Track Works fully integrated to the
Signaling system.
15.1. CIVIL WORKS
15.1.1. General
The stipulation stated in this Section specifies the requirements applicable to the Civil
Works for the extension of the MRT 3 Taft Pocket Track.
The works shall include the detailed design, supply, delivery, installation, testing &
commissioning, defects warranty and obtaining all permission from government
authorities and everything whether permanent or temporary in nature needed and
necessary for safe and proper execution of work and fulfillment of all obligations
required under this contract.
15.1.1.1. Scope of Work
The Contractor shall be responsible for:
a. Design, plan, and modification of MRT3 retaining wall structures affected
by extension of the Taft Pocket Track.
b. Other Civil Works required for work completion like restoration of MRT 3
perimeter fence, drainage, curbs and etc.
c. Ensure no disruption to MRT 3 daily train operations and adjacent traffic
flow along EDSA.
15.1.1.2. Applicable Standards The following are the main reference standard comprises the technical
requirements and the condition to be adopted for the execution of the works.
American Standards
- AASHTO
- ACI
- ASTM
- AWS
- PCI
British Standards
- BS
- CIRIA
- CRSI
European Norms
- CEN
133
- SCCEPG
French Norms
- AFNOR
- DTU
DPWH Standard Specifications
PNS
15.1.1.3. Special Site Conditions
Utmost importance shall be taken by the Contractor with regard to the special site
conditions affecting the design and construction of the project.
15.1.1.4. Performance Requirements
The contractor shall prepare design criteria, a preliminary set of standard
drawings, a list of the basic design drawings, and a set of final design drawings
and an outline of the procurement and construction specifications.
15.1.2. Materials Requirements Civil Work materials needed for the extension of Taft Pocket Track shall be complete
with all accessories and passed all the required testing in accordance to specifications
and standards and shall be approved by the Engineer before incorporating to work.
The Contractor shall ensure materials availability for small quantity production
intended for maintenance use.
15.1.2.1. Removal of Structures and Obstructions This Item shall consist of the removal wholly or in part and satisfactory disposal
of all structures, fences, old pavements and any other obstructions which are not
designated to remain. It shall also include salvaging of designated materials and
backfilling with approved fill materials. All rubbish from the TPT area shall
be disposed of and shall not allow accumulations.
15.1.2.2. Earthworks
All materials to be incorporated in the work shall pass all required testing and
certification and in accordance with the requirements of Part C Earthwork
DPWH Standard Specifications.
15.1.2.3. Aggregate Base / Sub-Ballast
The aggregate base (sub-ballast) shall be from approved source and conform to
the requirements of Item 201 Aggregate Base Course of the DPWH Standard
Specifications.
15.1.2.3.1. Geo-Textiles
This item covers geo-textile fabrics for use in subsurface drainage, hydraulic
control, erosion control, sediment control and pavement structures as a
waterproofing and stress relieving membrane in order to prevent mixing of
dissimilar materials.
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Geo-textile sheet for MRT3 shall be 13kn tensile strength and at least 0.90mm
thickness.
Materials and specifications for this section shall conform to Item 715 of
DPWH Standard Specifications.
15.1.2.4. Concrete Works
This section refers to the required concreting works for MRT3 retaining wall,
OCS posts unless specified and other concreting works needed for the extension
of Taft Pocket Track.
15.1.2.4.1. Concrete
The concrete shall be adequately workable and of proper consistency to permit
flow to forms and reinforcement during placement and no signs of aggregate
segregation. The designed minimum compressive strength of concrete at 28
days shall be 28 Mpa shall conform to AASHTO, ACI, ASTM and standards
applicable.
15.1.2.4.2. Cement All Portland cements shall be obtained from suppliers which have a quality
system for product conformity and shall conform to ASTM 150 or Item 700
of DPWH Standards Specification or approved equal.
15.1.2.4.3. Water Water shall be clean, fresh and potable and shall conform to Item 714 of
DPWH Standard Specifications.
15.1.2.4.4. Aggregates Aggregates shall be from approved source and shall not contain any deleterious
substances to prevent contamination and cement alkalis reactions.
All aggregates shall pass all required testing and shall conform to ASTM
Standards and Item 703 of DPWH Standard Specifications.
15.1.2.4.5. Admixtures
Suitable admixtures may be used to modify certain properties of concrete and
shall conform to ASTM C494. However, as they may at the same time
adversely affect other important concrete quality, the Contractor shall carry
out testing on concrete to which they are added.
All admixtures shall conform to relevant local and international specifications
and shall be approved by the Engineer.
15.1.2.4.6. Steel Reinforcement
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The Contractor shall specify basic and minimum standards for furnishing and
installing steel reinforcement for concrete. All reinforcing steel shall be hot
rolled weldable deformed steel bars obtained from approved supplier as
specified in ASTM A615M or BS 4449 and shall have the following minimum
yield strength:
a. 12 and smaller shall be 275 Mpa or grade 40
b. 16 and larger shall be 414 Mpa or grade 60
15.1.2.4.7. Formwork Forms shall be designed to produce hardened concrete of the shape, lines, levels
and dimensions indicated on the design drawings. The forms including form
supports which shall withstand the worst combination of all loads together with
all incidentals dynamic effects caused by placing, vibrating and compacting
concrete.
The Contractor shall specify basic and minimum standards for forms for
concrete structures and facilities and shall conform to ACI 301 and ACI 347
standards.
15.1.2.4.8. Materials for Curing Concrete
Concrete curing materials shall be of approved materials and conforms to
standards requirements. The materials shall be satisfactory of providing a
curing environment for optimal concrete quality, consistency, strength and
durability.
The following materials can be used for curing concrete by the Contractor or
any approved equal:
a. Liquid membrane forming compounds AASHTO M 148 / ASTM
C1315
b. Previous sheeting AASHTO M 184.3
c. Standard specification for sheet materials for curing compound ASTM
C171
15.1.2.4.9. Joint Fillers
Unless otherwise shown on the plans or in special provisions, materials for
expansion joint filler shall conform to the ASTM D-1751 requirements and
specifications.
15.1.2.4.10. Other Accessories
Reinforcement accessories, consisting of bar supports, spaces, ties, and similar
items as required for spacing, assembling, and supporting concrete in place shall
be provided conforming to reference standards.
15.1.2.5. Civil Miscellaneous Structures
This section refers to miscellaneous materials required and necessary to complete
the work in the extension of Taft Pocket Track.
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15.1.2.5.1. Curb and Gutter
Curb and gutter shall be constructed by concrete cast in conformity with the
design drawings and shall be in accordance with the plans and specifications
required by the Engineer.
Materials and execution shall conform to Item 600 of DPWH Standard
Specifications.
15.1.2.5.2. Fences
Fences necessary to maintain system security along the MRT3 perimeter shall
be provided by the Contractor and shall ensure that there are no related or
operational problems. Metal fences should be galvanized and or walls shall
have smooth surfaces and shall be painted.
MRT3 perimeter fence shall be constructed in conformity with the designs and
specifications required by the Engineer and shall be compatible with the
existing fenced materials.
Materials and execution shall conform to Item 604 of DPWH Standard
Specifications.
