EDILON Dex -K 2K - Contracts Finder
Transcription
EDILON Dex -K 2K - Contracts Finder
Product information sheet EDILON Dex®-K 2K 1 DESCRIPTION EDILON Dex-K 2K is a specially developed two-component adhesive system for wooden sleepers track retrofitting and lifetime extension, and the structural adhesion of a wide range of materials. The excellent mechanical properties of EDILON Dex-K 2K and its high adhesive strength on steel and wood are combined with a high compression strength and flexibility. 2 INTENDED USE 3 FEATURES & BENEFITS 4 POINTS OF ATTENTION 5 COMPOSITION EDILON Dex-K 2K is used in railway track applications for the recovery of the base plate to sleeper interface, repair of the screw hole integrity, bonding of the sleeper screws and resinification of wooden sleepers located in switches and crossings, and straight and curved track. In civil engineering applications EDILON Dex-K 2K is especially used as a universal adhesive system for structural bonding under aggravating circumstances. Features Benefits • High mechanical properties + Guarantees a strong and durable bond • Universal adhesive system + Excellent adhesion on a wide range of materials • Excellent adhesion on impregnated wooden sleepers • Fills up cracks in worn-out wooden sleepers + Improved load introduction will extend sleeper lifetime + Resifinication will strengthen the sleepers + Reduces indentation + Splitting of the sleepers is prevented • Fills sleeper screw holes + Improved and durable fixation of sleeper screws + No clearance needed therefore spring washers can be omitted + Encapsulates screws thus protecting against corrosion + Recovers sleeper damage due to hole drilling • Extends the lifetime of wooden sleepers + Reducing the risk of track failure + Improving track quality + Strong reduction of track Life Cycle Costs • Applicable under moist conditions • Preservation of performance at – 20° C till + 50 °C + Application conditions are not critical + Also applicable during rainy weather • Two component cartridge packaging + + + + + • Mixing control due to different component colours + Well mixed when homogeneous grey colour is obtained Ready for use Always the right mixing ratio Increases productivity Almost no loss of product Used cartridges can be used later with a new static mixer Explanation Point of attention • • Maximum layer thickness 10 mm This because of possible shrinkage at thicker adhesive layers EDILON Dex-K 2K is a solvent free, two-component adhesive based on special resins and mineral fillers. Refer to the EDILON Dex-K 2K Material Safety Data Sheet for more detailed information. 6 PRODUCT APPROVAL Network Rail – UK acceptance certificate PA05/00110/PU ProRail – NL edilon)(sedra bv Nijverheidsweg 23 NL-2031 CN Haarlem Product information sheet EDILON Dex-K 2K P.O. Box 1000 NL-2003 RZ Haarlem T +31 / (0)23 / 531 95 19 F +31 / (0)23 / 531 07 51 Reference: Page: [email protected] www.edilonsedra.com DATA Dex-K 2K (GB) 080204 rev 00 1 of 6 EDILON Dex-K 2K is supplied in cartridges of 600 ml for use with the EDILON Pneumatic cartridge dispenser or in a 25 kg packaging for use with the two component mixing and dispensing machine. 7 PACKAGING Both units are packed in the correct individual mixing proportions. The assembly packaging of EDILON Dex-K 2K is 16 units, static mixers included. Store EDILON Dex-K 2K either in the depot or at the place of work under dry conditions, in wellsealed containers and away from direct sunlight. The prescribed storage temperature lies between + 10 °C and + 30 °C. 8 STORAGE AND SHELF LIFE In its original, well-sealed packaging and under the above-mentioned conditions the EDILON Dex-K 2K has a shelf life of 18 months maximum. 