Engineering Specification Track L1-CHE-SPE-064 Ballast Supply Version: 1 Issued: October 2015 Owner: Engineering Group Approved By: Gordon Djurdjevic Track Engineering Manager PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 01/10/2015 1 Initial issue. Supersedes previous document L2-INF-SAS-002 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 10
Table of Contents 1 Purpose... 4 2 Scope... 4 3 Abbreviations... 4 4 Definitions... 4 5 References & Legislations... 4 6 Responsibilities... 4 7 Safety & Environmental... 5 8 Requirements... 5 8.1 Naming Convention for Ordering Ballast... 5 8.2 Manufacture of Railway Ballast... 5 8.2.1 General... 5 8.2.2 Material Properties... 5 8.2.3 Rejection of Proposed Ballast Material... 5 8.3 Sampling and Testing of Ballast... 6 8.3.1 Testing for Conformity... 6 8.3.2 Production Testing... 7 8.3.3 Inspection of Facilities... 7 8.4 Manufacture of Screening Used as Ballast... 7 8.4.1 General... 7 8.4.2 Material Properties... 7 8.4.3 19mm Screenings Grading Table... 8 8.5 Testing of Screenings... 8 8.6 Ballast Handling... 8 8.6.1 Ballast Delivery... 8 8.6.2 Ballast Stockpiling... 8 8.6.3 Ballast Loading... 9 9 Related Documents... 9 10 Records... 10 11 Appendices... 10 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 10
1 Purpose This specification sets out requirements for the supply, manufacturing, testing and handling of Ballast. 2 Scope This specification will cover the requirements for the supply of Ballast used for Contract purposes. 3 Abbreviations MTM QA Metro Trains Melbourne Quality Assurance 4 Definitions Australian Standard Ballast Nominal Size Superintendent Standards Published by Standards Australia. Ballast is a free draining coarse aggregate used to support railway tracks. The designation of an aggregate which gives an indication of the largest size particle present. Technical Representative nominated by the Chief Engineer s Office. 5 References & Legislations AS2758.7 2015 Aggregates and rock for engineering purposes Part 7: Railway Ballast AS1141 Methods for sampling and testing of aggregates 6 Responsibilities The Contractor shall be responsible for conformance to this document. The MTM Technical Representative nominated by the Chief Engineer s Office shall be responsible for the management of the technical requirements and shall ensure compliance in accordance with the MTM documented processes relevant to this specification. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 10
7 Safety & Environmental The general requirements in relation to safety are included in MTM s Safety Management System Manual (L0-SQE-MAN-002). L0-SQE-PRO-014 Safety and Environmental Requirements for Contractors Working on MTM Premises outline the requirements of contractors operating within MTM s premises. 8 Requirements 8.1 Naming Convention for Ordering Ballast Under the former PTC naming convention, there were two gradings of ballast: 53mm and 37mm. Under the naming convention in AS2758.7, there are also two gradings of ballast: 60mm and 50mm. These have now superseded the 53mm and 37mm gradings respectively. Therefore: A requirement for traditional 53mm ballast or 60mm nominal ballast shall be met by supply of 60mm nominal ballast to Table 1 in AS2758.7. A requirement for traditional 37mm ballast or 50mm nominal ballast shall be met by supply of 50mm nominal ballast to Table 1 in AS2758.7. Important Note: The 60mm graded aggregate also in Table 1 in AS2758.7 is not to be used as a railway ballast as part of MTM procedures. 8.2 Manufacture of Railway Ballast 8.2.1 8.2.2 8.2.3 General The whole of the material supplied shall be basalt or other approved rock and shall be clean, free from clay, dirt and other deleterious matter or weathered pieces of rock and free from dust. Material Properties Material supplied shall generally be in accordance with AS 2758.7 Aggregates and rock for engineering purposes - Part 7: Railway ballast except that the limiting values for the tests required to be carried out to AS 1141 Method for sampling and testing aggregates plus any additional tests required by this specification shall be as defined in Table 1. Rejection of Proposed Ballast Material Igneous or other rock, displaying minerals considered to be harmful to the overall performance of the ballast may be rejected following petrographic analysis or durability testing, even though the rock complies with other sections of the specification. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 10
AS1141 Part: Title Property Limiting Value 4 Bulk Density of Aggregate bulk density >1200 kg/m³ 6 Particle density and water absorption of coarse aggregate - Weighing-in-water particle density >2600 kg/m³ method. 11 Particle size distribution by sieving. grading Use Table 1 in AS 2758.7 14 Particle Shape, by Proportional Calliper <30% Mis-shapen particles (+ Amendment No.1) @ 2:1 calliper ratio 15 Flaky particles in ballast material retained on 6.70 mm sieve Flakiness Index <30% 21 Aggregate crushing value (passing 26.5 mm sieve and retained on 19.0 mm sieve) 22 Wet/dry strength variation 23 27 32 crushing value <25% wet strength wet/dry strength variation >175 kn <25% Los Angeles Value (+ Amendment No.1) resistance to abrasion <25% Resistance to wear by attrition (passing 53.0 mm sieve and retained on 37.5 mm sieve). wet attrition value <6% Weak Particles (including clay lumps, soft and friable particles) in Coarse Aggregates. weak particles <0.3% Table 1 8.3 Sampling and Testing of Ballast Unless otherwise specified below sampling and testing shall be carried out in accordance with the requirements of AS 2758.7 and the AS 1141 series of Standards. The Superintendent arranging supply of ballast shall obtain certification from suppliers for all new ballast supplied from: Quarries not previously used for the supply of Railway Ballast to this specification. Existing quarries used for the supply of Railway Ballast to this specification where the material being quarried changes. An independent party who shall be an approved member of the National Association of Testing Authorities (NATA) shall carry out the sampling and testing. Certification shall include documentation that the ballast has been sampled and tested in accordance with, and meets the requirements of this specification. The test report from the sampling and testing authority shall be submitted to MTM, even where this specification is not met. 8.3.1 Testing for Conformity A sample from the first 100 m3 of ballast produced shall be tested for full conformity with this technical specification, except when this requirement is waived by MTM. QA Records for all tests undertaken shall be stored on file by the Contractor and shall be made available upon request by the Superintendent. MTM may require additional sampling and testing where MTM suspects that the material is not to specification. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 10