15.1.2.5.3. Drainage Drainage for MRT3 shall be compatible with the existing drainage system. It shall be designed to remove completely excess water. Drainage pipes of
100mm Ø shall be perforated with 10mm Ø holes connected to PVC drain
pipes of the same diameter and spaced every 3 meters shall be used.
15.1.2.5.4. Cable Trough Cable trough shall be precast concrete provided with 20mm Ø drain holes
spaced every 5 meters. Cable through shall be 50mm thick and at least 270mm
in height. Each cable through of 300mm and 440mm wide respectively shall
consist in 3.2mm Ø welded wire fabrics spaced every 150mm and shall
conform to ASTM A185.
15.1.3. Construction Requirements
The Contractor shall be responsible for the construction means, methods, techniques,
sequences and procedures for coordinating all portions of the Work under the
Contract Documents.
The Contractor shall provide all superintendence during the execution of the Work as
may be necessary for the proper fulfillment of the Contractor’s obligations under the
Contract. It shall include the supervision and inspection by qualified professional
personnel experienced in railway construction whose responsibility shall be to ensure
the technical standards and workmanship, materials, and quality are being maintained
in accordance with the Scope of Work.
137
The Contractor shall design, supply and install materials for the extension of Taft
Pocket Track which satisfies to the minimum requirements of the specification and
Employer’s Requirements. The Contractor shall submit full details of the proposed
design to the Engineer for review and approval and shall not commence until written
acceptance has been received from the Engineer.
15.1.3.1. Removal of Structures and Obstructions
This Item shall consist in the partial or whole removal responding to the final
disposal of all structures: fences, old pavements and any other obstructions which
are not designated to be remained. It shall also include salvaging of designated
materials for backfilling with approved fill materials. All rubbish from project
area shall be disposed and accumulations shall not be allowed.
15.1.3.1.1. Execution
This section shall conform to Item 101 of DPWH Standard specifications
15.1.3.1.2. Dust control
The Contractor shall take appropriate action to check the spread of the dust in
the project site and avoid the creation of a nuisance in the surrounding area.
The Contractor shall not use water if it results in hazardous conditions such as
flooding or pollution and shall comply with all dust regulations imposed by
the local air pollution agencies.
15.1.3.1.3. Construction Protection
The Contractor shall ensure construction protection adequately during
execution of work in order not to affect the adjacent traffic flow along EDSA
Highway and MRT 3 operations.
The Contractor shall take all necessary precautions to protect personal (ppe)
and private property in the areas of work. Approved barriers and warning
signs shall be provided to reroute personnel/motorists around areas of
dangerous work
15.1.3.1.4. Rubbish / Debris Rubbish/debris shall be placed in approved Contractor furnished containers to
prevent spread and accumulation of dust and dirt. It shall be removed from the
area of work as often as necessary but not less than at least once at the end of
each workday.
15.1.3.1.5. Submittals
The Contractor shall submit the following:
a. Proposed demolition procedures for Engineer’s approval
b. Detailed description of equipment to be used for each sequence of
operation
c. Traffic management plan
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d. And other submittals required for work completion.
15.1.3.2. Earthworks
The work specifies in this section consists of stripping topsoil, excavating and
backfilling to attain indicated sub-grades and grades and conforms to Part C
Earthwork of DPWH Standard Specifications latest edition.
15.1.3.2.1. Excavation Remove materials within the indicated limits. The sub-grade is the lowest
elevation of excavation and it shall be inspected and approved by the Engineer
prior to placement of grade materials. Excavated materials satisfying the
requirements of Item 104 of the DPWH Standard Specifications may be used
as fill materials. Remove all surplus excavated materials.
15.1.3.2.2. General Excavation
a. Generally refers to excavation for the construction of track-way and
roadway as indicated on the design drawings.
b. Sub-grade preparation at sub-grade track way and roadway in
excavation areas shall have a minimum bearing capacity of 150 Kpa
and shall conform to Item 105 of DPWH Standard Specification.
c. Fill unauthorized excavation with approved fill materials by the
Engineer and compact to at least 90 percent of maximum dry density in
accordance with ASTM 698 of 200mm per compaction layer.
15.1.3.2.3. Structure Excavation
Ensure that the existing sub-grade, other than rock, will not be disturbed and
get loose by any excavation. If the sub-grade material is disturbed to a lesser
than 90% of FDT, measure should be taken to recover the sub-grade at least
90% FDT or higher, otherwise the disturbed material can be replaced by
equivalent material or with concrete of the same class as the sub-grade
structure.
The Contractor shall ensure that demolition and excavation of the adjacent
existing concrete road which is affected by the project shall not disrupt the
road traffic and not damaging to any other existing facilities.
15.1.3.2.4. Filling, Backfilling and Compacting
Gradation ASTM D422
Liquid Limit ASTM D4318
Plasticity Index ASTM D4318
Resistance (R. Value) ASTM D2844
Maximum Density ASTM D1557
Sand Equivalent California test 217 or ASTM D2419
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Refer to Item 104 of DPWH Standard Specifications.
15.1.3.2.5. Contractor’s Quality Control
Prior to and during the execution of the work, the Contractor’s Testing
Laboratory shall perform all necessary tests in accordance with the minimum
testing requirements and Item 104 of DPWH Standard Specifications. Field
Density Test for any sub-grade for track or for any soil for spread foundation
should be higher or at least 90%.
15.1.3.2.6. Submittals
The Contractor shall submit the following for Engineer’s review and approval:
a. Equipment to be utilized in the work
b. All necessary methods and procedures
c. All testing results and other materials certification
15.1.3.3. Aggregate Base / Sub-Ballast
This section specifies the furnishing, placing, spreading and compacting of
crushed aggregate base or sub-ballast in one or more layers in accordance with
specification and contract drawings.
15.1.3.3.1. Placing, Spreading and Compacting
The approved aggregate base course (sub-ballast) shall be placed, spread and
compacted in conformity with the requirement of DPWH Standard
Specifications Items 200.3.2 and 200.3.3 and contract drawings.
Geo-textile materials, execution and specifications for this section shall
conform to Item 715 of DPWH Standard Specifications.
15.1.3.3.2. Submittals
The Contractor shall submit the following for Engineer’s review and approval:
a. Geo-textile materials specifications
b. Equipment for to be utilized for the work
c. All necessary methods and procedures
d. Materials grading and testing results
e. Materials source and certificate of compliance
15.1.3.4. Concrete Works for Retaining Wall
This section covers procurement and placing of concrete. It specifies basic and
minimum standards for materials and equipment for the use of plain and
reinforced concrete.
All specifications discussed in this section will technically apply for the
construction of MRT3 retaining walls, OCS foundation if necessary and other
concrete works needed for the extension of the Taft Pocket Track.
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15.1.3.4.1. Quality Assurance
The Contractor shall be responsible for the quality control and quality
assurance for materials and construction to be included but not limited to the
following:
a. Complete quality assurance plan
b. Organizational chart for quality control
c. Qualifications of independent testing laboratories as well as names and
experience records of Contractors staff for implementing quality plans
d. Site laboratories locations, layout and equipment
e. Plans for testing products requiring testing and inspection at the
supplier’s premises and proposed procedures for ensuring quality
control is implemented
f. Provision of inspection and testing instruments and devices to ensure
proper performance of quality control
g. Verification by affidavits and certifications that the supplied products
meet requirements of reference specifications as specified in applicable
sections of specification
h. Tests to be regularly performed on all supplied materials
i. Lists of proposed stages at which specified inspection and
documentation shall be performed by the contractor and approved by
the Engineer
j. Forms of all test reports for all materials and items to be tested
k. Quality assurance plan system, documents control, handling and
storage procedures and check on quality records and auditing system
15.1.3.4.2. Execution
The Contractor shall establish methods and procedures for all activities needed
to complete the work in accordance with applicable specifications.
