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PT Freeport Indonesia
18-Oct-2013
Spec No. 60270518-RE-8100-RA-0001
Construction Specification
Embedded Track
AECOM Grasberg Haulage Railway
Construction Specification Embedded Track
Table of Contents
1.0 Introduction 1
1.1 Purpose 1
1.2 Scope 1
1.3 Referenced documents 1
1.4 Definitions 1
2.0 Track Installation prior to concreting 2
2.1 General 2
2.2 Rails 2
2.2.1 Cutting 2
2.2.2 Drilling 2
2.2.3 Minimum Closure Lengths 2
2.2.4 Rail Joints 2
2.2.5 Curved Track 2
2.3 Rail Welding 3
2.4 Concrete Sleepers/Tie Bars 3
2.5 Reinforcement 3
2.6 Track Geometry Tolerances 3
3.0 Concrete Construction 4
3.1 Lean Mix Concrete Mud Slab 4
3.1.1 General 4
3.1.2 Tolerances 4
3.2 Concrete Construction 4
3.2.1 General 4
3.2.2 Vibrating 4
3.2.3 Testing of concrete 4
3.2.4 Construction Joints 4
3.2.5 Slab Finish 5
3.2.6 Defective Concrete 5
4.0 Haulage Level Additional Requirements 6
4.1 Introduction 6
4.2 Reinforcing 6
4.3 Earthing and bonding 6
1.0 Introduction
1.1 Purpose
This specification details the requirements for the construction of embedded track on the PT Freeport Grasberg
Haulage Railway Project.
1.2 Scope
This specification is to be used by PT Freeport and any contractors for the construction of embedded track on the
PT Freeport Grasberg Haulage Railway Project.
The work areas covered include:-
- 2850 Undercut Level
- 2830 Extraction Level
- 2760 Haulage Level Rail Shop, Chute Galleries and Unloading Station tracks
- 2535 AB Terminal
The works to be carried out in accordance with this specification include:
- Track Construction
- Rail Joints
- Earthing and Bonding
- Concrete
- Drainage
It is the responsibility of the contractor to ensure all works meet the requirements detailed in this specification.
1.4 Definitions
Approved Approved in writing by PT Freeport Indonesia (PTFI).
Contractor The party engaged for the work to be carried out in accordance with the technical
specification and the design drawings.
Plain Line Track Rails, fastenings, sleepers etc.
Crossing work Switches, crossings and connecting rails including fasteners that connect between two
or more tracks.
Flash Butt Welding Resistance welding process that produces a weld at the mating surfaces of a butt joint
by a flashing action combined with an application of pressure after heating is
substantially completed, and completed by rapid upsetting of the rails.
Aluminothermic Weld Welding of rail ends in the field by means of a process of casting iron oxide and
aluminium.
2.2 Rails
2.2.1 Cutting
The contractor shall avoid any unnecessary cutting of rails.
Cutting of rail shall be carried out to ensure conformance to detailed specifications for rail end condition.
Cuts shall be square to the rail within a tolerance of 2.0mm over the width and/or height of the rail.
Standard rail panel length shall be a minimum of 11.5m
2.2.2 Drilling
When necessary to provide holes in the rail web, such holes shall be made only by drilling. Holes shall be parallel
throughout their depth, clean and square with the web. No two holes shall be closer than 127mm centres.
Where six hole fishplates are used, three holes shall be drilled in each rail end.
Hole positions at rail ends and turnouts shall conform to dimensions specified and shall be within horizontal and
vertical tolerances of 1.0mm
Fish plates shall be centrally placed over the adjoining rails.
2.2.3 Minimum Closure Lengths
In both jointed and continuous welded rail (CWR), the minimum rail length shall be 3.0m.
Rail joints in curved track alignment should be minimised but not less than 6.0m spacings unless otherwise
approved.
2.2.4 Rail Joints
Six hole fishplates to be used in the following locations:
- 2850 Undercut Level
- 2830 Extraction Level
- 2760 Haulage Level Rail Shop
- 2535 AB Terminal
Flash Butt or Aluminothermic welds shall be used on the Haulage level in the following locations:
- Chute Gallery tracks
- Unloading tracks
2.2.5 Curved Track
Rails for curved trackwork shall be pre-curved using a rail bending machine.
All curves shall be nominally gauge widened by 10mm. This may be achieved by reversing the angle guide plate
inserts.
2.5 Reinforcement
The reinforcement where shown on the rail track drawings shall be laid in-between sleeper ends or on the tie bars
and/or approved supports and shall be securely held in its correct position during the concrete placing operation
and until the concrete has hardened.
For reinforcing details, including locations in addition to the crossing work areas, refer to the relevant rail track
drawings.
Additional works shall be carried out on reinforcement located on The Haulage Level in accordance with Section 4
of this specification.
Tolerances
All concrete shall be constructed to the tolerances shown in table 2:
Table 2 Concrete Tolerances
Parameter Tolerance
Thickness of slab +50mm or -0mm
Cover to reinforcement +5mm or -3mm
Finished level of slab +0 or -5mm
4.2 Reinforcing
Refer to the rail track drawings.
End of Document