Freight Australia – Transportation Group Document Number: 2630

MANAGEMENT SYSTEM PROCEDURE

Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 1 of 7
Reference: Management System Manual -

1. PURPOSE

This Standard defines the requirements for the construction of new Class 1 and
2 tracks within the Freight Australia Network.

2. SCOPE

This standard applies to:

• Track work on existing lines nominated in a contract document as
being new track; and
• All new lines.

3. GENERAL

In addition to the requirements of this standard, all new Class 2 track shall, as
a minimum standard, conform to the design, construction and maintenance
standards requirements of Class 2 Upgraded Track as specified in other
standards.

3.1 DESIGN

New track construction is to be completed to a co-ordinated design for both

horizontal and vertical alignment.

3.2 MATERIALS

Unless specifically nominated in the contract all new track work is to be

constructed with new materials.

3.3 FORMATION CONDITION

Formation on which new track is constructed is to be completed to the

technical requirements the VRI Heavy Rail Track Construction Standard.

Track formation is to conform to VRI Standard Plan 598.

3.4 BALLAST

The completed ballast profile of all track work is to conform to the ballast
depth and shoulder width requirements as detailed in standard 2610 Track
Classification.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 2 of 7
Reference: Management System Manual -

On timber sleepered track on curves under 800 m radius the shoulder width is
to be increased to 450 mm on the high rail side of the curve and heaped 150
mm above the top of the sleeper.

At all other locations the shoulder and crib ballast level is to be flush with the
sleeper.

New ballast will be 53mm and supplied in accordance with ballast material
technical requirements of VRI Engineering Standard ENG-TE-SPE-4702.

The sub-surface profile at the interface with the subgrade shall provide a clear
drainage path to the formation surface drainage system, without impediment to
the flow paths.

Ballast is to be placed and compacted in accordance with Public Transport

Corporation Heavy Rail Track Construction Standards.

3.5 SLEEPERS

Steel sleepers are not type approved on Class 1 and 2 lines.

Interspersing of sleeper types is not permitted.

3.5.1 CONCRETE SLEEPERS

All concrete sleepers are to be type approved and must conform to

Specification TM44 except that:

All references to AS1085.14 refer to AS1085.14-1997.

Alternative suitable resilient fastening assemblies will be considered.
With reference to Clause 2.6 the concrete sleepers shall be cured by a low
pressure steam curing process in accordance with AS1085.14-1997.
With reference to Clause 3.2 Items v) and vii) the sleeper is to be designed to
meet the loading requirements of the following axle load, speed and axle
spacing combinations in addition to the nominated design rail seat load.

Axle Load Speed Axle Spacing

25 tonnes 80 km/h 1.7 m
23 tonnes 100 km/h 1.6 m
21 tonnes 115 km/h 1.6 m
19 tonnes 160 km/h 1.6 m

Loading analysis of the above axle load combinations is to be based on a

nominal track modulus of 20 MPa with a 53 kg/m rail.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 3 of 7
Reference: Management System Manual -

There must be no significant damage to the sleepers such as chipping of

concrete as a result of handling, tamping, ballast profiling, or other
construction or upgrading activity.

3.5.2 TIMBER SLEEPERS (CLASS 2 TRACK ONLY)

Timber sleepers are to be supplied in accordance with AS3818 1998 Parts 1 &
2

There must be no sleeper which can be assessed as becoming ineffective

sleepers - refer to Code of Practice for the Interstate Rail Network Volume 4
Part 3 Clause 2.4.3 within the next five years.

Sleepers shall be spaced in conformance with Circular CEC 3/87 Clause 6.

Sleepers shall be square to the centreline of straight track and radial to curved
track. Variations in spacing between the centrelines of sleepers shall not
exceed 20mm. There shall be a minimum of 10 sleepers per 6.850m, and
1,460 per kilometre.

Where existing track has a sleeper density greater than the nominal
requirements defined by 2610, and where timber sleepers are to be retained,
the existing density of sleepers shall not be reduced.

There must be no significant damage to the sleepers such as splitting, or

crushing as a result of handling, tamping, ballast profiling, or other
construction or upgrading activity.

3.6 FASTENINGS

Resilient fastening assemblies are to be supplied in accordance with Section

2.1.4 of Part 3 Infrastructure Guidelines of the Code of Practice for the
Interstate Rail Network.

Non-resilient fastening assemblies are to be supplied in accordance with

Section 2.1.5 of Part 3 Infrastructure Guidelines of the Code of Practice for the
Interstate Rail Network.

Only fastening systems which have been type approved by Freight Australia or
the former PTC, Victoria are to be used.

In new track all fastenings must be complete and fully effective for their
design purpose.

3.7 RAILS

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 4 of 7
Reference: Management System Manual -

New rail for Class 1 track is to be supplied as 60 kg/m rail in accordance with
Australian Standard AS 1085.1 – 2000. Rails must be laid in conformance
with CEC 3/87.

Head hardened rail shall be used on curves where traffic exceeds 10 MGT pa.

For Class 2 track 50 kg/m rail may be used with the approval of the
Infrastructure Manager.