8.3.2 8.3.3 Production Testing Production testing shall comprise: Particle size distribution testing, sampled at least once from each 1,000 m3 (1,500T) of ballast produced; Testing for misshapen particles, sampled at least once from each 1,000 m3 (1,500T) of ballast produced; Testing for flaky particles, sampled at least once from each 1,000 m3 (1500T) of ballast produced; and Testing for full conformity with this technical specification, sampled at least once from each 10,000 m3 (15,000T) of ballast produced, except where this requirement is waived by MTM. Sampling for production testing shall take place from ballast that has been delivered in accordance with the supply contract. QA Records for all production testing shall be stored on file by the Contractor and shall be made available upon request by the Superintendent. Inspection of Facilities MTM shall be provided access to inspect ballast production facilities at any unscheduled time during normal working hours for the purpose of: Observing sampling and testing procedures. Review plant and ballast production facilities. Carry out any additional sampling and testing. The Superintendent shall ensure that contracts with Sub-contractors provide for these inspections. 8.4 Manufacture of Screening Used as Ballast 8.4.1 8.4.2 General Where approval has been given to use screenings as track ballast due to certain local conditions (e.g. concrete bridge deck with only shallow depths available for ballast), screenings shall be nominal 19mm screenings. The whole of the 19mm screenings supplied shall be basalt or other approved rock and shall be clean, free from clay, dirt and other deleterious matter or weathered pieces of rock and free from dust. Material Properties Material supplied shall generally be in accordance with AS 2758.7 Aggregates and rock for engineering purposes - Part 7: Railway ballast except that the limiting values for the tests required to be carried out to AS 1141 Method for sampling and testing aggregates shall be as follows: PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 10
AS1141 Title Property Property Limiting Value Part 6 Particle density and water absorption of particle density >2500 kg/m³ coarse aggregate - Weighing-in-water method. 11 Particle size distribution by sieving. grading Use 19mm Screenings Table (below). 14 Particle Shape, by Proportional Calliper (+ Amendment No.1) mis-shapen particles <30% @ 2:1 calliper ratio 23 Los Angeles Value resistance to abrasion <25% (+ Amendment No.1) 32 Weak Particles (including clay lumps, soft and friable particles) in Coarse Aggregates. weak particles <0.3% 8.4.3 19mm Screenings Grading Table Standard Sieve Size Percentage by Weight Passing A.S. Sieves (mm) 63.0 53.0 37.5 26.5 19.0 13.2 9.50 6.70 3.35 - - - 100% 90-100% 30-50% 0-15% 0-5% 0-1% 8.5 Testing of Screenings For screenings, tests to AS1141 parts 6, 11, 14, 23 & 32 shall be carried out. 8.6 Ballast Handling 8.6.1 8.6.2 Ballast Delivery Prepared ballast shall be handled at the producing plant in such a manner that it is kept clean and free from segregation. Vehicles used for transportation shall be clean and free from rubbish and substances which may foul or damage the ballast. Ballast Stockpiling The Superintendent shall arrange for the management of ballast. MTM supplied ballast shall be maintained separately from any Contractors ballast. This shall include physical separation as well as separation of stockpile usage record keeping. When ballast is removed from stockpile for distribution into track, it shall conform to the same specification requirements defined in Section 8.2.2. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 10
Ballast distributed into track, which does not meet the specified quality requirements shall be removed and replaced. Ballast shall be stored stockpiled and handled in conditions which prevent material contamination, segregation and degradation. The movement of machinery over the stockpiled ballast shall be limited to minimize any degradation. 8.6.3 Ballast Loading The Superintendent shall ensure that there is a procedure for loading ballast and recording amount loaded including: Loading equipment to be used. Method of measuring loaded amounts of ballast. Loading Process. The loading process shall include provisions for: Minimising wastage of ballast. Avoiding unnecessary handling which may degrade the ballast in any manner by: Repeated mechanical handling. Unnecessary dropping of material. Contamination from the base of stockpiles or other sources. Ballast loading records shall be maintained based on one of the following methods: Measured weights (using certified loading scales) of the loaded hoppers or of the ballast passing through the device used to load the ballast directly into the hoppers or by truck and delivered to site, as directed by the Superintendent. Average weight agreements for each type of ballast hopper in the loaded condition. Ballast shall only be transported in accredited ballast hoppers, in trains operated by an accredited Operator, or by truck and delivered to site, as directed by the Superintendent. Ballast shall be loaded in a safe and environmentally acceptable manner particularly with regard to dust nuisance and noise levels. 9 Related Documents N/A PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 10
10 Records QA records detailing the conformance of ballast to this specification shall be maintained by the Contractor. These records shall be made available to MTM upon request by the Superintendent. QA records shall detail the individual tests used to demonstrate conformance to this specification, production tests and the results produced by each of these tests. 11 Appendices N/A PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 10