The following works shall be included:
a. Survey and setting out
b. Rebar installations
c. Formwork installations
d. Inspection before placing concrete
e. Handling and placing of concrete
f. Compaction of concrete
g. Concrete surface finishing
h. Concrete curing
15.1.3.4.3. Submittals
Prior to the works, the Contractor shall submit the following documents for
the Engineer’s review and approval:
a. Quality assurance plan
b. Applicable reference codes
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c. Sources and characteristics of concrete materials comprising cement,
coarse and fine aggregates, admixtures, water and reinforcement
d. Proposed concrete mix design accompanied by all relevant data for
materials sources and testing
e. Methods of concrete mixing, transportation, placing, compacting and
curing
f. Details of batching plant
g. Quality control procedures comprising methods of sampling as well as
site laboratory equipment and experience records and number of
quality control personnel
h. In addition to other requirements regarding design calculations and
details of proposed construction methods including type of equipment,
plans of execution and corresponding calculations
i. Traffic management plan
j. And other submittals which conform to 4.1.3.4.1 Quality Assurance
15.1.3.4.4. Tolerances The concrete work shall be constructed to an accuracy which shall permit the
proper assembly of components and installations and shall be compatible with
the finish.
The accuracy of the work shall be within the tolerances shown on the
drawings or specified elsewhere and in the absence of any other requirements,
shall comply with the following:
All laying out dimensions ±5 mm
Concrete surface level ±5 mm
15.1.3.5. Civil Miscellaneous Structures
This section shall consist of all Civil Miscellaneous Structures required for supply
and installations necessary to complete the Civil Works for the extension of
MRT3 Taft Pocket Track.
15.1.3.5.1. Submittals
The Contractor shall submit the following for the Engineer’s approval:
a. Detailed design drawings for each Civil Miscellaneous Structures and
Materials
b. Method and procedures for each Civil Miscellaneous Works
c. Materials compliance certificate and testing results
d. And all other submittals needed to complete the work
15.2. TRACK WORKS
15.2.1. General
The provisions stated in this document are related to the specific requirements
applicable to the track system for the extension of MRT3 Taft Pocket Track.
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Trackworks system under this Contract shall conform to the most recent practices of
the American Railway Engineering Association (AREA), Union Internationale des
Chemins de Fer (UIC), International Standards Organizations (ISO) and the practices
and specifications of recently constructed mass transit systems of equivalent capacity
and characteristics constructed within the last five (5) years. It shall be of proven
design satisfying the system performance requirements and shall be compatible with
the existing MRT3 system. It shall also satisfy requirements with regards to train
kinematic gauge, service life, reliability, maintainability and safety.
The works shall include design, supply, installation, test & commission and obtaining
all permission from government authorities and everything whether permanent or
temporary in nature necessary for safe and proper execution of work and fulfillment
of all obligations required under this contract. It shall also include the training of the
Employer maintenance personnel, supply of maintenance and repair manuals, as-built
records and rectification of defects liability period of the installed ballasted tracks
system.
15.2.1.1. Scope of Work This section specifies the scope of work of the Contractor as follows:
a. Design, plan, supply and installation of all track materials required for the
extension of Taft Pocket Track in order to accommodate a four-car train,
i.e. to relocate a turnout in order to extend the Taft Pocket Track of about
19m.
b. The workmanship shall be in accordance to specifications and quality
standards and shall not disrupt the MRT3 daily operations and adjacent
traffic flow along EDSA.
15.2.1.2. Standards and Regulations
The work shall conform to the laws and regulations existing in the Philippines and
shall generally be in compliance with the Philippines Standards and Codes of
Practices unless specifically provided for in this document.
In addition, the following standards may be considered as long as they do not
compromise the Employer’s Requirements
ACI - American Concrete Institute
ANSI - American National Standards Institute
ASA - American Standard Association
AREA - American Railway Engineering Association
CEN - Comité Européen de Normalisation
ISO - International Standard Organization
UIC - Union Internationale des Chemins de Fer
JIS - Japanese Industrial Standards
AS - Australian Standards
BS - British Standards
AASHTO - American Association of State Highway &
Transportation Office
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ASTM - American Society for Testing and Materials
PCI - Pre-stressed Concrete Institute
15.2.1.3. Special Site Conditions
The Contractor acknowledges that it has thoroughly investigated and satisfied
itself as to all general and local conditions affecting the work. The failure of the
Contractor to accustom himself with such conditions will not relieve him from any
responsibility for completing the works under this contract. The Contractor shall
be fully responsible for any damage caused to the site or other existing facilities
due to his track works equipment movements and transportation and restore these
damages to its original state at his own expense.
15.2.1.4. Design Criteria The following data will constitute for the design of trackworks for MRT3:
a. Track gauge 1435mm
b. Train speed 65kph
c. Concrete tie spacing 750mm
d. Rail inclination 1:20
e. Axle load 90kn
f. Ballasts depth minimum 250mm Mainline
g. Rail profile UIC 54
h. Depot track minimum radius 25m
i. Concrete tie length 2500mm
j. Concrete tie weight 250kg
k. Concrete tie compressive strength 50Mpa
l. Concrete tie stress transfer strength 30Mpa
m. Pre-stressing wire diameter 6.5mm
n. Pre-stressing wire ultimate tensile strength minimum 1700MPa
15.2.2. MATERIALS REQUIREMENTS Trackworks materials needed for the extension of Taft Pocket Track shall be complete
with all accessories and passed all the required testing in accordance to specifications
and standards and shall be approved by the Engineer before incorporating to work.
The Contractor shall ensure materials availability for small quantity production
intended for maintenance use.
15.2.2.1. Ballast
Ballast shall be of crushed rock containing no carbonates or slag; it shall be hard,
strong, angular, and durable particles. Ballast rock shall be highly resistant against
crushing, grinding, and chemically inert. It shall be weather resistant and of
homogenous structure. The Ballast shall be free from dust, soil, clay, plant matter
and substances likely to be detrimental to the rocks.
15.2.2.2. Special Trackworks
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Unless specified, the materials required for the extension of Taft Pocket Track
refers to the supply and replacement of timber ties and other defective fastening
system that will not be suitable for their re-installation.
15.2.2.2.1. Switch and Crossing Ties Switch and crossing ties shall conform to 4.2.2.3 Monoblock Concrete Ties
15.2.2.2.2. Joints
All special trackworks joints shall either be alumino-thermic welded by an
approved welding materials and procedures for UIC 54 rail or insulated
fishplates of approved materials and specifications.
15.2.2.2.3. Rail Fastening System
Concrete ties associated rail fastening system shall be Pandrol type e-series
elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with
UIC specifications.