Rails must be destressed and continuously welded in conformance with CEC

3/87. Procedures for aluminothermic welding shall comply with TM35 Public
Transport Corporation Technical Specification, Joining of Rails by
Aluminothermic Welding,

3.8 RAIL GRINDING

The gauge face and head of new rail in new track is to be ground sufficiently
to remove manufacturing surface defects and residual stress, while retaining
the manufactured rail profile.

3.9 WELDING AND ADJUSTMENT

Aluminothermic welding is to be in accord with TM 35 and Flashbutt welding

is to be in accord with TM36.

All track is to be laid to a controlled alignment and adjusted to a neutral

temperature of 38 degrees Celsius + 2, -0.

3.10 TURNOUTS

All new mainline turnouts are:

• To be type approved
• To be supplied in accordance with PTCV Standard TM34
• To have tangential design switches
• To be fully plated with resilient fasteners
• To have concrete bearers if installed adjacent to concrete track, on
curves or as specified in the contract.

New turnouts shall be constructed in accordance with Public Transport

Corporation Heavy Rail Track Construction Standards.

Ballast shall conform with the requirements of Clause 3.4 above.

Welding of rails in new turnouts shall be in accordance with Clause 3.9 above.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 5 of 7
Reference: Management System Manual -

3.11 DRAINAGE DESIGN

3.11.1 TRACK FORMATION SURFACE/SUB-SURFACE DRAINAGE

Drainage is to be designed and installed for new track and any associated new
earthworks formation to cater for a 1 in 50 year recurrence interval without
flooding of the track structure above the ballast / formation interface.

In multiple track areas, formation and drainage will be profiled to ensure

provision of working drainage paths, adequate for the assessed maximum run-
off, between rail track and formation drainage. Where the drainage paths
cannot be provided by surface drains, suitable subsurface drains will be
installed.

Surface drainage from the ballast of any track will be collected into a drainage
system without flowing across the formation and under the ballast of any other
track.

3.11.2 BRIDGES, CULVERTS AND PIPED WATERWAY CROSSINGS

All new bridges constructed in new or extended formation are to be designed

to cater for a 1 in 100 year recurrence interval. Culverts constructed in new or
extended formation are to be designed for a 1 in 50 year recurrence interval.

Any modification works carried out to existing bridges, culverts or piped

waterway crossings are to be such that the existing capacity of the structures
will not be reduced.

4. LEVEL CROSSINGS

All new track through level crossings on Class 1 and 2 tracks are to have the
following track structure:
• New 60 kg/m rail
• A minimum ballast depth of 300 mm
• Removable road surfaces
• Site specific drainage and crossfall to ensure that the track structure
drains and in multiple track areas this is to be provided for each track
i.e. water should not drain across more than one track.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 6 of 7
Reference: Management System Manual -

5. NEW TRACK GEOMETRY FOR CLASS 1 & CLASS 2

UPGRADED TRACK

New track is to be completed so that it is below the following Track Recording

Car tolerances for VQI and the VQI component parameters as shown in Table
1.

The VQI and parameter measures are applicable to measurement lengths

between 500 m and 1,000 m, excluding turnouts.

Table 1 New Track Recording Car Standard

Measure Limits on Tangent Track Limits on Curved Track
Top 6 6
Twist (10m) 7 8
Gauge 5 5
Cant 6 8
Line 6 7
VQI 30 34

New track, constructed to Class 1 track classification is to be completed to

the geometry tolerances shown in table 2.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003
 Freight Australia – Transportation Group Document Number: 2630
MANAGEMENT SYSTEM PROCEDURE
Subject: Issue Date: October 2003
TRACK CONSTRUCTION STANDARDS Revision: 1.0
Page 7 of 7
Reference: Management System Manual -

Table 2 New Track Completed Geometry Tolerances

Measure Tolerance
Gauge:
Curves - measured in field +4mm –3mm
Curves - measured by Track Recorder +5mm –3mm
Straights - measured in field +4mm –3mm
Straights - measured by Track Recorder +5mm –3mm
Variation in 2m 4mm
Line - tangents and curves (excluding transitions)
Mid ordinate deviation from design in 10m 5mm
chord length
Alignment
Variation from survey monuments 15mm
Variation between adjacent survey 10mm
monuments + 10 mm –5mm
Variation from design at platforms (“+” is away
from platform)
Twist - rate of change of cant (tangents and circular
curves) 5 mm (1 in 700)
In 3.5m 14 mm (1 in 700)
In 10m
Twist - rate of change of cant (transitions) -
variation from design
In 10m ±4mm
Cant
Maximum difference to design ±5mm
Top surface
Defects in 10m chord 5mm
Defects in 10m chord, with 1.8m offset 5mm
Track Level
Plain Track +/- 25 mm with
minimum ballast
depth

Through platforms and overbridges +/- 15 mm

6. TURNOUT GEOMETRY

New turnouts, installed in new track will conform to the geometry tolerances
in Table 2 above as well as the manufacturer's tolerances for installation of
components in the switches and crossings.

Correct at time of printing.

Uncontolled document once printed - Monday, 01 December 2003