RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Work Method for Bridge Sleeper Replacement

1.

General
Bridge Sleeper Replacement Works will be performed as part of the Track Rehabilitation Works. Before
conducting track raising, track shifting and track tamping, bridge sleeper replacement will be conducted
where there are damage or defects in the existing track. MSJO will propose locations for bridge sleeper
replacement after the survey of the tracks after which approval from the Engineer will be received. This
work method will cover the step by step process of bridge sleeper replacement. MSJO will plan and
propose a location for the temporary bridge sleeper storage at Bekasi Station, Bekasi Timur Station and
Cikarang Station. Prior to the commencement of the bridge sleeper replacement, survey will be carried
out to check the existing track alignment and track center line. More importantly, rail elevation check is
conducted very carefully at each sleeper point from which to be calculated is the value of top of I beam to
top of rail. After calculation, all bridge sleeper thickness requirements can be determined and adjusted
before installation. Basically, adjustment method for bridge sleeper thickness will be performed by
chipping the underside contact surface between the sleeper and the supporting I-beam. All new bridge
sleepers are to be marked with new numbers and installed at the correct positions.
Bamboo
Wooden 8/12 ctc 2.5m

Down Track

10

11

12

13

14

15

16

17

18

19

20

21

22

10

11

12

13

14

15

16

17

18

19

20

21

22

Up Track

PLAN OF BRIDGE

2.

Work Method for Bridge Sleeper Replacement

2.1

Loading of Bridge Sleepers.

1)

The new bridge sleepers that are for use on the replacement works are loaded unto the trolley.
Maximum load capacity is 18 pieces by each trolley. Sleeper loading to the trolley will be carried out
manually as necessary.

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RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

2.2

Bridge Sleeper Distribution

1)

Manual bridge sleeper loading to the Trolley by 4 labourers.

2)

Receipt of Work Permit from the Employer/PT. KAI for the use of Trolley before the commencement
of repalcement works.

3)

Trolley will not be too fast during operation to avoid undue occurences.

4)

Trolley will be equipped with brake system and available scotch block for wheel stopper.

2.3

Unloading
1)

2.4

Sleeper unloading for the bridge where the sleepers are to be installed is done manually.
Installation of Temporary Platform on the Side of the Bridge

1)

Installation of temporary platform on the side of bridge for access and material handling during the
bridge sleeper replacement work.

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Bamboo

Up Track

Down Track

RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Wooden 8/12 ctc 2.5m

2.5

Survey and Reference Marking to the Bridge

1)

Existing rail level markings on the bridge beam to make sure rail level is correct.

2)

Marking of the track center on the sleeper and marking off of the set value to the bridge beam at every
2.5m.

2.6

Removal of Rail Fasteners

1)

Removal of the rail fasteners at approx 10 meter of the lenght of tracks.

2)

Collection of the old fasteners and placement into plastic bags for return to DGR.

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RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

2.7

Up Track

Down Track

Remove Fastening

Removal of Existing Bridge Sleepers

1)

Rail lifting up by rail jacks.

2)

Existing bridge sleepers will be removed after each and every 2 sleepers and three pcs at one time.

3)

Loosen the fixing bolts of the existing bridge sleepers and remove.

4)

Pull out the existing bridge sleepers from the side portion of the tracks and place these on the
temporary platform.

Up Track

Down Track

Remove Existing
Wooden Sleeper

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Jack

RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Remove
Existing Wooden Sleeper

2.8

Installation of the New Bridge Sleepers

1)

Installation of new base plates and temporary fixing by screw spikes.

2)

Insertion of the new bridge sleeper from the opposite removal side.

3)

Installation of the new fixing bolts of the bridge sleepers and temporary tightening.

Up Track

Down Track

Installation New
Wooden Sleeper

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Jack

RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

Instal NEW Woooden Sleeper

2.9

Next 3 Bridge Sleepers Replacement

1)

2.10

Adopt and repeat activity 2.7 and 2.8

Rail Alignment

1)

Rail fastening by the use of pan puller

2)

Horizontal alignment check by off set marking at every 2.5m.

3)

Gauge check

4)

Final tightening of the bridge sleeper bolts and base plate bolts.

Up Track

Down Track

Installation Fastening

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RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

2.11

Adopt and repeat activity 2.6 to 2.10 until the completion of the work.

2.12

Dismantle temporary platform.

2.13

Hauling of the existing or old bridge sleepers to the temporary storage area.

1)

Existing or old bridge sleepers move to the temporary storage area so as to maintain safe train
operations.

2.14

Line Clearing
Ensure that existing, old, excess or salvaged materials, equipment and tools are removed before leaving
the site. When there is no impact unto the train operations, speed restriction sign boards can be removed
and confirmed with the station representative of the train operaor PT. KAI.

TO CIKARANG

3.

Working Time
Wooden sleeper replacement work will be carried out during the window time at night time.

4.

Coordination and Safety

Prior to the commencement of this Bridge sleeper replacement works, coordination will be carried out by
the representative of the train operator PT. KAI located at stations near both ends of the work site. Work
Permits from the Employer and/or PT. KAI will be arranged, and maintain good communication in order
to avoid any train accident and/or incident. All demolished materials, equipment and tools will be
removed before leaving the site. Train accidents are thus prevented..

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RAILWAY ELECTRIFICATION AND DOUBLE-DOUBLE TRACKING OF JAVA MAIN LINE PROJECT

PACKAGE B1: RAILWAY FACILITY CONSTRUCTION FOR BEKASI TO CIKARANG

5.

Detail Time Schedule

Window Time Schedule for Bridge Sleeper Replaacement

Bridge Sleeper Replacement

No

Dur.
(min.)

Description

Unit

Window Time ( Installation Sign 3 )

ls

120

2 Removal of Rail Clip

pcs

68

15

3 Lifting up of Existing Rail

tm

10

20

4 Removal of Existing Bridge Sleeper

each

17

30

5 Install New Bridge Sleeper

each

17

30

6 Install of Fastener Bridge Sleeper

pcs

68

15

7 Cek Track Alignment

tm

10

30

8 Cleaning

ls

10

9 Removal Sign 3

ls

10

Qty

HOUR
1

Remarks

1 Preparation

Train normal operation

Sign 2c

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