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Grasberg Haulage Railway

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

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0001_Construction Specification Embedded Track_REV 0.doc
Revision 0 18-Oct-2013
Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 1
Construction Specification Embedded Track

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.

1.3 Referenced documents


AECOM
60270518-RE-8100-RA-0002 Construction Specification Ballasted Track
ARTC
ETE-01-03: Non-Destructive Testing of Rail (for Internal & Surface Defects)
ETN-01-04: Manual for Non-Destructive Testing of Rail

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.

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0001_Construction Specification Embedded Track_REV 0.doc
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Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 2
Construction Specification Embedded Track

2.0 Track Installation prior to concreting


2.1 General
A work method statement shall be prepared by the contractor for approval by PTFI prior to any works being
carried out.

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.

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0001_Construction Specification Embedded Track_REV 0.doc
Revision 0 18-Oct-2013
Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 3
Construction Specification Embedded Track

2.3 Rail Welding


For details on procedures and testing of Flash Butt and Aluminothermic welds, refer:
60270518-RE-8100-RA-0002 Construction Specification Ballasted Track

2.4 Concrete Sleepers/Tie Bars


Pre stressed concrete sleepers are detailed on the track drawings as a way of achieving correct gauge and line.
Sleepers shall be laid central to the track and at right angles to the centreline of the track unless otherwise
specified. 200mm square concrete blocks can be used to raise the track to design level. If used, the blocks shall
be placed under the sleeper in line with the rail foot.
Alternatively, tie bars can be used in place of the concrete sleepers. Tie bars shall be placed at the maximum
spacing of 3m and be adjusted and tightened to keep rail to gauge. Tie bars are not to be placed in the fish plate
holes near the ends of the rails.
Tie bars shall be steel rods minimum 18mm diameter.
In all areas where tie bars are used, each rail shall supported using concrete blocks a minimum of 200mm square
to achieve line and level. The maximum support spacing is 3m.
Blocks shall be placed under the rail at each tie bar location as well as under end of switches and under the
centre of each crossing

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.

2.6 Track Geometry Tolerances


Track shall be constructed to the tolerances shown in table 1.
Measurements shall be recorded at 10m intervals along every track.
Table 1 Track Geometry Tolerances

Parameter Tolerance Description

Horizontal Centreline Position 10 mm Measured against design co-ordinates


Change in horizontal deviation from design
Horizontal Line 3 mm
measured over 10m
Vertical Level +10 mm Measured against design levels
Change in deviation from design levels
Top (change in deviation vs. design) 3 mm
measured over 10m
Gauge 3 or -0 mm Measured between inside edges of the rails
Difference in level between top surface of the
Cross Level Tolerance 3 mm
two rails

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0001_Construction Specification Embedded Track_REV 0.doc
Revision 0 18-Oct-2013
Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 4
Construction Specification Embedded Track

3.0 Concrete Construction


3.1 Lean Mix Concrete Mud Slab
3.1.1 General
A lean mix concrete mud slab layer beneath the track slab shall be constructed in any areas where greater than
normal over break occurs in the rock material during the mining of the drifts.
The minimum lean mix concrete strength is 15MPa.
The use of a concrete mud slab layer in other areas may be used to provide a level base for the embedded track
foundation.
3.1.2 Tolerances
The top of the lean mix concrete mud slab shall match in to the mined out rock floor so as to create a generally
level surface for the placement of the concrete embedded track.
The completed lean mix concrete mud slab base level shall be within -50mm and +0mm of the designed surface
level.

3.2 Concrete Construction


3.2.1 General
For general notes on concrete, reinforcement and concrete strength refer to the rail track drawings.
Concrete strength shall be 32MPa unless otherwise shown on the rail track drawings.
No motor traffic shall be allowed on to the concrete until a minimum strength of 14MPa has been achieved.
The contractor shall place the concrete outside each of the tracks before placing the concrete between the tracks.
Each section of concrete shall be a maximum of 11m in length to allow for rail overhang and shall be poured
monolithic, in one continuous operation unless otherwise directed and approved by PTFI.
The placing of concrete shall be rapid and continuous between planned construction joints, and it shall be
distributed so that when consolidated and finished, the slab thickness, surface shape and levels shown on the
drawings will be achieved at all locations.
The contractor shall take particular care that no concrete enters the working compartments of the switches of
turnouts.
3.2.2 Vibrating
All concrete shall be vibrated to consolidate the concrete and eliminate air bubbles from under the rail foot.
3.2.3 Testing of concrete
During the progress of the works the contractor shall arrange tests to be carried out.
Testing methodology and frequency is to be confirmed.
3.2.4 Construction Joints
Construction joints shall be simple butt-joints unless shown otherwise on the rail track drawings.
For embedded track concrete pours greater than 11.5m, joints 90 degrees to the rails shall be grooved in the
surface at 11.5m spacings to control shrinkage cracking.

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0001_Construction Specification Embedded Track_REV 0.doc
Revision 0 18-Oct-2013
Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 5
Construction Specification Embedded Track

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

3.2.5 Slab Finish


Slab surface shall be uniformly graded to the design cross section profile, free of bumps, hollows and other
irregularities. All exposed concrete surfaces shall be true, even and free from stone pockets, depressions and
projections. Defects or voids shall be made good by methods approved by PTFI.
A groove shall be formed along the running edge of each rail to provide a flangeway for the train wheels. The
groove shall be formed using a trowel to match the flangeway dimensions shown on the rail track drawings.
Any unsatisfactory finish shall be rectified by the contractor and to the complete satisfaction of PTFI.
Upon completion, the surface shall be carefully protected against damage by other construction activities.
3.2.6 Defective Concrete
The contractor shall be fully responsible for employing effective methods of placing, protecting, and curing
concrete, and for adequacy of forms. Approval of any such working methods by PTFI will be tentative only, and
shall not relieve the contractor of his responsibility.

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0001_Construction Specification Embedded Track_REV 0.doc
Revision 0 18-Oct-2013
Prepared for PT Freeport Indonesia ABN: N/A
AECOM Grasberg Haulage Railway 6
Construction Specification Embedded Track

4.0 Haulage Level Additional Requirements


4.1 Introduction
The Haulage Level (unlike The Service Levels Undercut, Extraction and AB Terminal) is electrified and
reinforced; this following section outlines the requirements. (To be expanded and completed)

4.2 Reinforcing
Refer to the rail track drawings.

4.3 Earthing and bonding


Details are to be confirmed.

End of Document

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Revision 0 18-Oct-2013
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