9 CHEMICAL & PHYSICAL PROPERTIES Property Density cured product Standard DIN 53 479 Value 1.72 ± 0.05 Colour mixed product Grey Colour component 1 White Colour component 2 Black Units g/cm³ Viscosity component 1 at +23 °C EN ISO 3219 80 Pas Viscosity component 2 at +25 °C EN ISO 3219 106 Pas Viscosity mixed product. at +25 °C EN ISO 3219 46 Pas Mixing ratio by weight component 1 : component 2 100 : 117 Mixing ratio by volume component 1 : component 2 100 : 100 Reactivity at + 25 °C (viscosity 200 Pas) • • ISO 10364 11 Additional information minutes Test results, are determined with cured material after 7 days at a temperature of + 20 °C, unless specified otherwise. The applied test samples and test methods can be changed without further notice. Product information sheet EDILON Dex-K 2K Reference: Page: DATA Dex-K 2K (GB) 080204 rev 00 2 of 6 10 MECHANICAL PROPERTIES Property Standard Tensile strength EN ISO 527 Modulus of elasticity EN ISO 178 Flexural strength EN ISO 178 Shear strength ASTM D1002 Tensile strength steel Value Unit 34 MPa 6300 MPa > 75 MPa > 15 MPa ISO 6922 > 38 MPa Compression strength after 24 hours EN ISO 604 > 110 MPa Compression strength after 7 days EN ISO 604 > 110 MPa Hardness after 24 hours DIN 53 505 90 ± 5 Shore D Hardness after 7 days DIN 53 505 90 ± 5 Shore D Hardness at + 100 °C) ISO 188 54 ± 5 Shore D Surface wear resistance (TWA) ISO 9352 < 541 µl / 1000 rotations Adhesive properties steel (St37-2) EN ISO 4624 > 40 MPa • • > Additional information Test results, are determined with cured material after 7 days at a temperature of + 20 °C, unless specified otherwise. The applied test samples and test methods can be changed without further notice. 11 SURFACE PRE-TREATMENT The durability of the system, in which EDILON Dex-K 2K is applied, is directly dependent on the pre-treatment of the surface prior to the application. For optimum adhesion performance the prepared surface should be clean. EDILON Dex-K 2K is applied directly after surface pre-treatment. Steel surfaces: In order to obtain optimal adhesion on steel surfaces, surface pre-treatment must be carried out at all times. Loose parts, dust and dirt, mill scale, rust and other contaminants must be thoroughly removed from the steel surface. In case of galvanized steel the surface must be free of zinc salts as well. IMPORTANT NOTE: EDILON Dex-K 2K must be applied as quickly as possible after the pretreatment the steel surfaces. Steel surfaces must be completely dry prior to application. In order to avoid that rust develops in the time between preparation and application, steel surfaces could only be stored in dry conditions. • Untreated steel: Blast cleaning to meet the demands of Sa 2.5 according to EN ISO 8501-1. The surface roughness Rz should be 50-70 μm. • Galvanized steel: Sweep blast cleaning with a non-metallic type of abrasive according to NEN 5254 Wooden surfaces: In order to obtain optimal adhesion on wooden surfaces, surface pre-treatment must be carried out at all times. All wooden surfaces must be sound, and dust, dirt, grease, loose parts or any other contaminants must be thoroughly removed. A wooden surface that has been grinded or milled is considered sufficiently prepared after blowing off all loose parts and dust. 12 USER INSTRUCTIONS Refer to the EDILON Dex-K 2K User instruction sheet for detailed application instructions. Product information sheet EDILON Dex-K 2K Reference: Page: DATA Dex-K 2K (GB) 080204 rev 00 3 of 6 13 APPLICATION CONDITIONS Conditions Value Additional information Surface Dry – wet, clean Only apply the product on pre-treated surfaces (see 11.) To determine visually Weather conditions Dry - wet Or in a conditioned environment Air temperature + 5 °C till + 35 °C Surface temperature + 5 °C till + 35 °C Product temperature + 15 °C till + 30 °C • Applies to any surface on which the product is applied. At sunny and light cloudy weather, the surface temperature is always higher than the air temperature due to radiation heat from the sun Recommended measuring device: TQC Dew Check. 