a. Inspection of rail ends b. Rail cutting and set the required gap c. Loosening of rail fastenings d. Rail end preparation and alignment e. Preheating and welding f. Finishing and alignment g. Weld testing h. Replacement of defective welds i. Records of thermit welding

Each procedure shall be in accordance with the AREA Manual for Railway Engineering, the products or welding kit specifications itself and other applicable standards.

13.1.3.10.2 Quality Assurance

This section shall conform to requirement in 2.1.3.1.1 Quality Assurance Program.

13.1.3.10.3 Weld Testing

All weld testing and submittals shall be performed by a duly accredited independent testing laboratory in accordance with quality control requirements and applicable standards. In order to qualify the welding kits, welding crews, and production welds; the following test shall be carried out:

a. Radiographic testing b. Ultrasonic testing c. Slow bend testing d. Hardness test e. Rolling load test f. Magnetic particle test g. Visual test

13.1.3.10.4 Tolerances

All alumino-thermic welds will be in the suspended portion of rail between supports. The weld shall not encroach 150mm from tie ends or baseplate support. Finished weld using 1 meter straight edge shall have the following tolerances:

a. Rail head surface +0.3 / 0.0 mm b. Rail gauge face +0.3 / 0.0 mm

13.1.3.10.5 Submittals

The Contractor shall submit the following:

a. Detailed specifications, proposed materials, methods and procedures to be used for the thermit welding process, b. Certification from the supplier or manufacturer that the materials delivered to site conforms to the specifications,

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c. Welding supervisor qualifications with a minimum 3 years thermit welding experience. The welding supervisor shall be replaced only with the Engineer’s prior approval, d. Schedule of CWR lengths and CWR string Designation system, e. All material testing and weld test results, f. Test equipment certificate and calibration, g. And all submittals shall be in accordance with 2.1.3.1.2 Submittals.

13.1.3.11 Grade/Road Crossing

This section specifies the requirements for the supply and installation of materials required for the construction of grade/road crossings at MRT3 Depot.

The contractor shall perform the work in accordance to applicable standards and approved methods, procedures and materials by the Engineer. The Contractor shall take all necessary safety measures for an organized construction work and to avoid interruption to depot train movement and maintenance work.

13.1.3.11.1 Bituminous Material Installation

It shall conform to Item 307 of DPWH Standard Specifications

13.1.3.11.2 Submittals

a. Shop drawings for the crossing showing details and arrangement of the rail support and anchoring system including dimensions and tolerances b. Grade/road crossings installation procedures c. Approved job mix formula of the bituminous materials to be use d. And all other required documents to necessary to complete the work

TABLE 1 TRACK CONSTRUCTION TOLERANCES

Gauge Cant / Cross Horizontal Vertical Type of Track Variation Level Alignment Alignment

Mainline Ballasted N/A N/A N/A N/A Track Depot Ballasted -2, +3 mm ±3 mm ±4 mm 0, +5 mm Track

Notes:

 Variation is measured between the designed and actual alignment at any point in the track  Horizontal alignment is measured in mm by 10m chord placed at the gauge line of the rail running face.  Vertical alignment is measured in mm by 10m chord at the head of the datum rail.  Rail cant may vary between 1 in 18 and 1 in 22

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 Maximum twist is 1 in 1000

14. DEPOT EQUIPMENT/FACILITIES

14.1 INTRODUCTION

Under the capacity expansion project additional trains are to be provided to increase capacity. Upgrading of existing maintenance facilities and additional workshop equipments are necessary to support the project.

The overhaul area in MRT3 depot was utilized fully whilst conducting general overhauling and at times also when carrying out car body repairs. It was necessary for some parts to be fork lifted in order to transfer to the bogie hoisting area. To complement the present bogie hoisting area, it is necessary to provide a service track and turntables for bogies to link the two areas. Please refer to MRT3 Workshop Improvement Lay-out.

14.2 WORKSHOP IMPROVEMENT (Infrastructure)

14.2.1 General

All works under this section shall be carried out in accordance with all the governing codes and regulations that are hereby made part of these specifications. The plans and these specifications are complementary and what is called for in one shall be as if called for in both.

Applicable Standards

The following are the main reference standard comprises the technical requirements and the condition to be adopted for the execution of the works.

AASHTO - American Association of State Highway and Transportation Office ACI - American Concrete Institute PCI - Prestressed Concrete Institute ANSI - American National Standard Institute ASTM - American Society for Testing and Materials AWS - American Welding Society PNS - Philippine National Standards DPWH Standard Specification PEC - Philippine Electrical Code NEMA - National Electrical Manufacturer’s Association

Work in General

The work shall consist of providing all items, materials, operations or methods listed, implied, mentioned or scheduled on the drawings and/or herein, including all labor, supervision and equipment necessary to the proper completion and execution of the works except those portions of the work that are clearly stated to be done by others.

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Work Included

The work to be done under this section shall include the furnishing of all tools, labor, supervision, equipment, fixtures and all necessary materials, each complete and proper working condition unless one or other is specifically excluded or stated otherwise in this specifications but not limited to the works below:

Relocation, removal and demolition, re-installation of existing equipment and other works as required in carrying out removal, demolition and modifications to existing lighting, fixtures, pneumatic lines and branch circuits. Such necessary improvements and modifications to the electrical and mechanical works because of structural and architectural changes shall form part of the scope of this section even if not specifically identified.

Visit to Site

The Contractor is advised to visit and satisfy himself as to the local conditions and facilities that may affect his work. He will be deemed to have fully completed this study before preparing his proposal and no subsequent claim on the grounds of inadequate or insufficient information shall be entertained.

14.2.1.1 CONVERSION OF LEVELED TRACK TO MAINTENANCE PIT TRACK

A portion of Tracks 19 and 20 shall be converted to a maintenance pit (40 M each) so that bogies can be dismounted from the car using the mobile lifting jacks. All compressed air supply complete with quick connect coupling, valves and fittings shall be provided with the same materials used as of the existing pit including other associated utilities (electrical/ mechanical) inside the pit. The depth of the pit shall be 1.2 M from top of rail. Please refer to MRT3 Workshop Improvement Lay-out.

14.2.1.2 SERVICE TRACK FROM TRACK 17 TO BOGIE WASH TRACK

A service track from track 17, 18, 19 and 20 to bogie wash track shall be provided to be connected by means of bogie turn tables for easy access to cleaning in the bogie wash room during dismounting. Please refer to MRT3 Workshop Improvement Lay- out.

14.2.2 WORKSHOP EQUIPMENT (Additional)

14.2.2.1 DESCRIPTION

The scope of this section is to provide specification for the supply, installation, testing and commissioning and subsequent training of operators in relation to additional Depot Equipment.

Warranty

The supplier shall provide the MRT3 with a two (2) year period of warranty coverage for the equipment issued that will commence upon written confirmation of final acceptance. Refurbished equipment shall also be guaranteed for not less than 2 years.

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Submittals

Supplier shall provide written instruction in English language pertaining to the operation, servicing and maintenance of the equipment.

The O & M manuals shall be provided from the delivery of equipment. It shall describe the method and theory of the operation, equipment characteristics and specifications, as well as maintenance and troubleshooting procedures. Complete parts list, troubleshooting flowcharts and guidelines and safety precautions shall be included.

Supplier shall provide shop drawings in A1 size including “As Built” drawing.

Reliability, Availability, Maintainability and Safety

The supplier shall provide the equipment’s reliability, availability, maintainability and safety criteria based on EN 50126 or acceptable equivalent Standard. It shall be based or compatible with the existing installed equipment or even better.

Training

Supplier shall provide training in the proper and safe use of the equipment proposed and shall describe/facilitate the proposed training program. The supplier shall provide all training materials, training tools and venues.

Spare Parts

The supplier shall be responsible for the availability and supply (shall provide) of all initial spares at site during installation, commissioning and the warranty period.

Consumable spares comprising those items which are required for routine replacement or usage to meet the manufacturer’s recommended servicing and maintenance programs shall also be provided for use during the warranty period and for one (1) year service after the warranty period. Included in this supply shall be those items which are expected to fail during the specified period based on the manufacturer’s known or predicted failure rate.

The contractor shall ensure the availability of these spare parts for at least 4-four years.

Delivery, Storage and Handling

Materials shall be delivered to the site in the original sealed containers or packages, and shall bear the manufacturer’s name and brand designation. Where materials are covered by a reference specification number, type and plan as applicable. Materials shall be stored and handled in a manner to protect them from damage during the entire construction period.

