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, 125 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 22 126 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. 127 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. 128 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.