15.2.2.3. Monoblock Concrete Ties
Concrete ties shall be monoblock pre-tensioned concrete. It shall be 250kgs and
2500mm long. Alternative concrete ties could be considered if they are
compatible with the existing concrete ties in MRT3 in terms of general profile,
dimension and strength. The Contractor must ensure that alternative designs must
have a successful history performance of at least five (5) years in service under
comparable conditions. Any alternative design must be specifically approved by
the Engineer.
15.2.2.3.1. Concrete The concrete minimum 28 days design compressive strength for concrete ties
shall be 50 Mpa as determined by ASTM C39.
15.2.2.3.2. Aggregates
Both fine and course aggregates shall meet the requirements of the AREA
specification for aggregates.
All aggregates shall pass all required testing and shall conform to Item 703 of
DPWH Standard Specifications.
15.2.2.3.3. Admixtures
Chemical admixtures for concrete shall conform to ASTM C494. Additives
containing chlorides shall not be used.
Suitable admixtures may be used to modify certain properties of concrete.
However, as they may at the same time adversely affect other important
concrete quality, the Contractor shall carry out testing on concrete to which
they are added.
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15.2.2.3.4. Pre-stressing Tendons
The wire shall be 6.5mm diameter complying with ASTM A864 or ASTM
881 and shall have a minimum tensile strength of 1700 MPa. Tendons shall
not be contaminated with mud, oil, grease or chloride salts. Tendons with
corrosion shall not be used.
15.2.2.3.5. Rail Fastening System
Concrete ties associated rail fastening system shall be Pandrol type e-series
elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with
UIC specifications.
15.2.2.4. Timber Cross and Switch Ties
The ties shall be unbored and air dried hardwood of untreated Jarrah timber
species for exposed mainline turnouts or any approved equivalent.
15.2.2.5. Rails
Standard rail cross-section shall be UIC 54 (54.43 kg/m) of grade 900A with a
minimum tensile strength of 880 Mpa and shall meet the requirements of the UIC
Standards.
15.2.2.6. Thermit Welding
This refers to the materials and other services required for joining UIC 54 using
alumino-thermic welding process.
15.2.2.6.1. Thermit Welding Kits
Thermit welding materials shall be manufactured by Thermit Australia Pty Ltd
or approved equivalent compatible to the existing welding materials used in
MRT3.
15.2.2.6.2. Thermit Welding Equipment
Welding equipment and accessories required for welding operation shall be
use and installed in accordance to manufacturer’s recommendation, contract
drawings and applicable specifications.
15.2.2.7. Other Track Materials
Other track materials and appurtenances needed to complete the work shall be
approved materials by the Engineer and installed in accordance to manufacturer’s
recommendation, contract drawings and applicable specifications.
15.2.2.7.1. Insulated Rail Joints
Rail joints shall be made up of two rolled steel fishplates designed to fit UIC
54 rail profile and with four holes drilled by an approved drilling machine.
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Bolts shall be of high strength provided with spring and flat washers and shall
conform to applicable UIC standards.
15.2.2.7.2. Check Rails
Check rail shall be machined from UIC 33 profile of not harder than grade
900A rail steel and supported by brackets connected to the rail. Bolt
connection shall utilize steel components conforming to UIC leaflets 864/2.0
and 864/3.0 appertaining to technical specifications for the supply of track
bolts and spring washers respectively.
15.2.2.7.3. Rail Fastening System
Concrete ties associated rail fastening system shall be Pandrol type e-series
elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with
UIC specifications.
15.2.2.7.4. Lubricants The Contractor shall provide a dry film lubricant for application to special
tracks sliding plates. It shall have a low electrical conducting properties and
subject for Engineer’s approval.
15.2.3. CONSTRUCTION REQUIREMENTS The Contractor shall be responsible for the construction means, methods, techniques,
sequences and procedures for coordinating all portions of the Work under the
Contract Documents.
The Contractor shall provide all superintendence during the execution of the Work as
may be necessary for the proper fulfillment of the Contractor’s obligations under the
Contract. It shall include the supervision and inspection by qualified professional
personnel experienced in railway construction whose responsibility shall be to ensure
the technical standards and workmanship, materials, and quality are being maintained
in accordance with the Scope of Work.
The Contractor shall design, supply and install a ballasted tracks system which
satisfies to the minimum requirements of the specification and Employer’s
Requirements. The Contractor shall submit full details of the proposed design to the
Engineer for review and approval and shall not commence until written acceptance
has been received from the Engineer.
15.2.3.1. Ballasted Trackworks Construction
This section applies to construction of all ballasted tracks both plain and special
tracks for MRT3 both Depot and Mainline.
15.2.3.1.1. Quality Assurance Program
a. The Contractor shall establish, implement and maintain a quality
assurance program to provide verification of compliance with contract
requirements. The quality assurance program shall consist of detailed
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procedures and instructions for monitoring and controlling those
activities related to quality during design, fabrication, delivery,
handling, storage, installation, inspection and testing. The areas which
the quality assurance program shall address include the following:
Review and control of quality procedures and instructions,
Calibration of construction measuring and testing tools and
equipment,
Qualification and certification of Personnel,
Tests and inspections
Procurement quality assurance,
Identification and control of items, and
Handling, delivery and storage of materials.
b. Adequate records shall be maintained by the Contractor in accordance
with the requirements of his quality assurance program and shall
include the following:
Evaluation of subcontractors’ and suppliers’ qualifications and
past performance,
Results of inspections and tests,
Certificates of compliance,
Qualified procedures for special processes,
Personnel certifications,
Measuring and test equipment calibration certificates, and
Transmittals of contract related information.
c. The appropriate requirements of the Contractor’s quality assurance
program shall be imposed upon subcontractors and suppliers.
d. The quality assurance activities of the Contractors/subcontractors and
suppliers will be subject to Engineer’s verification, inspection and
audit at any time.
15.2.3.1.2. Submittals The Contractor shall submit the following:
a. The Quality Assurance Program
b. Applicable reference codes
c. Detailed construction schedule
d. Detailed design and shop drawings for all Contractors supplied
materials and other track materials required including fastening system
for the construction of both ballasted track and special track works.
e. Pre-construction inspection reports
f. Qualifications of registered Surveyors
g. Certificate of calibration for specified tools and equipment by
independent testing laboratory accepted by the Engineer
h. Details and arrangement of equipment, materials and personnel to be
used during the various construction stages. Maximum construction
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loads shall be identified and submitted to the Engineer for review prior
to any construction equipment being allowed to construction site
i. Details for the protection of rails, special track works, other track
materials and facilities from damage by construction equipment and
road traffic,
j. Production information forms and test reports on welds,
k. Rail laying records,
l. Calculation to determine Neutral Rail Temperature for Depot and
Mainline.
m. Method statement for natural or artificial de-stressing works for
ballasted track and ballasted special track works both Depot and
Mainline.
n. Procedures for handling and anchoring CWR,
o. Procedures for rail grinding and subsequent cleanup including a daily
rail grinding log indicating grinding date, locations, number of passes
of grinder, manufacturer and model number of grinder,
p. And all other documents needed for the completion of the work and
subject for Engineer’s review and approval.
15.2.3.1.3. Electrical Testing The Contractor shall perform all tests of electrical resistance and continuity for
insulated rail joints, running rail, running rail to running rail and track to earth.
Any installations which fail shall be rectified by the Contractor at his own
expense and retested until acceptance by the Engineer.