14.2.2.2 HAND ACTUATED TURNTABLE FOR BOGIES (5 Units)

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This equipment is designed for transfer of bogies from one track to another for repair and overhaul and shall be mounted in a concrete pit. The top of the turntable shall be at the same level of the workshop floor so as not to hinder trolley movement. The turntable shall be manually operated; at least two-2 personnel could easily rotate the table with a maximum load of 6 tons. Rail gauge to be used shall be the same as the existing rail (Rail Gauge = 1,435 mm). The gap between the foundation and the turn out table shall be less than 10mm. A stopper shall also be provided so that the table will not move when at rest position. The supply shall include (for each turntable):

 The turntable  The running platform  The peripheral joint ring

Each turntable shall consist of mechanical assembly bearing on a center pivot and several carrier rollers running on circular platform.

RAM CRITERIA DIMENSION

Reliability No more than one failure per year

Availability 95% after breakdowns and maintenance

Maintainability Equipment to be back in service at maximum tone half day after failure

14.2.2.3 MOBILE LIFTING JACKS (1 Set / 12 Units – 50 KN Capacity)

This equipment is used to jack-up LRV in simultaneous, synchronized and a safe manner in order that items of running gear and some under frame mounted equipment, such as bogies, can be removed and replacement items fitted. The design of the jacks shall be such that personnel shall be able to work safely under an LRV being supported by these jacks without the necessity of providing additional supports.

The jacks will be controlled from one control station which will be provided with a means of enabling the maintainer to monitor the jacking process is proceeding safely and synchronized. The number of jacks being controlled during jacking operations will be variable.

Control and power cabling for the jacks that could be under hatches will be strong enough to bear any likely imposed weight, for example fork lift trucks or another jack. The intension is to keep this cabling to a minimum on the workshop floor. Connection between jacks and the floor sockets will be via suitably robust connectors and cables.

It is required to have a set of mobile jacks arranged to be able to lift one single LRV.

RAM CRITERIA DIMENSION Reliability No more than one failure per year Availability 95% after breakdowns and maintenance Maintainability Equipment to be back in service at maximum two days after failure

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14.2.2.4 TRAVELLING LIFTING TABLES IN PIT (1 Unit – 20 KN Capacity)

This equipment is designed for removal of equipment fitted on the under frames of LRV. It shall also be designed for carrying in the equipment after removal from the LRV to the end of the pit for transfer to a hoist.

RAM CRITERIA DIMENSION

Reliability No more than one failure per year Availability 98% after breakdowns and maintenance Equipment to be back in service at maximum one half day after Maintainability failure

14.2.2.5 JIB CRANES (2 Units – 20 KN Capacity)

This equipment is mainly used in the overhaul workshop. They shall be used for the movement of large assemblies/sub-assemblies in a single area.

RAM CRITERIA DIMENSION Reliability No more than one failure per year Availability 97.5% after breakdowns and maintenance Equipment to be back in service at maximum one half day after Maintainability failure

15 TAFT POCKET TRACK

MRT3 presently has already approached the limit of practical capacity. Therefore, capacity expansion and improvements become particularly timely and an important objective to be implemented.

The present three-car trains shall be improved to four-car trains in the implementation of this Capacity Expansion.

The present retaining wall, tracks and wayside equipment installed at Taft Pocket Track (TPT) shall be modified and lengthened accordingly to accommodate 4-car trains.

Modification works should not in any way disrupt the current system operations.

The extension of the Pocket Track shall be completely interfaced and integrated with the signaling system, power supply, catenary system and track works.

The works will require demolition and replacement of some length of the affected wall structure. It requires redesign, relocation and replacement the cables relevant to signaling and Overhead Catenary System (OCS).

The technical specifications relevant to each portion of the works are as follows, but not limited to:

a. Part 1 – Civil Works b. Part 2 – Track works c. Part 3 – Overhead Catenary System

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d. Part 4 – Signaling System

The Signaling Upgrade shall not be included in this contract. The upgrade of the signaling system shall be carried out by the Signaling Provider of the MRT3.

The contractor shall follow the design requirement and specification of the Signaling system to make the Power & OCS system, Civil Works and Track Works fully integrated to the Signaling system.

15.1. CIVIL WORKS

15.1.1. General

The stipulation stated in this Section specifies the requirements applicable to the Civil Works for the extension of the MRT 3 Taft Pocket Track.

The works shall include the detailed design, supply, delivery, installation, testing & commissioning, defects warranty and obtaining all permission from government authorities and everything whether permanent or temporary in nature needed and necessary for safe and proper execution of work and fulfillment of all obligations required under this contract.

15.1.1.1. Scope of Work

The Contractor shall be responsible for:

a. Design, plan, and modification of MRT3 retaining wall structures affected by extension of the Taft Pocket Track.

b. Other Civil Works required for work completion like restoration of MRT 3 perimeter fence, drainage, curbs and etc.

c. Ensure no disruption to MRT 3 daily train operations and adjacent traffic flow along EDSA.

15.1.1.2. Applicable Standards

The following are the main reference standard comprises the technical requirements and the condition to be adopted for the execution of the works.

 American Standards - AASHTO - ACI - ASTM - AWS - PCI  British Standards - BS - CIRIA - CRSI  European Norms - CEN

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- SCCEPG  French Norms - AFNOR - DTU  DPWH Standard Specifications  PNS

15.1.1.3. Special Site Conditions

Utmost importance shall be taken by the Contractor with regard to the special site conditions affecting the design and construction of the project.

15.1.1.4. Performance Requirements

The contractor shall prepare design criteria, a preliminary set of standard drawings, a list of the basic design drawings, and a set of final design drawings and an outline of the procurement and construction specifications.

15.1.2. Materials Requirements

Civil Work materials needed for the extension of Taft Pocket Track shall be complete with all accessories and passed all the required testing in accordance to specifications and standards and shall be approved by the Engineer before incorporating to work. The Contractor shall ensure materials availability for small quantity production intended for maintenance use.

15.1.2.1. Removal of Structures and Obstructions

This Item shall consist of the removal wholly or in part and satisfactory disposal of all structures, fences, old pavements and any other obstructions which are not designated to remain. It shall also include salvaging of designated materials and backfilling with approved fill materials. All rubbish from the TPT area shall be disposed of and shall not allow accumulations.

15.1.2.2. Earthworks

All materials to be incorporated in the work shall pass all required testing and certification and in accordance with the requirements of Part C Earthwork DPWH Standard Specifications.

15.1.2.3. Aggregate Base / Sub-Ballast

The aggregate base (sub-ballast) shall be from approved source and conform to the requirements of Item 201 Aggregate Base Course of the DPWH Standard Specifications.

15.1.2.3.1. Geo-Textiles

This item covers geo-textile fabrics for use in subsurface drainage, hydraulic control, erosion control, sediment control and pavement structures as a waterproofing and stress relieving membrane in order to prevent mixing of dissimilar materials.

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Geo-textile sheet for MRT3 shall be 13kn tensile strength and at least 0.90mm thickness.

Materials and specifications for this section shall conform to Item 715 of DPWH Standard Specifications.

15.1.2.4. Concrete Works

This section refers to the required concreting works for MRT3 retaining wall, OCS posts unless specified and other concreting works needed for the extension of Taft Pocket Track.

15.1.2.4.1. Concrete

The concrete shall be adequately workable and of proper consistency to permit flow to forms and reinforcement during placement and no signs of aggregate segregation. The designed minimum compressive strength of concrete at 28 days shall be 28 Mpa shall conform to AASHTO, ACI, ASTM and standards applicable.

15.1.2.4.2. Cement

All Portland cements shall be obtained from suppliers which have a quality system for product conformity and shall conform to ASTM 150 or Item 700 of DPWH Standards Specification or approved equal.

15.1.2.4.3. Water

Water shall be clean, fresh and potable and shall conform to Item 714 of DPWH Standard Specifications.

15.1.2.4.4. Aggregates

Aggregates shall be from approved source and shall not contain any deleterious substances to prevent contamination and cement alkalis reactions.

All aggregates shall pass all required testing and shall conform to ASTM Standards and Item 703 of DPWH Standard Specifications.

15.1.2.4.5. Admixtures

Suitable admixtures may be used to modify certain properties of concrete and shall conform to ASTM C494. However, as they may at the same time adversely affect other important concrete quality, the Contractor shall carry out testing on concrete to which they are added.

All admixtures shall conform to relevant local and international specifications and shall be approved by the Engineer.