14 SAFETY RECOMMENDATIONS During application of EDILON Dex-K 2K, it is imperative that protective clothing, rubber gloves and safety goggles are worn. Provide sufficient ventilation when working with EDILON Dex-K 2K. Before using EDILON Dex-K 2K, please refer to the packing label and the EDILON Dex-K 2K Material Safety Data Sheet for more detailed safety recommendations. EDILON Dex-K 2K must be stored in the original well-sealed packaging. 15 MIXING EDILON Dex-K 2K is mixed by the use of a static mixer in combination with an EDILON Pneumatic cartridge dispenser which achieves a maximum pressure of 8 bar. Always check the correct mixing prior to use EDILON Dex-K 2K and after changing a static mixer. A correct mixing can be recognized by the homogeneous grey colour of the mixed product. Dispense at least 6 cm of mixed material until this homogeneous grey colour is obtained. For the application of EDILON Dex-K 2K at temperatures below + 20 °C edilon)(sedra advises to use the EDILON Cartridge heater type 2002. By use of the cartridge heater the cartridges EDILON Dex-K 2K are heated to a maximum of + 30 °C. For an optimal use of the EDILON Dex-K 2K, the product temperature must be at least + 20 °C. When during or after the use of EDILON Dex-K 2K mixing failures are noticed, all adhesions performed with the failed cartridge should be removed. The properties of EDILON Dex-K 2K will only be achieved after correct mixing of both components. The processing time of the EDILON Dex-K 2K is depending on the product temperature and the amount of mixed product. As an indication the processing time related to the product temperature is presented in the following table. Product temperature [ °C] Processing time [minutes] 15 20 25 30 20 13 11 9 Product information sheet EDILON Dex-K 2K Reference: Page: DATA Dex-K 2K (GB) 080204 rev 00 4 of 6 16 CURING The minimum curing time of EDILON Dex-K 2K is related to the surface temperature. Material can be exposed after the minimum curing time to a short (less than 1 minute) load. After 24 hours the material can be fully loaded. Surface temperature [°C] 17 CLEANING 18 DISPOSAL CONSIDERATIONS Minimal curing period after mixing [hours] 5 11 10 4.5 15 3.5 20 2.5 25 1.5 30 1 35 0.5 Clean used tools immediately after use with EDILON Toolcleaner. Refer to the EDILON Toolcleaner Material Safety Data Sheet before use. The following waste products can arise at the application of EDILON Dex-K 2K: Description Type of waste Cured product Non-hazardous waste Waste code - Packaging with cured product Non- hazardous waste - Packaging with component 1 or component 2 Hazardous waste 15 01 10 Packaging with uncured product Hazardous waste 15 01 10 The waste products should be incinerated in a suitable installations and according to the local authority regulations or disposed according to the prescriptions of the European list of waste products. 19 PRODUCT ADVICE Before deciding upon the use of the EDILON Dex-K 2K system for an application, we strongly advise contacting edilon)(sedra to discuss the correct system choice and at the same time to take advantage of our extensive experience in design and application. All technical information given in this Product Information Sheet is based on many years experience and is correct to the best of our knowledge. As the technical information given here is of a general nature, it is therefore not intended for specification purposes. Product information sheet EDILON Dex-K 2K Reference: Page: DATA Dex-K 2K (GB) 080204 rev 00 5 of 6 The edilon)(sedra advice in regard to technical applications either verbal, written or by means of experiments is given in good faith and to the best of our knowledge. It is given as a general indication and without obligation, also in respect of third party protection. This does not remove the users obligation to control that the delivered edilon)(sedra product is suitable for the intended purpose and that the necessary precautionary measures have been taken. Application, use and