15.2.3.1.4. Inspection
The Contractor shall inspect the construction area prior to installation of
trackworks for any damages and discrepancies with propose installation plan
and correct said discrepancies authorized by the Engineer.
15.2.3.1.5. Track Laying Construction for Ballasted Tracks
The Contractor shall submit method statement for a systematic rail laying
construction for Engineer’s review and approval.
General ballasted tracks construction shall include the following procedures:
a. Survey and setting out correct tracks and special track alignment.
b. Base preparation
c. Placement of bottom ballasts on an approved base
d. Placement of concrete sleepers or timber ties
e. Placing of rails and fastening to concrete sleepers or timber ties
f. Welding of rails to form continues welded rail
g. Fastening of concrete sleepers or timber ties
h. Placement of top ballasts
i. Initial surfacing and aligning
j. De-stressing work
k. Final surfacing and alignment
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l. Test and inspection of finished tracks
m. Site Cleaning
Refer to Table 1 “Track Construction Tolerances” where indicated the
allowable geometric design variation for track work construction.
The Contractor shall assists the Engineer in his inspection of the finished track
with a track geometry measuring device that capable of measuring various
track alignment parameters with accuracy more than the tolerances specified
in Table 1 “Track Construction Tolerances” and submit the print-out for
Engineer’s approval and record. Any data being out of tolerance shall be
rectify by the Contractor and shall be re-inspected by the Engineer.
Before final acceptance by the Engineer, the Contractor shall perform
ultrasonic inspection of all running rails and special track works to detect
flaws in rail, joints and welds.
15.2.3.1.6. Track Laying Construction for Ballasted Special Tracks
Special trackwork construction shall conform to Clause 4.2.3.1.5 Track
Laying Construction for Ballasted Tracks except the use of track geometry
measuring device since geometry alignment for special tracks will be checked
manually.
15.2.3.1.7. Mockup Tracks Not Applicable.
15.2.3.1.8. Final Acceptance Before final acceptance by the Engineer, the Contractor shall perform and
satisfy rail grinding of all rails to remove the corrosion and shall complete
ultrasonic testing inspection to detect flaws for running rails, special
trackworks and welded joints.
15.2.3.2. Ballast The Contractor shall supply and install ballasts of approved materials required for
the extension of the MRT3 Taft Pocket Track.
15.2.3.2.1. Testing Requirements
a. Grading
Size of Sieve Opening % Passing by Weight
Ballast for MRT 3 (Size 3 AREA
Manual)
63.5 mm 100%
50.8 mm 95-100%
38.1 mm 35-70%
25.4 mm 0-15%
12.7 mm 0-5%
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b. Deleterious substances present in prepared ballasts shall not exceed the
following:
c. Percentage of wear shall not exceed 25% after testing in a Los Angeles
abrasion testing machine in accordance with ASTM C535. d. The bulk specific gravity and percentage of absorption shall be 2.60
and 1% respectively in accordance with ASTM C127.
e. The magnesium carbonate content shall be tested and defined in
accordance with ASTM C25. No carbonates shall be allowed.
15.2.3.2.2. Submittals
The Contractor shall submit the following for Engineer’s review and approval:
a. Ballast source certificate of compliance
b. Tests results mentioned in 4.2.3.2.1 Testing Requirements
c. And all other test required to complete the work
15.2.3.3. Special Trackworks
The Work of the Contractor in this section refers only for the relocation of the
existing 1:6 turnout and replacement of timber/switch ties and other associated
fastening system that found defective during the execution of the work. It shall be
in accordance to design, specifications, standards and scope of work.
15.2.3.3.1. Quality Assurance
Shall conform to 4.2.3.1.1 Quality Assurance Program
15.2.3.3.2. Submittals
The Contractor shall submit the following for Engineer’s review and approval:
a. Shop drawings showing details and arrangements of special trackwork
relocation,
b. Proposed welding, joining and test procedures for special trackwork,
c. Contractor’s system specification for marking and identifying sizes,
types and composition of products, as well as identifying parts for the
purpose of proper location during installation,
Material Percent by
Weight Method of Test
Soft Pieces 5% AASHTO - T189
Fine less than No. 200
Sieve 1% ASTM C117
Clay lumps and Friable
Particles 0.5% ASTM C142
Flakiness Index 20% BS 812
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d. Certificates of material compliance required by this specifications,
e. Test report of chemical analysis and Brinell hardness of running rail,
electric insulation, and other tests required by this specification.
15.2.3.3.3. Inspection and Acceptance For the inspection of material under this Contract, the terms set forth in
“Materials Inspection, Test and Claims,” under the UIC Specifications for
Special Track Work shall apply, except as listed herein.
The Contractor will make available to the Engineer all the necessary facilities
to examine the work during its progress as well as the finished product to
satisfy him that the materials comply with the Specification. The Contractor
will provide templates and 1 meter straight edges to check flangeways, rail
end, and switch rail planing.
15.2.3.4. Monoblock Concrete Ties
This section specifies the requirement for the supply and installation of pre-
stressed monoblock concrete ties with complete rail fastening system compatible
with the existing system of MRT 3.
15.2.3.4.1. Design Criteria
As specified in 4.2.3.1.4 Inspection
15.2.3.4.2. Marking, Delivery, Storage and Stacking
Mark on top of the ties with indented or raised letters to indicate the
manufacturer, year of manufacture, mould number and project identification.
Contractor must securely brace ties during transportation to prevent from any
movement that could cause damage. During transportation, ties should be in
horizontal position supported with wooden spacer blocks so that the top
surface does not make contact with ties loaded above. Do not stack ties more
than 6 layers during transport.
The Contractor shall store concrete ties in a location that would avoid
additional handling until the final distribution or within the area
designated by the Engineer.
15.2.3.4.3. Quality Assurance and Inspection
Before production commences, the Contractor shall prepare a quality control
manual for approval by the Engineer and shall include details of:
Management organization
Responsibilities of production and quality control personnel
Plant standards
Checks to be carried out by the production personnel
Inspection and testing to carried out by quality control personnel
Procedures for approving sources of materials
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Procedures to ensure all measuring equipment is properly calibrated
Procedures to ensure that concrete ties are not shipped until acceptance
load testing is complete
Quality audit procedures
This section shall also conform to 4.2.3.1.1 Quality Assurance Program
15.2.3.4.4. Submittals
a. Quality control program
b. Concrete mix design
c. Concrete curing procedures
d. Method and procedures for concrete ties production
e. Tensile strength test results
f. Rail fastening system technical specifications and drawings
g. Pre-stressing wire technical specification
h. All materials test results needed to complete the work and before
incorporating to concrete ties production
This section shall also conform to 4.2.3.1.2 Submittals
15.2.3.5. Timber Cross and Switch Ties
This section comprises specifications for the supply and installation of new timber
cross ties, switch ties, switch machine ties required for the relocation of MRT3
Taft Pocket Track turnout 1:6 of approved source and shall be compatible with the
existing materials.
15.2.3.5.1. Quality Requirements
Ties shall be free of defects that may impair their strength or durability.