15.1.2.4.6. Steel Reinforcement

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The Contractor shall specify basic and minimum standards for furnishing and installing steel reinforcement for concrete. All reinforcing steel shall be hot rolled weldable deformed steel bars obtained from approved supplier as specified in ASTM A615M or BS 4449 and shall have the following minimum yield strength:

a. 12  and smaller shall be 275 Mpa or grade 40 b. 16  and larger shall be 414 Mpa or grade 60

15.1.2.4.7. Formwork

Forms shall be designed to produce hardened concrete of the shape, lines, levels and dimensions indicated on the design drawings. The forms including form supports which shall withstand the worst combination of all loads together with all incidentals dynamic effects caused by placing, vibrating and compacting concrete.

The Contractor shall specify basic and minimum standards for forms for concrete structures and facilities and shall conform to ACI 301 and ACI 347 standards.

15.1.2.4.8. Materials for Curing Concrete

Concrete curing materials shall be of approved materials and conforms to standards requirements. The materials shall be satisfactory of providing a curing environment for optimal concrete quality, consistency, strength and durability. The following materials can be used for curing concrete by the Contractor or any approved equal: a. Liquid membrane forming compounds AASHTO M 148 / ASTM C1315 b. Previous sheeting AASHTO M 184.3 c. Standard specification for sheet materials for curing compound ASTM C171 15.1.2.4.9. Joint Fillers

Unless otherwise shown on the plans or in special provisions, materials for expansion joint filler shall conform to the ASTM D-1751 requirements and specifications.

15.1.2.4.10. Other Accessories

Reinforcement accessories, consisting of bar supports, spaces, ties, and similar items as required for spacing, assembling, and supporting concrete in place shall be provided conforming to reference standards.

15.1.2.5. Civil Miscellaneous Structures

This section refers to miscellaneous materials required and necessary to complete the work in the extension of Taft Pocket Track.

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15.1.2.5.1. Curb and Gutter

Curb and gutter shall be constructed by concrete cast in conformity with the design drawings and shall be in accordance with the plans and specifications required by the Engineer.

Materials and execution shall conform to Item 600 of DPWH Standard Specifications.

15.1.2.5.2. Fences

Fences necessary to maintain system security along the MRT3 perimeter shall be provided by the Contractor and shall ensure that there are no related or operational problems. Metal fences should be galvanized and or walls shall have smooth surfaces and shall be painted.

MRT3 perimeter fence shall be constructed in conformity with the designs and specifications required by the Engineer and shall be compatible with the existing fenced materials.

Materials and execution shall conform to Item 604 of DPWH Standard Specifications.

15.1.2.5.3. Drainage

Drainage for MRT3 shall be compatible with the existing drainage system. It shall be designed to remove completely excess water. Drainage pipes of 100mm Ø shall be perforated with 10mm Ø holes connected to PVC drain pipes of the same diameter and spaced every 3 meters shall be used.

15.1.2.5.4. Cable Trough

Cable trough shall be precast concrete provided with 20mm Ø drain holes spaced every 5 meters. Cable through shall be 50mm thick and at least 270mm in height. Each cable through of 300mm and 440mm wide respectively shall consist in 3.2mm Ø welded wire fabrics spaced every 150mm and shall conform to ASTM A185.

15.1.3. Construction Requirements

The Contractor shall be responsible for the construction means, methods, techniques, sequences and procedures for coordinating all portions of the Work under the Contract Documents.

The Contractor shall provide all superintendence during the execution of the Work as may be necessary for the proper fulfillment of the Contractor’s obligations under the Contract. It shall include the supervision and inspection by qualified professional personnel experienced in railway construction whose responsibility shall be to ensure the technical standards and workmanship, materials, and quality are being maintained in accordance with the Scope of Work.

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The Contractor shall design, supply and install materials for the extension of Taft Pocket Track which satisfies to the minimum requirements of the specification and Employer’s Requirements. The Contractor shall submit full details of the proposed design to the Engineer for review and approval and shall not commence until written acceptance has been received from the Engineer.

15.1.3.1. Removal of Structures and Obstructions

This Item shall consist in the partial or whole removal responding to the final disposal of all structures: fences, old pavements and any other obstructions which are not designated to be remained. It shall also include salvaging of designated materials for backfilling with approved fill materials. All rubbish from project area shall be disposed and accumulations shall not be allowed.

15.1.3.1.1. Execution

This section shall conform to Item 101 of DPWH Standard specifications

15.1.3.1.2. Dust control

The Contractor shall take appropriate action to check the spread of the dust in the project site and avoid the creation of a nuisance in the surrounding area. The Contractor shall not use water if it results in hazardous conditions such as flooding or pollution and shall comply with all dust regulations imposed by the local air pollution agencies.

15.1.3.1.3. Construction Protection

The Contractor shall ensure construction protection adequately during execution of work in order not to affect the adjacent traffic flow along EDSA Highway and MRT 3 operations.

The Contractor shall take all necessary precautions to protect personal (ppe) and private property in the areas of work. Approved barriers and warning signs shall be provided to reroute personnel/motorists around areas of dangerous work

15.1.3.1.4. Rubbish / Debris

Rubbish/debris shall be placed in approved Contractor furnished containers to prevent spread and accumulation of dust and dirt. It shall be removed from the area of work as often as necessary but not less than at least once at the end of each workday.

15.1.3.1.5. Submittals

The Contractor shall submit the following:

a. Proposed demolition procedures for Engineer’s approval b. Detailed description of equipment to be used for each sequence of operation c. Traffic management plan

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d. And other submittals required for work completion.

15.1.3.2. Earthworks

The work specifies in this section consists of stripping topsoil, excavating and backfilling to attain indicated sub-grades and grades and conforms to Part C Earthwork of DPWH Standard Specifications latest edition.

Gradation ASTM D422

Liquid Limit ASTM D4318 Plasticity Index ASTM D4318

Resistance (R. Value) ASTM D2844 Maximum Density ASTM D1557

Sand Equivalent California test 217 or ASTM D2419

15.1.3.2.1. Excavation

Remove materials within the indicated limits. The sub-grade is the lowest elevation of excavation and it shall be inspected and approved by the Engineer prior to placement of grade materials. Excavated materials satisfying the requirements of Item 104 of the DPWH Standard Specifications may be used as fill materials. Remove all surplus excavated materials.

15.1.3.2.2. General Excavation

a. Generally refers to excavation for the construction of track-way and roadway as indicated on the design drawings. b. Sub-grade preparation at sub-grade track way and roadway in excavation areas shall have a minimum bearing capacity of 150 Kpa and shall conform to Item 105 of DPWH Standard Specification. c. Fill unauthorized excavation with approved fill materials by the Engineer and compact to at least 90 percent of maximum dry density in accordance with ASTM 698 of 200mm per compaction layer.

15.1.3.2.3. Structure Excavation

Ensure that the existing sub-grade, other than rock, will not be disturbed and get loose by any excavation. If the sub-grade material is disturbed to a lesser than 90% of FDT, measure should be taken to recover the sub-grade at least 90% FDT or higher, otherwise the disturbed material can be replaced by equivalent material or with concrete of the same class as the sub-grade structure.

The Contractor shall ensure that demolition and excavation of the adjacent existing concrete road which is affected by the project shall not disrupt the road traffic and not damaging to any other existing facilities.

15.1.3.2.4. Filling, Backfilling and Compacting

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Refer to Item 104 of DPWH Standard Specifications.

15.1.3.2.5. Contractor’s Quality Control

Prior to and during the execution of the work, the Contractor’s Testing Laboratory shall perform all necessary tests in accordance with the minimum testing requirements and Item 104 of DPWH Standard Specifications. Field Density Test for any sub-grade for track or for any soil for spread foundation should be higher or at least 90%.

15.1.3.2.6. Submittals

The Contractor shall submit the following for Engineer’s review and approval:

a. Equipment to be utilized in the work b. All necessary methods and procedures c. All testing results and other materials certification

15.1.3.3. Aggregate Base / Sub-Ballast

This section specifies the furnishing, placing, spreading and compacting of crushed aggregate base or sub-ballast in one or more layers in accordance with specification and contract drawings.

15.1.3.3.1. Placing, Spreading and Compacting

The approved aggregate base course (sub-ballast) shall be placed, spread and compacted in conformity with the requirement of DPWH Standard Specifications Items 200.3.2 and 200.3.3 and contract drawings.

Geo-textile materials, execution and specifications for this section shall conform to Item 715 of DPWH Standard Specifications.

15.1.3.3.2. Submittals

The Contractor shall submit the following for Engineer’s review and approval:

a. Geo-textile materials specifications b. Equipment for to be utilized for the work c. All necessary methods and procedures d. Materials grading and testing results e. Materials source and certificate of compliance

15.1.3.4. Concrete Works for Retaining Wall

This section covers procurement and placing of concrete. It specifies basic and minimum standards for materials and equipment for the use of plain and reinforced concrete.

All specifications discussed in this section will technically apply for the construction of MRT3 retaining walls, OCS foundation if necessary and other concrete works needed for the extension of the Taft Pocket Track.

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15.1.3.4.1. Quality Assurance

The Contractor shall be responsible for the quality control and quality assurance for materials and construction to be included but not limited to the following:

a. Complete quality assurance plan b. Organizational chart for quality control c. Qualifications of independent testing laboratories as well as names and experience records of Contractors staff for implementing quality plans d. Site laboratories locations, layout and equipment e. Plans for testing products requiring testing and inspection at the supplier’s premises and proposed procedures for ensuring quality control is implemented f. Provision of inspection and testing instruments and devices to ensure proper performance of quality control g. Verification by affidavits and certifications that the supplied products meet requirements of reference specifications as specified in applicable sections of specification h. Tests to be regularly performed on all supplied materials i. Lists of proposed stages at which specified inspection and documentation shall be performed by the contractor and approved by the Engineer j. Forms of all test reports for all materials and items to be tested k. Quality assurance plan system, documents control, handling and storage procedures and check on quality records and auditing system

15.1.3.4.2. Execution

The Contractor shall establish methods and procedures for all activities needed to complete the work in accordance with applicable specifications.

The following works shall be included:

a. Survey and setting out b. Rebar installations c. Formwork installations d. Inspection before placing concrete e. Handling and placing of concrete f. Compaction of concrete g. Concrete surface finishing h. Concrete curing

15.1.3.4.3. Submittals

Prior to the works, the Contractor shall submit the following documents for the Engineer’s review and approval:

a. Quality assurance plan b. Applicable reference codes

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c. Sources and characteristics of concrete materials comprising cement, coarse and fine aggregates, admixtures, water and reinforcement d. Proposed concrete mix design accompanied by all relevant data for materials sources and testing e. Methods of concrete mixing, transportation, placing, compacting and curing f. Details of batching plant g. Quality control procedures comprising methods of sampling as well as site laboratory equipment and experience records and number of quality control personnel h. In addition to other requirements regarding design calculations and details of proposed construction methods including type of equipment, plans of execution and corresponding calculations i. Traffic management plan j. And other submittals which conform to 4.1.3.4.1 Quality Assurance

15.1.3.4.4. Tolerances

The concrete work shall be constructed to an accuracy which shall permit the proper assembly of components and installations and shall be compatible with the finish.

The accuracy of the work shall be within the tolerances shown on the drawings or specified elsewhere and in the absence of any other requirements, shall comply with the following:

 All laying out dimensions ±5 mm  Concrete surface level ±5 mm

15.1.3.5. Civil Miscellaneous Structures

This section shall consist of all Civil Miscellaneous Structures required for supply and installations necessary to complete the Civil Works for the extension of MRT3 Taft Pocket Track.

15.1.3.5.1. Submittals

The Contractor shall submit the following for the Engineer’s approval:

a. Detailed design drawings for each Civil Miscellaneous Structures and Materials b. Method and procedures for each Civil Miscellaneous Works c. Materials compliance certificate and testing results d. And all other submittals needed to complete the work

15.2. TRACK WORKS

15.2.1. General

The provisions stated in this document are related to the specific requirements applicable to the track system for the extension of MRT3 Taft Pocket Track.

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Trackworks system under this Contract shall conform to the most recent practices of the American Railway Engineering Association (AREA), Union Internationale des Chemins de Fer (UIC), International Standards Organizations (ISO) and the practices and specifications of recently constructed mass transit systems of equivalent capacity and characteristics constructed within the last five (5) years. It shall be of proven design satisfying the system performance requirements and shall be compatible with the existing MRT3 system. It shall also satisfy requirements with regards to train kinematic gauge, service life, reliability, maintainability and safety.

The works shall include design, supply, installation, test & commission and obtaining all permission from government authorities and everything whether permanent or temporary in nature necessary for safe and proper execution of work and fulfillment of all obligations required under this contract. It shall also include the training of the Employer maintenance personnel, supply of maintenance and repair manuals, as-built records and rectification of defects liability period of the installed ballasted tracks system.

15.2.1.1. Scope of Work

This section specifies the scope of work of the Contractor as follows:

a. Design, plan, supply and installation of all track materials required for the extension of Taft Pocket Track in order to accommodate a four-car train, i.e. to relocate a turnout in order to extend the Taft Pocket Track of about 19m.

b. The workmanship shall be in accordance to specifications and quality standards and shall not disrupt the MRT3 daily operations and adjacent traffic flow along EDSA.

15.2.1.2. Standards and Regulations

The work shall conform to the laws and regulations existing in the Philippines and shall generally be in compliance with the Philippines Standards and Codes of Practices unless specifically provided for in this document.

In addition, the following standards may be considered as long as they do not compromise the Employer’s Requirements

ACI - American Concrete Institute ANSI - American National Standards Institute ASA - American Standard Association AREA - American Railway Engineering Association CEN - Comité Européen de Normalisation ISO - International Standard Organization UIC - Union Internationale des Chemins de Fer JIS - Japanese Industrial Standards AS - Australian Standards BS - British Standards AASHTO - American Association of State Highway & Transportation Office

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ASTM - American Society for Testing and Materials PCI - Pre-stressed Concrete Institute

15.2.1.3. Special Site Conditions

The Contractor acknowledges that it has thoroughly investigated and satisfied itself as to all general and local conditions affecting the work. The failure of the Contractor to accustom himself with such conditions will not relieve him from any responsibility for completing the works under this contract. The Contractor shall be fully responsible for any damage caused to the site or other existing facilities due to his track works equipment movements and transportation and restore these damages to its original state at his own expense.

15.2.1.4. Design Criteria

The following data will constitute for the design of trackworks for MRT3:

a. Track gauge 1435mm b. Train speed 65kph c. Concrete tie spacing 750mm d. Rail inclination 1:20 e. Axle load 90kn f. Ballasts depth minimum 250mm Mainline g. Rail profile UIC 54 h. Depot track minimum radius 25m i. Concrete tie length 2500mm j. Concrete tie weight 250kg k. Concrete tie compressive strength 50Mpa l. Concrete tie stress transfer strength 30Mpa m. Pre-stressing wire diameter 6.5mm n. Pre-stressing wire ultimate tensile strength minimum 1700MPa

15.2.2. MATERIALS REQUIREMENTS

Trackworks materials needed for the extension of Taft Pocket Track shall be complete with all accessories and passed all the required testing in accordance to specifications and standards and shall be approved by the Engineer before incorporating to work. The Contractor shall ensure materials availability for small quantity production intended for maintenance use.

15.2.2.1. Ballast

Ballast shall be of crushed rock containing no carbonates or slag; it shall be hard, strong, angular, and durable particles. Ballast rock shall be highly resistant against crushing, grinding, and chemically inert. It shall be weather resistant and of homogenous structure. The Ballast shall be free from dust, soil, clay, plant matter and substances likely to be detrimental to the rocks.

15.2.2.2. Special Trackworks

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Unless specified, the materials required for the extension of Taft Pocket Track refers to the supply and replacement of timber ties and other defective fastening system that will not be suitable for their re-installation.

15.2.2.2.1. Switch and Crossing Ties

Switch and crossing ties shall conform to 4.2.2.3 Monoblock Concrete Ties

15.2.2.2.2. Joints

All special trackworks joints shall either be alumino-thermic welded by an approved welding materials and procedures for UIC 54 rail or insulated fishplates of approved materials and specifications.

15.2.2.2.3. Rail Fastening System

Concrete ties associated rail fastening system shall be Pandrol type e-series elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with UIC specifications.

15.2.2.3. Monoblock Concrete Ties

Concrete ties shall be monoblock pre-tensioned concrete. It shall be 250kgs and 2500mm long. Alternative concrete ties could be considered if they are compatible with the existing concrete ties in MRT3 in terms of general profile, dimension and strength. The Contractor must ensure that alternative designs must have a successful history performance of at least five (5) years in service under comparable conditions. Any alternative design must be specifically approved by the Engineer.

15.2.2.3.1. Concrete

The concrete minimum 28 days design compressive strength for concrete ties shall be 50 Mpa as determined by ASTM C39.

15.2.2.3.2. Aggregates

Both fine and course aggregates shall meet the requirements of the AREA specification for aggregates.

All aggregates shall pass all required testing and shall conform to Item 703 of DPWH Standard Specifications.

15.2.2.3.3. Admixtures

Chemical admixtures for concrete shall conform to ASTM C494. Additives containing chlorides shall not be used.

Suitable admixtures may be used to modify certain properties of concrete. However, as they may at the same time adversely affect other important concrete quality, the Contractor shall carry out testing on concrete to which they are added.