Defects such as decay, large splits, large shakes, excessive grain slope, large
holes and large knots will not be acceptable. All timber ties shall be cut by saw
and the cross section shall be 225mm wide and 140mm deep. Standard cross-
ties shall have a length of 2440 mm. Size and length tolerances shall be as
follows:
a. Width - plus 10 mm/minus0
b. Depth - plus 12 mm/minus 0
c. Length - plus 50 mm/minus 0
Each timber shall be examined on the top, bottom, sides and ends. Cross and
switch tie shall not exceed the following allowable amount of defects:
Type of Warp Allowable Amount
Spring 25 mm
Bow 9 mm
Crook 25 mm
Cup 6 mm
Twist 6 mm
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All ends of timber ties shall be cut square and provided by anti-
split end plates. End plates shall be applied flush to the end surfaces of the tie and will
remain securely seated and withstand rail vibration.
The Contractor is required to determine the number and dimensions of switch
ties for each turnout and shall be specified in general turnout arrangement
drawing and shall conform to dimension tolerances stated above.
15.2.3.5.2. Testing and Inspection
The Contractor shall assume full responsibility for all required testing and give
the Engineers sufficient notice when testing in any form is proposed so that
Engineers could inspect and witness the tests.
The Engineer may inspect the ties during production process or after delivery
at the job site and or after placement on the grade for track utilization.
Whether or not the Engineer test or inspect any materials, the Contractor will
not be relieved from any responsibility regarding defects or other failures to
meet the contract requirements.
15.2.3.5.3. Marking, Finishing and Workmanship
Ties shall be branded or marked permanently with approved materials to show
ownership, manufacturer’s identification and year of production on one end.
Tie machining and workmanship shall follow and conform to the applicable
standards.
15.2.3.5.4. Submittals
The Contractor shall submit the following requirements:
a. Quality control program for all method and procedures to ensure
compliance with standards quality
b. The name of timber and its source for approval,
c. Timber ties Manufacturers specifications
d. Official certificates of inspection in conformance with the reference
standards including data regarding hammer band confirming timber
grading,
e. Data regarding proposed tie machining & stamping,
f. The Inspectors report form duly accomplished (as described by the
reference standards for Inspection of Timber Products) and submit to
the Engineer prior to tie shipment from the production plant,
g. Certification that the manufacturer has a minimum 5 years experience
in manufacturing timber switch ties and as a supplier to major rail
transit system.
h. Completed tests results.
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15.2.3.6. Rails
This section specifies the supply and installation of required rails for the extension
of MRT3 Taft Pocket Track in accordance to specification and standards.
15.2.3.6.1. Test Requirements The Contractor shall perform the following tests:
a. Chemical composition analysis
b. Mechanical property
c. Tensile strength
d. Brinell hardness test
e. Shape, dimension and appearance inspection
f. Ultrasonic test
Each rail shall be ultra sonically tested over its full length to determine its
interior conditions prior to delivery to the work site. The rail must be free
from all detrimental defects having unfavorable effect on the strength of the
rail while in service.
The Contractor shall be responsible for all required testing and shall give
Engineer sufficient notice of proposed testing so that Engineer may inspect
and witness the tests in accordance to UIC specifications.
15.2.3.6.2. Quality Assurance and Inspection This section shall also conform to 4.2.3.1.1 Quality Assurance Program
The quality system for rail manufacture shall be certified at least to ISO 9002
and shall be based on precise terms and conditions which ensure compliance
with the various rail specifications.
The Engineer will monitor from time to time the Contractor’s methods,
procedures, and processes for compliance with the accepted program and all
records of test and inspection.
15.2.3.6.3. Marking, Packaging, Handling, Transporting, and Storage
a. Obligatory marks in the UIC 54 rail shall be in accordance with UIC
Code 860 O as follows in-relief marks which shall be very legible in
characters raised on one side of the web indicating:
Identification mark of the mill,
Year of manufacture (last two figures),
Symbol of steel grade, and
Symbol of rail section in kg/m weight
b. The Contractor shall submit for approval a detailed procedure for
marking, packaging, delivery, handling, transporting and storage of
rails. Contractor shall take all necessary precautions to ensure that
rails will not be bent, deformed or damage during handling and
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transporting and it shall be kept clear of any standing water during
stacking and storage.
15.2.3.6.4. Submittals
The contractor is required to submit the following:
a. Certification that rail manufacturer has at least 10 years experience in
the large scale manufacture of running rails as specified herein and as a
supplier of rail to major railroads and transit systems.
b. Certification from supplier or manufacturer that all the rails
manufactured and delivered on site are in conformance with UIC
specification and that the required tests were performed as represented
by the submitted test result.
c. Tests Certificates as prescribe in 4.2.3.8.1 Rail Welding
d. Detailed production process of rails
e. Certification of the manufacture’s process in accordance to ISO 9002.
f. And all other documents needed for the completion of work.
Rails shall be guaranteed by the supplier/manufacturer from date of
manufacture plus 5 years to the date of acceptance of works against any
defects attributable to manufacture.
15.2.3.7. Track Appurtenances and Other Track Materials
This section specifies the requirements for the design, supply, and installation of
other track materials required for the extension of MRT3 Taft Pocket Track.
15.2.3.7.1. Submittals
The Contractor shall submit all detailed design drawings for each trackworks
materials in accordance with applicable specifications and subject for
Engineer’s review and approval.
a. Detailed design drawing for each Other Track Materials and
corresponding fastening system
b. Installation methods and procedures
c. Materials manufacturer specifications
d. Material compliance certificate and testing results
e. And other submittals required to complete the work
15.2.3.8. Welding of Rail
Unless specified, this section specifies the furnishing of all labor, material,
equipment and services by the Contractor which are necessary for joining new
UIC 54 rails using alumino-thermic welding process in accordance to approved
specifications, standards and manufacturer specification for materials and
equipment.
15.2.3.8.1. Rail Welding
Welding process shall include the following procedures:
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a. Inspection of rail ends
b. Rail cutting and set the required gap
c. Loosening of rail fastenings
d. Rail end preparation and alignment
e. Preheating and welding
f. Finishing and alignment
g. Weld testing
h. Replacement of defective welds
i. Records of thermit welding
Each procedure shall be in accordance with the AREA Manual for Railway
Engineering, the products or welding kit specifications itself and other
applicable standards.
15.2.3.8.2. Quality Assurance
This section shall conform to requirement in 4.2.3.1.1 Quality Assurance
Program
15.2.3.8.3. Weld Testing
All weld testing and submittals shall be performed by a duly accredited
independent testing laboratory in accordance with quality control requirements
and applicable standards. In order to qualify the welding kits, welding crews,
and production welds; the following test shall be carried out:
a. Radiographic testing
b. Ultrasonic testing
c. Slow bend testing
d. Hardness test
e. Rolling load test
f. Magnetic particle test
g. Visual test
15.2.3.8.4. Tolerances
All alumino-thermic welds will be in the suspended portion of rail between
supports. The weld shall not encroach 150mm from tie ends or baseplate
support. Finished weld using 1 meter straight edge shall have the following
tolerances:
a. Rail head surface +0.3 / 0.0 mm
b. Rail gauge face +0.3 / 0.0 mm
15.2.3.8.5. Submittals
The Contractor shall submit the following:
a. Detailed specifications, proposed materials, methods and procedures to
be used for the thermit welding process,
b. Certification from the supplier or manufacturer that the materials
delivered to site conforms to the specifications,
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c. Welding supervisor qualifications with a minimum 3 years thermit
welding experience. The welding supervisor shall be replaced only
with the Engineer’s prior approval,
d. All material testing and weld test results,
e. Test equipment certificate and calibration,
f. And all submittals shall be in accordance with 4.2.3.1.2 Submittals
TABLE 1
TRACK CONSTRUCTION TOLERANCES
Notes:
1. Variation is measured between the designed and actual alignment at any point in the
track
2. Horizontal alignment is measured in mm by 10m chord placed at the gauge line of the
rail running face.