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15.2.2.3.4. Pre-stressing Tendons

The wire shall be 6.5mm diameter complying with ASTM A864 or ASTM 881 and shall have a minimum tensile strength of 1700 MPa. Tendons shall not be contaminated with mud, oil, grease or chloride salts. Tendons with corrosion shall not be used.

15.2.2.3.5. Rail Fastening System

Concrete ties associated rail fastening system shall be Pandrol type e-series elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with UIC specifications.

15.2.2.4. Timber Cross and Switch Ties

The ties shall be unbored and air dried hardwood of untreated Jarrah timber species for exposed mainline turnouts or any approved equivalent.

15.2.2.5. Rails

Standard rail cross-section shall be UIC 54 (54.43 kg/m) of grade 900A with a minimum tensile strength of 880 Mpa and shall meet the requirements of the UIC Standards.

15.2.2.6. Thermit Welding

This refers to the materials and other services required for joining UIC 54 using alumino-thermic welding process.

15.2.2.6.1. Thermit Welding Kits

Thermit welding materials shall be manufactured by Thermit Australia Pty Ltd or approved equivalent compatible to the existing welding materials used in MRT3.

15.2.2.6.2. Thermit Welding Equipment

Welding equipment and accessories required for welding operation shall be use and installed in accordance to manufacturer’s recommendation, contract drawings and applicable specifications.

15.2.2.7. Other Track Materials

Other track materials and appurtenances needed to complete the work shall be approved materials by the Engineer and installed in accordance to manufacturer’s recommendation, contract drawings and applicable specifications.

15.2.2.7.1. Insulated Rail Joints

Rail joints shall be made up of two rolled steel fishplates designed to fit UIC 54 rail profile and with four holes drilled by an approved drilling machine.

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Bolts shall be of high strength provided with spring and flat washers and shall conform to applicable UIC standards.

15.2.2.7.2. Check Rails

Check rail shall be machined from UIC 33 profile of not harder than grade 900A rail steel and supported by brackets connected to the rail. Bolt connection shall utilize steel components conforming to UIC leaflets 864/2.0 and 864/3.0 appertaining to technical specifications for the supply of track bolts and spring washers respectively.

15.2.2.7.3. Rail Fastening System

Concrete ties associated rail fastening system shall be Pandrol type e-series elastic rail clip manufactured by Pandrol Australia Pty. Ltd in accordance with UIC specifications.

15.2.2.7.4. Lubricants

The Contractor shall provide a dry film lubricant for application to special tracks sliding plates. It shall have a low electrical conducting properties and subject for Engineer’s approval.

15.2.3. CONSTRUCTION REQUIREMENTS

The Contractor shall be responsible for the construction means, methods, techniques, sequences and procedures for coordinating all portions of the Work under the Contract Documents.

The Contractor shall provide all superintendence during the execution of the Work as may be necessary for the proper fulfillment of the Contractor’s obligations under the Contract. It shall include the supervision and inspection by qualified professional personnel experienced in railway construction whose responsibility shall be to ensure the technical standards and workmanship, materials, and quality are being maintained in accordance with the Scope of Work.

The Contractor shall design, supply and install a ballasted tracks system which satisfies to the minimum requirements of the specification and Employer’s Requirements. The Contractor shall submit full details of the proposed design to the Engineer for review and approval and shall not commence until written acceptance has been received from the Engineer.

15.2.3.1. Ballasted Trackworks Construction

This section applies to construction of all ballasted tracks both plain and special tracks for MRT3 both Depot and Mainline.

15.2.3.1.1. Quality Assurance Program

a. The Contractor shall establish, implement and maintain a quality assurance program to provide verification of compliance with contract requirements. The quality assurance program shall consist of detailed

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procedures and instructions for monitoring and controlling those activities related to quality during design, fabrication, delivery, handling, storage, installation, inspection and testing. The areas which the quality assurance program shall address include the following:

 Review and control of quality procedures and instructions,  Calibration of construction measuring and testing tools and equipment,  Qualification and certification of Personnel,  Tests and inspections  Procurement quality assurance,  Identification and control of items, and  Handling, delivery and storage of materials.

b. Adequate records shall be maintained by the Contractor in accordance with the requirements of his quality assurance program and shall include the following:

 Evaluation of subcontractors’ and suppliers’ qualifications and past performance,  Results of inspections and tests,  Certificates of compliance,  Qualified procedures for special processes,  Personnel certifications,  Measuring and test equipment calibration certificates, and  Transmittals of contract related information.

c. The appropriate requirements of the Contractor’s quality assurance program shall be imposed upon subcontractors and suppliers.

d. The quality assurance activities of the Contractors/subcontractors and suppliers will be subject to Engineer’s verification, inspection and audit at any time.

15.2.3.1.2. Submittals

The Contractor shall submit the following:

a. The Quality Assurance Program b. Applicable reference codes c. Detailed construction schedule d. Detailed design and shop drawings for all Contractors supplied materials and other track materials required including fastening system for the construction of both ballasted track and special track works. e. Pre-construction inspection reports f. Qualifications of registered Surveyors g. Certificate of calibration for specified tools and equipment by independent testing laboratory accepted by the Engineer h. Details and arrangement of equipment, materials and personnel to be used during the various construction stages. Maximum construction

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loads shall be identified and submitted to the Engineer for review prior to any construction equipment being allowed to construction site i. Details for the protection of rails, special track works, other track materials and facilities from damage by construction equipment and road traffic, j. Production information forms and test reports on welds, k. Rail laying records, l. Calculation to determine Neutral Rail Temperature for Depot and Mainline. m. Method statement for natural or artificial de-stressing works for ballasted track and ballasted special track works both Depot and Mainline. n. Procedures for handling and anchoring CWR, o. Procedures for rail grinding and subsequent cleanup including a daily rail grinding log indicating grinding date, locations, number of passes of grinder, manufacturer and model number of grinder, p. And all other documents needed for the completion of the work and subject for Engineer’s review and approval.

15.2.3.1.3. Electrical Testing

The Contractor shall perform all tests of electrical resistance and continuity for insulated rail joints, running rail, running rail to running rail and track to earth.

Any installations which fail shall be rectified by the Contractor at his own expense and retested until acceptance by the Engineer.

15.2.3.1.4. Inspection

The Contractor shall inspect the construction area prior to installation of trackworks for any damages and discrepancies with propose installation plan and correct said discrepancies authorized by the Engineer.

15.2.3.1.5. Track Laying Construction for Ballasted Tracks

The Contractor shall submit method statement for a systematic rail laying construction for Engineer’s review and approval.

General ballasted tracks construction shall include the following procedures:

a. Survey and setting out correct tracks and special track alignment. b. Base preparation c. Placement of bottom ballasts on an approved base d. Placement of concrete sleepers or timber ties e. Placing of rails and fastening to concrete sleepers or timber ties f. Welding of rails to form continues welded rail g. Fastening of concrete sleepers or timber ties h. Placement of top ballasts i. Initial surfacing and aligning j. De-stressing work k. Final surfacing and alignment

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l. Test and inspection of finished tracks m. Site Cleaning

Refer to Table 1 “Track Construction Tolerances” where indicated the allowable geometric design variation for track work construction.

The Contractor shall assists the Engineer in his inspection of the finished track with a track geometry measuring device that capable of measuring various track alignment parameters with accuracy more than the tolerances specified in Table 1 “Track Construction Tolerances” and submit the print-out for Engineer’s approval and record. Any data being out of tolerance shall be rectify by the Contractor and shall be re-inspected by the Engineer.

Before final acceptance by the Engineer, the Contractor shall perform ultrasonic inspection of all running rails and special track works to detect flaws in rail, joints and welds.

15.2.3.1.6. Track Laying Construction for Ballasted Special Tracks

Special trackwork construction shall conform to Clause 4.2.3.1.5 Track Laying Construction for Ballasted Tracks except the use of track geometry measuring device since geometry alignment for special tracks will be checked manually.

15.2.3.1.7. Mockup Tracks

Not Applicable.

15.2.3.1.8. Final Acceptance

Before final acceptance by the Engineer, the Contractor shall perform and satisfy rail grinding of all rails to remove the corrosion and shall complete ultrasonic testing inspection to detect flaws for running rails, special trackworks and welded joints.

15.2.3.2. Ballast

The Contractor shall supply and install ballasts of approved materials required for the extension of the MRT3 Taft Pocket Track.

15.2.3.2.1. Testing Requirements

a. Grading

Size of Sieve Opening % Passing by Weight Ballast for MRT 3 (Size 3 AREA Manual)

63.5 mm 100%

50.8 mm 95-100%

38.1 mm 35-70%

25.4 mm 0-15%

12.7 mm 0-5%

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b. Deleterious substances present in prepared ballasts shall not exceed the following:

Percent by Material Method of Test Weight

Soft Pieces 5% AASHTO - T189 Fine less than No. 200 1% ASTM C117 Sieve Clay lumps and Friable 0.5% ASTM C142 Particles

Flakiness Index 20% BS 812

c. Percentage of wear shall not exceed 25% after testing in a Los Angeles abrasion testing machine in accordance with ASTM C535. d. The bulk specific gravity and percentage of absorption shall be 2.60 and 1% respectively in accordance with ASTM C127. e. The magnesium carbonate content shall be tested and defined in accordance with ASTM C25. No carbonates shall be allowed.

15.2.3.2.2. Submittals

The Contractor shall submit the following for Engineer’s review and approval:

a. Ballast source certificate of compliance b. Tests results mentioned in 4.2.3.2.1 Testing Requirements c. And all other test required to complete the work

15.2.3.3. Special Trackworks

The Work of the Contractor in this section refers only for the relocation of the existing 1:6 turnout and replacement of timber/switch ties and other associated fastening system that found defective during the execution of the work. It shall be in accordance to design, specifications, standards and scope of work.

15.2.3.3.1. Quality Assurance

Shall conform to 4.2.3.1.1 Quality Assurance Program

15.2.3.3.2. Submittals

The Contractor shall submit the following for Engineer’s review and approval:

a. Shop drawings showing details and arrangements of special trackwork relocation, b. Proposed welding, joining and test procedures for special trackwork, c. Contractor’s system specification for marking and identifying sizes, types and composition of products, as well as identifying parts for the purpose of proper location during installation,

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d. Certificates of material compliance required by this specifications, e. Test report of chemical analysis and Brinell hardness of running rail, electric insulation, and other tests required by this specification.

15.2.3.3.3. Inspection and Acceptance

For the inspection of material under this Contract, the terms set forth in “Materials Inspection, Test and Claims,” under the UIC Specifications for Special Track Work shall apply, except as listed herein.

The Contractor will make available to the Engineer all the necessary facilities to examine the work during its progress as well as the finished product to satisfy him that the materials comply with the Specification. The Contractor will provide templates and 1 meter straight edges to check flangeways, rail end, and switch rail planing.

15.2.3.4. Monoblock Concrete Ties

This section specifies the requirement for the supply and installation of pre- stressed monoblock concrete ties with complete rail fastening system compatible with the existing system of MRT 3.

15.2.3.4.1. Design Criteria

As specified in 4.2.3.1.4 Inspection

15.2.3.4.2. Marking, Delivery, Storage and Stacking

Mark on top of the ties with indented or raised letters to indicate the manufacturer, year of manufacture, mould number and project identification.

Contractor must securely brace ties during transportation to prevent from any movement that could cause damage. During transportation, ties should be in horizontal position supported with wooden spacer blocks so that the top surface does not make contact with ties loaded above. Do not stack ties more than 6 layers during transport.

The Contractor shall store concrete ties in a location that would avoid additional handling until the final distribution or within the area designated by the Engineer.

15.2.3.4.3. Quality Assurance and Inspection

Before production commences, the Contractor shall prepare a quality control manual for approval by the Engineer and shall include details of:

 Management organization  Responsibilities of production and quality control personnel  Plant standards  Checks to be carried out by the production personnel  Inspection and testing to carried out by quality control personnel  Procedures for approving sources of materials

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 Procedures to ensure all measuring equipment is properly calibrated  Procedures to ensure that concrete ties are not shipped until acceptance load testing is complete  Quality audit procedures

This section shall also conform to 4.2.3.1.1 Quality Assurance Program

15.2.3.4.4. Submittals

a. Quality control program b. Concrete mix design c. Concrete curing procedures d. Method and procedures for concrete ties production e. Tensile strength test results f. Rail fastening system technical specifications and drawings g. Pre-stressing wire technical specification h. All materials test results needed to complete the work and before incorporating to concrete ties production

This section shall also conform to 4.2.3.1.2 Submittals

15.2.3.5. Timber Cross and Switch Ties

This section comprises specifications for the supply and installation of new timber cross ties, switch ties, switch machine ties required for the relocation of MRT3 Taft Pocket Track turnout 1:6 of approved source and shall be compatible with the existing materials.

15.2.3.5.1. Quality Requirements

Ties shall be free of defects that may impair their strength or durability. Defects such as decay, large splits, large shakes, excessive grain slope, large holes and large knots will not be acceptable. All timber ties shall be cut by saw and the cross section shall be 225mm wide and 140mm deep. Standard cross- ties shall have a length of 2440 mm. Size and length tolerances shall be as follows:

a. Width - plus 10 mm/minus0 b. Depth - plus 12 mm/minus 0 c. Length - plus 50 mm/minus 0

Each timber shall be examined on the top, bottom, sides and ends. Cross and switch tie shall not exceed the following allowable amount of defects:

Type of Warp Allowable Amount

Spring 25 mm

Bow 9 mm

Crook 25 mm Cup 6 mm Twist 6 mm

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All ends of timber ties shall be cut square and provided by anti- split end plates. End plates shall be applied flush to the end surfaces of the tie and will remain securely seated and withstand rail vibration.

The Contractor is required to determine the number and dimensions of switch ties for each turnout and shall be specified in general turnout arrangement drawing and shall conform to dimension tolerances stated above.

15.2.3.5.2. Testing and Inspection

The Contractor shall assume full responsibility for all required testing and give the Engineers sufficient notice when testing in any form is proposed so that Engineers could inspect and witness the tests.

The Engineer may inspect the ties during production process or after delivery at the job site and or after placement on the grade for track utilization. Whether or not the Engineer test or inspect any materials, the Contractor will not be relieved from any responsibility regarding defects or other failures to meet the contract requirements.

15.2.3.5.3. Marking, Finishing and Workmanship

Ties shall be branded or marked permanently with approved materials to show ownership, manufacturer’s identification and year of production on one end.

Tie machining and workmanship shall follow and conform to the applicable standards.

15.2.3.5.4. Submittals

The Contractor shall submit the following requirements:

a. Quality control program for all method and procedures to ensure compliance with standards quality b. The name of timber and its source for approval, c. Timber ties Manufacturers specifications d. Official certificates of inspection in conformance with the reference standards including data regarding hammer band confirming timber grading, e. Data regarding proposed tie machining & stamping, f. The Inspectors report form duly accomplished (as described by the reference standards for Inspection of Timber Products) and submit to the Engineer prior to tie shipment from the production plant, g. Certification that the manufacturer has a minimum 5 years experience in manufacturing timber switch ties and as a supplier to major rail transit system. h. Completed tests results.

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15.2.3.6. Rails

This section specifies the supply and installation of required rails for the extension of MRT3 Taft Pocket Track in accordance to specification and standards.

15.2.3.6.1. Test Requirements

The Contractor shall perform the following tests:

a. Chemical composition analysis b. Mechanical property c. Tensile strength d. Brinell hardness test e. Shape, dimension and appearance inspection f. Ultrasonic test

Each rail shall be ultra sonically tested over its full length to determine its interior conditions prior to delivery to the work site. The rail must be free from all detrimental defects having unfavorable effect on the strength of the rail while in service.

The Contractor shall be responsible for all required testing and shall give Engineer sufficient notice of proposed testing so that Engineer may inspect and witness the tests in accordance to UIC specifications.

15.2.3.6.2. Quality Assurance and Inspection

This section shall also conform to 4.2.3.1.1 Quality Assurance Program

The quality system for rail manufacture shall be certified at least to ISO 9002 and shall be based on precise terms and conditions which ensure compliance with the various rail specifications.

The Engineer will monitor from time to time the Contractor’s methods, procedures, and processes for compliance with the accepted program and all records of test and inspection.

15.2.3.6.3. Marking, Packaging, Handling, Transporting, and Storage

a. Obligatory marks in the UIC 54 rail shall be in accordance with UIC Code 860 O as follows in-relief marks which shall be very legible in characters raised on one side of the web indicating:

 Identification mark of the mill,  Year of manufacture (last two figures),  Symbol of steel grade, and  Symbol of rail section in kg/m weight

b. The Contractor shall submit for approval a detailed procedure for marking, packaging, delivery, handling, transporting and storage of rails. Contractor shall take all necessary precautions to ensure that rails will not be bent, deformed or damage during handling and

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transporting and it shall be kept clear of any standing water during stacking and storage.