3. Vertical alignment is measured in mm by 10m chord at the head of the datum rail.
4. Rail cant may vary between 1 in 18 and 1 in 22
5. Maximum twist is 1 in 1000.
15.3. SIGNALING
15.3.1. Introduction
The Terms of Reference (TOR) for the Pocket Track Extension Project under
Signaling System defines the scope of works to be undertaken in the extension of
pocket track.
The Signaling Upgrade shall not be included in this contract. The upgrade of the
signaling system shall be carried out by the Signaling Provider of the MRT3.
The contractor shall follow the design requirement and specification of the Signaling
system to make the Power & OCS system, Civil Works and Track Works fully
integrated to the Signaling system.
15.3.2. Background
Few months prior to the opening of MRT 3 line (Buendia to Taft station) to the public
on July 2000, the Pocket Track which is linked to the Northbound track of Taft
Avenue was discovered to have insufficient length to accommodate the safe operation
of a 4-car train passing from South side of the Pocket Track. Series of meetings and
Type of Track Gauge
Variation
Cant / Cross
Level
Horizontal
Alignment
Vertical
Alignment
Mainline
Ballasted Track
-2, +3 mm
±3 mm
±3 mm
±3 mm
Depot Ballasted
Track
N/A
N/A
N/A
N/A
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discussions have been held between the Contractors, Engineers and Owner to resolve
the issue and finally decided to optimize the pocket track by allowing passage of 3-car
train only. Consequently, the ATP balises were relocated to effectively protect the
train’s operation even considering the worst case scenario of trespassing down the
pocket signal in restricted aspect.
Optimization of pocket track was done through the relocation of balises which
consummates the braking distance of the train. The braking distance calculation was
based on the following data:
Vehicle condition - Empty
Brake Deceleration - 2.09 m/s²
ATP antenna to vehicle face distance - 2.8 m
1st wheel to vehicle face distance - 3m
Gradient - 0.146 %
Over-run speed passing the red signal - 19 KPH
After the relocation of balises, the testing was subsequently undertaken. The 3-car
train operation successfully passed the test. The Contractor henceforth issued a safety
certification that the pocket track is passable to 3-car trains and guaranteed that the
installed ATP was functioning normally whatever the situation or scenario.
The test for the 4-car train operation was also conducted in the pocket track and the
result showed that the fouling point clearance requirement was not able to satisfy the
safety criteria.
15.3.3. Recommendation
In order to meet the requirement for the complete operation of 4-car train
configuration in the pocket track, the only option is to extend the track at the northern
side (going to the direction of Magallanes station), which will include the following
major activities:
a) Re-design / removal / replacement of wall structure.
b) Re-design / removal / replacement of tracks including ballast and installation
of additional rails and accessories.
c) Re-design / removal / replacement of Overhead Catenary Section (OCS)
including posts and installation of additional OCS and post.
d) Re-design / removal / relocation / replacement of Signaling equipment
including hardware/software.
15.3.4. Pocket Track Data
The data presented herein are actual parameters gathered at site which may serve to
aid the Contractor in the conceptual redesign of the pocket track. However, it is the
Contractor’s obligation to confirm the accurate data through site survey before using
them as parameters in the detailed engineering design.
Location of Pocket Track Northbound Track, approx. 300
meters from Taft Avenue
Station
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Distance Between Signals 138 m
Straight Track 130 m
3-car Train Length 97 m
IRJ to IRJ Distance 133.8 m
4-car Train Length 127 m
Length Between ATP Antennas (4-car) 121.4 m
Track Circuit TX and RX Distance 1m
from IRJ
15.3.5. Pocket Track Operation
The pocket track is a temporary stabling area for reserve train or even defective train.
Trains can enter in the south side and exit on the north side through route setting.
Train may also exit from the south side going to Taft Avenue station through manual
route setting. Nevertheless, the automaton cannot be used in the pocket track
operation.
15.4. POWER SUPPLY AND OCS
15.4.1. General Requirements
With the intention to extend the length of the Taft Pocket Track to accommodate four-
car trains, the OCS for the TPT shall have to be extended as well.
15.4.1.1. Re-Configuration and Extension of the OCS This Specification defines the minimum requirements to be met by the
Contractor’s proposed reconfiguration and extension of the OCS along the Pocket
Track.
The OCS supplied and erected under this Contract shall be integrated and
compatible with the existing OCS system installed on the MRT 3 line. The new
installation shall satisfy the requirements with respect to vehicle envelope,
pantographs, interface, service life, safety, reliability and maintainability.
All OCS assemblies, fittings and components removed from the existing
installation shall be reused wherever possible for the new installation.
Prior to Contract Award, the Contractor must demonstrate that he has a very clear
understanding of the existing OCS Equipment and Systems. In this connection
visits to MRT 3 are mandatory during the tendering period to ensure that the
Contractor is fully aware of the present ‘as installed’ systems and the necessity for
compatibility and integration with the new equipment and systems.
As the Works under this Contract will involve activities on a ‘live’ railway, the
Contractor shall adopt and adhere to the Operator’s Rules of Procedures at all
times. All works shall be done during non traffic hours.
Under no circumstances, shall the Contractor cause disruption to the revenue
service. All staging works, timing and method statements shall be approved by the
Engineer before any night or day work is permitted to commence.
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15.4.2. The Existing OCS System
The existing OCS system is of traditional metro design for a 750 Vdc railway utilizing
pole mounted cantilevers, messenger wires, droppers, contact wires, tensioning
devices, anchor blocks, section insulators, insulators and guy wires. The existing track
length within the Pocket track is 110 m and the extension will add a further 19 m.
The Contractor’s attention is drawn to Section VII Drawings, which shows the present
configuration and linkage to the Mainline.
15.4.3. Scope of Works
The Scope of Works shall include but not limited to:
Detailed design, procurement, delivery, installation, testing and
commissioning.
Integration of the new tension lengths with the existing system utilizing the
same assemblies and components or equivalents as presently installed.
Interfaces with civil, track and signaling works.
Replacement of contact wires, messenger wires and droppers.
Rearrangements of tensioning devices and anchors.
Electrical and Mechanical design calculations.
Submission of material samples for approval by the Engineer inclusive of
corrosion protection such as galvanizing and steel MIL specifications.
Rectification of defects during DLP.
Training of the Owner’s maintenance staff.
O&M manuals inclusive of parts catalogue, repair instructions, maintenance
instructions, test results from commissioning.
As built drawings, schematic drawings, line diagrams, interface drawings and
dimensional/tolerance criteria.
Recommendations for the provision of spares and special tools in
liaison/coordination with the Owner’s Maintenance Provider.
15.4.3.1. Contractor’s Responsibility
The Contractor shall take full responsibility for the detailed design, construction
and performance of the OCS under this section of the overall Contract.