15.2.3.6.4. Submittals

The contractor is required to submit the following:

a. Certification that rail manufacturer has at least 10 years experience in the large scale manufacture of running rails as specified herein and as a supplier of rail to major railroads and transit systems. b. Certification from supplier or manufacturer that all the rails manufactured and delivered on site are in conformance with UIC specification and that the required tests were performed as represented by the submitted test result. c. Tests Certificates as prescribe in 4.2.3.8.1 Rail Welding d. Detailed production process of rails e. Certification of the manufacture’s process in accordance to ISO 9002. f. And all other documents needed for the completion of work.

Rails shall be guaranteed by the supplier/manufacturer from date of manufacture plus 5 years to the date of acceptance of works against any defects attributable to manufacture. 15.2.3.7. Track Appurtenances and Other Track Materials

This section specifies the requirements for the design, supply, and installation of other track materials required for the extension of MRT3 Taft Pocket Track.

15.2.3.7.1. Submittals

The Contractor shall submit all detailed design drawings for each trackworks materials in accordance with applicable specifications and subject for Engineer’s review and approval.

a. Detailed design drawing for each Other Track Materials and corresponding fastening system b. Installation methods and procedures c. Materials manufacturer specifications d. Material compliance certificate and testing results e. And other submittals required to complete the work

15.2.3.8. Welding of Rail

Unless specified, this section specifies the furnishing of all labor, material, equipment and services by the Contractor which are necessary for joining new UIC 54 rails using alumino-thermic welding process in accordance to approved specifications, standards and manufacturer specification for materials and equipment.

15.2.3.8.1. Rail Welding

Welding process shall include the following procedures:

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a. Inspection of rail ends b. Rail cutting and set the required gap c. Loosening of rail fastenings d. Rail end preparation and alignment e. Preheating and welding f. Finishing and alignment g. Weld testing h. Replacement of defective welds i. Records of thermit welding

Each procedure shall be in accordance with the AREA Manual for Railway Engineering, the products or welding kit specifications itself and other applicable standards.

15.2.3.8.2. Quality Assurance

This section shall conform to requirement in 4.2.3.1.1 Quality Assurance Program

15.2.3.8.3. Weld Testing

All weld testing and submittals shall be performed by a duly accredited independent testing laboratory in accordance with quality control requirements and applicable standards. In order to qualify the welding kits, welding crews, and production welds; the following test shall be carried out:

a. Radiographic testing b. Ultrasonic testing c. Slow bend testing d. Hardness test e. Rolling load test f. Magnetic particle test g. Visual test

15.2.3.8.4. Tolerances

All alumino-thermic welds will be in the suspended portion of rail between supports. The weld shall not encroach 150mm from tie ends or baseplate support. Finished weld using 1 meter straight edge shall have the following tolerances:

a. Rail head surface +0.3 / 0.0 mm b. Rail gauge face +0.3 / 0.0 mm

15.2.3.8.5. Submittals

The Contractor shall submit the following:

a. Detailed specifications, proposed materials, methods and procedures to be used for the thermit welding process, b. Certification from the supplier or manufacturer that the materials delivered to site conforms to the specifications,

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c. Welding supervisor qualifications with a minimum 3 years thermit welding experience. The welding supervisor shall be replaced only with the Engineer’s prior approval, d. All material testing and weld test results, e. Test equipment certificate and calibration, f. And all submittals shall be in accordance with 4.2.3.1.2 Submittals TABLE 1 TRACK CONSTRUCTION TOLERANCES

Gauge Cant / Cross Horizontal Vertical Type of Track Variation Level Alignment Alignment

Mainline -2, +3 mm ±3 mm ±3 mm ±3 mm Ballasted Track

Depot Ballasted N/A N/A N/A N/A Track

Notes: 1. Variation is measured between the designed and actual alignment at any point in the track 2. Horizontal alignment is measured in mm by 10m chord placed at the gauge line of the rail running face. 3. Vertical alignment is measured in mm by 10m chord at the head of the datum rail. 4. Rail cant may vary between 1 in 18 and 1 in 22 5. Maximum twist is 1 in 1000.

15.3. SIGNALING

15.3.1. Introduction

The Terms of Reference (TOR) for the Pocket Track Extension Project under Signaling System defines the scope of works to be undertaken in the extension of pocket track.

The Signaling Upgrade shall not be included in this contract. The upgrade of the signaling system shall be carried out by the Signaling Provider of the MRT3.

The contractor shall follow the design requirement and specification of the Signaling system to make the Power & OCS system, Civil Works and Track Works fully integrated to the Signaling system.

15.3.2. Background

Few months prior to the opening of MRT 3 line (Buendia to Taft station) to the public on July 2000, the Pocket Track which is linked to the Northbound track of Taft Avenue was discovered to have insufficient length to accommodate the safe operation of a 4-car train passing from South side of the Pocket Track. Series of meetings and

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discussions have been held between the Contractors, Engineers and Owner to resolve the issue and finally decided to optimize the pocket track by allowing passage of 3-car train only. Consequently, the ATP balises were relocated to effectively protect the train’s operation even considering the worst case scenario of trespassing down the pocket signal in restricted aspect.

Optimization of pocket track was done through the relocation of balises which consummates the braking distance of the train. The braking distance calculation was based on the following data:

 Vehicle condition - Empty  Brake Deceleration - 2.09 m/s²  ATP antenna to vehicle face distance - 2.8 m st  1 wheel to vehicle face distance - 3m  Gradient - 0.146 %  Over-run speed passing the red signal - 19 KPH

After the relocation of balises, the testing was subsequently undertaken. The 3-car train operation successfully passed the test. The Contractor henceforth issued a safety certification that the pocket track is passable to 3-car trains and guaranteed that the installed ATP was functioning normally whatever the situation or scenario.

The test for the 4-car train operation was also conducted in the pocket track and the result showed that the fouling point clearance requirement was not able to satisfy the safety criteria. 15.3.3. Recommendation

In order to meet the requirement for the complete operation of 4-car train configuration in the pocket track, the only option is to extend the track at the northern side (going to the direction of Magallanes station), which will include the following major activities:

a) Re-design / removal / replacement of wall structure. b) Re-design / removal / replacement of tracks including ballast and installation of additional rails and accessories. c) Re-design / removal / replacement of Overhead Catenary Section (OCS) including posts and installation of additional OCS and post. d) Re-design / removal / relocation / replacement of Signaling equipment including hardware/software.

15.3.4. Pocket Track Data

The data presented herein are actual parameters gathered at site which may serve to aid the Contractor in the conceptual redesign of the pocket track. However, it is the Contractor’s obligation to confirm the accurate data through site survey before using them as parameters in the detailed engineering design.

Location of Pocket Track Northbound Track, approx. 300 meters from Taft Avenue Station

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Distance Between Signals 138 m Straight Track 130 m 3-car Train Length 97 m IRJ to IRJ Distance 133.8 m 4-car Train Length 127 m Length Between ATP Antennas (4-car) 121.4 m Track Circuit TX and RX Distance 1m from IRJ

15.3.5. Pocket Track Operation

The pocket track is a temporary stabling area for reserve train or even defective train. Trains can enter in the south side and exit on the north side through route setting. Train may also exit from the south side going to Taft Avenue station through manual route setting. Nevertheless, the automaton cannot be used in the pocket track operation.

15.4. POWER SUPPLY AND OCS

15.4.1. General Requirements

With the intention to extend the length of the Taft Pocket Track to accommodate four- car trains, the OCS for the TPT shall have to be extended as well.

15.4.1.1. Re-Configuration and Extension of the OCS

This Specification defines the minimum requirements to be met by the Contractor’s proposed reconfiguration and extension of the OCS along the Pocket Track.

The OCS supplied and erected under this Contract shall be integrated and compatible with the existing OCS system installed on the MRT 3 line. The new installation shall satisfy the requirements with respect to vehicle envelope, pantographs, interface, service life, safety, reliability and maintainability.

All OCS assemblies, fittings and components removed from the existing installation shall be reused wherever possible for the new installation.

Prior to Contract Award, the Contractor must demonstrate that he has a very clear understanding of the existing OCS Equipment and Systems. In this connection visits to MRT 3 are mandatory during the tendering period to ensure that the Contractor is fully aware of the present ‘as installed’ systems and the necessity for compatibility and integration with the new equipment and systems.

As the Works under this Contract will involve activities on a ‘live’ railway, the Contractor shall adopt and adhere to the Operator’s Rules of Procedures at all times. All works shall be done during non traffic hours.

Under no circumstances, shall the Contractor cause disruption to the revenue service. All staging works, timing and method statements shall be approved by the Engineer before any night or day work is permitted to commence.

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15.4.2. The Existing OCS System

The existing OCS system is of traditional metro design for a 750 Vdc railway utilizing pole mounted cantilevers, messenger wires, droppers, contact wires, tensioning devices, anchor blocks, section insulators, insulators and guy wires. The existing track length within the Pocket track is 110 m and the extension will add a further 19 m.

The Contractor’s attention is drawn to Section VII Drawings, which shows the present configuration and linkage to the Mainline.

15.4.3. Scope of Works

The Scope of Works shall include but not limited to:

 Detailed design, procurement, delivery, installation, testing and commissioning.  Integration of the new tension lengths with the existing system utilizing the same assemblies and components or equivalents as presently installed.  Interfaces with civil, track and signaling works.  Replacement of contact wires, messenger wires and droppers.  Rearrangements of tensioning devices and anchors.  Electrical and Mechanical design calculations.  Submission of material samples for approval by the Engineer inclusive of corrosion protection such as galvanizing and steel MIL specifications.  Rectification of defects during DLP.  Training of the Owner’s maintenance staff.  O&M manuals inclusive of parts catalogue, repair instructions, maintenance instructions, test results from commissioning.  As built drawings, schematic drawings, line diagrams, interface drawings and dimensional/tolerance criteria.  Recommendations for the provision of spares and special tools in liaison/coordination with the Owner’s Maintenance Provider.

15.4.3.1. Contractor’s Responsibility

The Contractor shall take full responsibility for the detailed design, construction and performance of the OCS under this section of the overall Contract.

15.4.4. Catenary Conductors

2 Contact wire shall be made up of 170mm solid grooved hard drawn copper conforming to ASTM B47. The upper lobe of the contact wire shall match the existing contact wire installed at MRT 3 to assure interchangeability of clips. Other contact wire particulars include:

 Weight : 1.511 kg/m  Breaking Load : 5900 kg -5 0  Coefficient of Expansion : 1.7 x 10 / C 0  Resistance @ 20 C : 0.1040 Ω/km 2  Modulus of Elasticity : 12000 kg/mm

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Conductor tensions shall be in accordance with the requirements of appropriate ASTM standards. Thirty percent cross-sectional area loss due to wear of the contact wire and the effect of the temperature change shall be taken into consideration in the design of the conductor tension and ampacity.

The ampacity of the OCS shall meet the operational requirements of four-car trains running at 120-second headways with a traction power configuration proposed in the Concept Design Drawings.

15.4.4.1. Insulators

Insulators shall be porcelain, toughened glass polyester or other material with proven rail or railway system service. Insulators shall have a single or multiple sheds designed for minimum maintenance requirements and be self cleaning by the action of rain. Double insulation is not required as it is not intended to carry out ‘live line’ work.

15.4.4.2. Splices

Each wire run of contact wire must be continuous from anchor to anchor except in the case of cut-in insulators. Contact wire splices shall not be permitted. Feeder wires may have splices as required to connect drum lengths of conductor. The manufacturer shall warrant that splices are capable of withstanding tensions up to 100% of the breaking load of the conductor.

15.4.4.3. Section Insulators

The OCS Contractor is to provide Section Insulators at locations indicated.

The Section Insulators (SI) shall be designed and installed in such a way that it shall provide a smooth passage to pantographs without any loss of contact and without the introduction of unreasonable mechanical forces.

The SI shall permit the pantograph on the vehicle to collect the maximum demand current without interruption during passage across the SI.

16. NORTH TURNBACK

In conjunction with the plan of DOTC- MRT3 to connect LRT Line 1 and MRT3 for the convenience of the riding public, the “Terminal Station” of LRT Line 1 is to be constructed near Trinoma.

The LRT Line 1 “Terminal Station” is planned to be located adjacently to MRT3 North Avenue Station. The said station shall have connecting walkways for the easy transfer of passengers from Line 1 to MRT3 and vice versa.

Consequently in this concept, the area where the existing turn-back facility of MRT3 would be affected by the “Terminal Station” of LRT Line 1, the turn-back facility of MRT3 at the North Avenue Station will be modified to a double crossover turnout.

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The new double cross-over turnout shall be constructed using track slabs methodology. The track slab is deemed to be the best option considering that there is an existing track structure at the site where the new turnout will be installed.

16.1. SIGNALING

The Signaling works shall not be included in this contract.

The contractor shall follow the design requirement and specification of the Signaling Provider to make the Power & OCS system, Civil Works and Track Works fully integrated to the Signaling system.

16.2. CIVIL WORKS

The turn-back facility of MRT3 shall be transferred to the front-end (north-end) of the North Avenue Station using a double crossover turnout.

The new double cross-over turnout shall be constructed using track slabs methodology.

The civil works on the MRT3 North Avenue turn-back facility shall not be included in this contract.

16.3. TRACK WORKS

A new double cross over turnout utilizing track slab methodology shall be constructed at the north-end side of the North Avenue Station.

Please refer to Section VII Drawings A.5.1 for the illustration of the said new turnout.

The track works on the MRT3 North Avenue turn-back facility shall not be included in this contract.

16.4. CIVIL WORKS

16.4.1. General

This applies to the non- ballasted plain line on the structure in the main line and on the non-ballasted turnouts. The concrete plinth rest on the elevated structure deck and transmits the train loads to the deck. The integrity of the track structure in retaining track gauge and security of the rail requires that the plinth do not move on the concrete deck.

The concrete plinth should not be subjected to extraneous forces from the flexing of the structure. This is ensured by the plinth being made in discrete lengths and not being continuous. The lengths of plinths are planned at 4.0 meters for curved track with 600 mm fastening spacing and 3.55 meters for the 750 mm fastener spacing of straight track (>600 meter radius).

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The design of plain line non-ballasted track structure assumes the following: continuous welded rail, plinth design with plinth anchors, starter bars and key concrete surface of the structure, discrete supports (not continuous support), baseplates anchored to plinth, rail elasticity fastened to baseplate and rail to baseplate insulated. To ensure the integrity of the track structure, the concrete plinth to the deck connection needs to be checked for:

a. Lateral shear under lateral holdings

b. Stability against overturning of the plinth

c. Resistance against longitudinal movement of the plinth

The objectives of the non-ballasted track design will be continuous welded rail, discrete (not continuous) support to enable matching of rail head top and running faces when changing rails or making repair insertions to worn rail during maintenance, ability to make alumino-thermic welds during both constructions and maintenance and ability to accommodate hog, sag and other tolerances to the finished supporting structure.

The plain line non-ballasted track structure may be different in the case of turnouts. There will be also local adjustments to the non-ballasted track design for items such as expansion switches with baseplates. The objectives of non-ballasted track structure for switch and crossing work will be as for the plain line track with the following additional points: ability to use the same or eliminate the steelwork components of switches and crossings, including the baseplates used on ballasted tracks, ability to attached powered point machines on required side (or either side), ability to make reliable attachment of stockrails and switches for signaling to ensure closure and detection of switch toes and ability to accommodate switch machine rodding, clamplocks etc. as required by the signaling.

16.2.1.1. Scope of Work

This section defines the scope of work of contractor which is design, supply and installation of new double cross-over turnout with complete ancillaries at the existing North Avenue Station turnback, such as but not limited to plinth/switch ties fasteners, switch/guard rails and relocation/installation of existing & new motorized switches with LOB.

The workmanship shall be in accordance with specification and quality with minimal disruption to MRT3 operations.

16.2.1.2. Standards and Regulations

The work shall conform to the laws and regulations existing in the Philippines and shall generally be in the compliance with the Philippines Standards and Codes of Practices, unless specifically provided for in this document.

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In addition, the following standards may be considered as long as they do not compromise the Employer’s Requirements

ACI - American Concrete Institute

ANSI - American National Standards Institute

ASA - American Standard Association

AREA - American Railway Engineering Association

CEN - Comité Européen de Normalisation

ISO - International Standard Organization

UIC - Union Internationale des Chemins de Fer

JIS - Japanese Industrial Standards

AS - Australian Standards

BS - British Standards

AASHTO - American Association of State Highway & Transportation Office

ASTM - American Society for Testing and Materials

PCI - Prestressed Concrete Institute

The standards and codes used for the track materials shall be as for the relevant material specification, such as UIC and JIS.

The standard and codes used for the concrete works shall be as for the civil engineering works on the project. This shall apply for such items as

 Cement  Concrete mixes and finishes  Reinforcement

16.2.1.3. Design Criteria

Loads: a) Vertical Loads

1) Wheel Loads (refer to attached MRT3 axle load and 5.2.1.4) 2) Centrifugal Force (lateral and resultant vertical) 3) Wind (lateral and resultant vertical)

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