15.4.4. Catenary Conductors
Contact wire shall be made up of 170mm2 solid grooved hard drawn copper
conforming to ASTM B47. The upper lobe of the contact wire shall match the
existing contact wire installed at MRT 3 to assure interchangeability of clips. Other
contact wire particulars include:
Weight : 1.511 kg/m
Breaking Load : 5900 kg
Coefficient of Expansion : 1.7 x 10-5 /0C
Resistance @ 200C : 0.1040 Ω/km
Modulus of Elasticity : 12000 kg/mm2
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Conductor tensions shall be in accordance with the requirements of appropriate
ASTM standards. Thirty percent cross-sectional area loss due to wear of the contact
wire and the effect of the temperature change shall be taken into consideration in the
design of the conductor tension and ampacity.
The ampacity of the OCS shall meet the operational requirements of four-car trains
running at 120-second headways with a traction power configuration proposed in the
Concept Design Drawings.
15.4.4.1. Insulators
Insulators shall be porcelain, toughened glass polyester or other material with
proven rail or railway system service. Insulators shall have a single or multiple
sheds designed for minimum maintenance requirements and be self cleaning by
the action of rain. Double insulation is not required as it is not intended to carry
out ‘live line’ work.
15.4.4.2. Splices
Each wire run of contact wire must be continuous from anchor to anchor except in
the case of cut-in insulators. Contact wire splices shall not be permitted. Feeder
wires may have splices as required to connect drum lengths of conductor. The
manufacturer shall warrant that splices are capable of withstanding tensions up to
100% of the breaking load of the conductor.
15.4.4.3. Section Insulators
The OCS Contractor is to provide Section Insulators at locations indicated.
The Section Insulators (SI) shall be designed and installed in such a way that it shall provide a smooth passage to pantographs without any loss of contact and
without the introduction of unreasonable mechanical forces.
The SI shall permit the pantograph on the vehicle to collect the maximum demand
current without interruption during passage across the SI.
16. NORTH TURNBACK
In conjunction with the plan of DOTC-MRT3 to connect LRT Line 1 and MRT3 for the
convenience of the riding public, the “Terminal Station” of LRT Line 1 is to be
constructed near Trinoma.
The LRT Line 1 “Terminal Station” is planned to be located adjacently to MRT3 North
Avenue Station. The said station shall have connecting walkways for the easy transfer of
passengers from Line 1 to MRT3 and vice versa.
Consequently in this concept, the area where the existing turn-back facility of MRT3
would be affected by the “Terminal Station” of LRT Line 1, the turn-back facility of
MRT3 at the North Avenue Station will be modified to a double crossover turnout.
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The new double cross-over turnout shall be constructed using track slabs methodology.
The track slab is deemed to be the best option considering that there is an existing track
structure at the site where the new turnout will be installed.
16.1. SIGNALING
The Signaling works shall not be included in this contract.
The contractor shall follow the design requirement and specification of the Signaling
Provider to make the Power & OCS system, Civil Works and Track Works fully
integrated to the Signaling system.
16.2. CIVIL WORKS
The turn-back facility of MRT3 shall be transferred to the front-end (north-end) of the
North Avenue Station using a double crossover turnout.
The new double cross-over turnout shall be constructed using track slabs
methodology.
The civil works on the MRT3 North Avenue turn-back facility shall not be included in
this contract.
16.3. TRACK WORKS
A new double cross over turnout utilizing track slab methodology shall be constructed
at the north-end side of the North Avenue Station.
Please refer to Section VII Drawings A.5.1 for the illustration of the said new turnout.
The track works on the MRT3 North Avenue turn-back facility shall not be included
in this contract.
16.4. CIVIL WORKS
16.4.1. General
This applies to the non- ballasted plain line on the structure in the main line and on
the non-ballasted turnouts. The concrete plinth rest on the elevated structure deck and
transmits the train loads to the deck. The integrity of the track structure in retaining
track gauge and security of the rail requires that the plinth do not move on the
concrete deck.
The concrete plinth should not be subjected to extraneous forces from the flexing of
the structure. This is ensured by the plinth being made in discrete lengths and not
being continuous. The lengths of plinths are planned at 4.0 meters for curved track
with 600 mm fastening spacing and 3.55 meters for the 750 mm fastener spacing of
straight track (>600 meter radius).
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The design of plain line non-ballasted track structure assumes the following:
continuous welded rail, plinth design with plinth anchors, starter bars and key
concrete surface of the structure, discrete supports (not continuous support),
baseplates anchored to plinth, rail elasticity fastened to baseplate and rail to baseplate
insulated. To ensure the integrity of the track structure, the concrete plinth to the deck
connection needs to be checked for:
a. Lateral shear under lateral holdings
b. Stability against overturning of the plinth
c. Resistance against longitudinal movement of the plinth
The objectives of the non-ballasted track design will be continuous welded rail,
discrete (not continuous) support to enable matching of rail head top and running
faces when changing rails or making repair insertions to worn rail during
maintenance, ability to make alumino-thermic welds during both constructions and
maintenance and ability to accommodate hog, sag and other tolerances to the finished
supporting structure.
The plain line non-ballasted track structure may be different in the case of turnouts.
There will be also local adjustments to the non-ballasted track design for items such
as expansion switches with baseplates. The objectives of non-ballasted track structure
for switch and crossing work will be as for the plain line track with the following
additional points: ability to use the same or eliminate the steelwork components of
switches and crossings, including the baseplates used on ballasted tracks, ability to
attached powered point machines on required side (or either side), ability to make
reliable attachment of stockrails and switches for signaling to ensure closure and
detection of switch toes and ability to accommodate switch machine rodding,
clamplocks etc. as required by the signaling.
16.2.1.1. Scope of Work
This section defines the scope of work of contractor which is design, supply and
installation of new double cross-over turnout with complete ancillaries at the existing
North Avenue Station turnback, such as but not limited to plinth/switch ties fasteners,
switch/guard rails and relocation/installation of existing & new motorized switches
with LOB.
The workmanship shall be in accordance with specification and quality with minimal
disruption to MRT3 operations.
16.2.1.2. Standards and Regulations
The work shall conform to the laws and regulations existing in the Philippines and
shall generally be in the compliance with the Philippines Standards and Codes of
Practices, unless specifically provided for in this document.
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In addition, the following standards may be considered as long as they do not
compromise the Employer’s Requirements
ACI - American Concrete Institute
ANSI - American National Standards Institute
ASA - American Standard Association
AREA - American Railway Engineering Association
CEN - Comité Européen de Normalisation
ISO - International Standard Organization
UIC - Union Internationale des Chemins de Fer
JIS - Japanese Industrial Standards
AS - Australian Standards
BS - British Standards
AASHTO - American Association of State Highway &
Transportation Office
ASTM - American Society for Testing and Materials
PCI - Prestressed Concrete Institute
The standards and codes used for the track materials shall be as for the relevant
material specification, such as UIC and JIS.
The standard and codes used for the concrete works shall be as for the civil
engineering works on the project. This shall apply for such items as
Cement
Concrete mixes and finishes
Reinforcement
16.2.1.3. Design Criteria
Loads: a) Vertical Loads
1) Wheel Loads (refer to attached MRT3 axle load and 5.2.1.4)
2) Centrifugal Force (lateral and resultant vertical)
3) Wind (lateral and resultant vertical)