processing of the edilon)(sedra products take place outside the control possibilities of edilon)(sedra. They therefore fall under the responsibility of the end user. Naturally, edilon)(sedra stands by its guarantee of the quality of its products. We kindly refer you to our standard sales conditions. It is sometimes useful to perform application tests or to develop special variations for certain projects. For more detailed or specific information concerning specifications and applications please contact edilon)(sedra. By issue of this product information sheet earlier revisions are no longer valid. Applicable sampling and test methods are subject to change without notice. All rights reserved. No part of this publication may be reproduced and/or published by print, photo print, microfilm or any other means without the prior written consent of edilon)(sedra bv. ® EDILON Dex is a registered trademark | = CHANGES COMPARED TO THE PREVIOUS VERSION, ALWAYS CHECK THAT YOU HAVE THE MOST RECENT REVISION. 080204/2005-1201-3/0808 rev 00 Date of issue: 29-08-2008 edilon)(sedra bv Nijverheidsweg 23 NL-2031 CN Haarlem Product information sheet EDILON Dex-K 2K P.O. Box 1000 NL-2003 RZ Haarlem T +31 / (0)23 / 531 95 19 F +31 / (0)23 / 531 07 51 Reference: Page: [email protected] www.edilonsedra.com DATA Dex-K 2K (GB) 080204 rev 00 6 of 6 DLR Beckton Link Viaduct Confidential Appendix D. Product Data Sheet for Timber Treatment 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 32 DLR Beckton Link Viaduct Confidential THIS PAGE INTENTIONALLY BLANK 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 33 Osmose, TechnicalDataSheet TDS1789 April2004 CelcureAC-500 for industrialvacuum CelcureAC-500liquid concentrofe DESCRIPTION PROPERTIES CelcureAC-500 is a water-basedwood preservative system, whichcontainsan alkalinecopperquaternary including an organic co-biocide (a quatemary andboricacid. compound), Colour: CelcureAC-500concentrateis blue. Density:1.23gtcm3at 20 'C. : Solublein water. Miscibility andsweet,amineodour. Odour: Slightammoniacal pH: 10.6 and CelcureAC-500is suppliedas a liquidconcentrate dilutedsolutionsare appliedto timberin an industrial, controlledtreatmentprocessusing vacuum pressure impregnation. PACKAGING and STORAGE IBC or bulk. CelcureAC-500concentrateshouldbe stored in a designated, lockable area to prevent access.Keep away from food, drink and unauthorised stuffs. animalfeeding FORUSE RECOMMENDATIONS APPROVAL CelcureAC-500is for use onlyas a woodpreservative. CelcureAC-500liquidconcentrateis dilutedwith water to obtain a Treating Solution with a concentration between1o/oand 10% m/m,accordingto the treatment specification. CelcureAC-500is approvedby the UK Healthand Safety Executive under The Control of Pesticides Regulations1986 (as amended)for use as directed. HSE No. 7404. The approvalholder and marketing companyin the UK is ProtimSolignumLimited. Mixingof the productfromthe IBCor bulkstoragetank should be with an automateddosing system.This requiresminimaloperatorinvolvementand reduces on exposureof the operatorto the product.Information the useof the systemcan be obtainedfromOsmose. CelcureAC-500containscoppercarbonatehydroxide, benzalkonium chlorideandboricacid. Precautions The handlingand safety precautionsshown on the and CelcureAC-500productlabelmustbe understood followedat all times.Use only as describedon the label.See the CelcureAC-500productlabeland the MaterialSafetyDataSheetfor furtherinformation. Care must be taken to avoid exposure,particularlyto the eyes and by inhalation,so appropriatepersonal proteitiveequipmentmust be worn. Wash splashes fromskinor eyesimmediatelY. to fishand otheraquaticlife. The productis dangerous or ground. watercourses Do notcontaminate Alwaysreadthe label.Usepesticidessafely. CelcureAC-500freofingsolulion DESCRIPTION CelcureAC-500treatingsolutionis a dilutionwith water to a concentration of CelcureAC-500liquidconcentrate, mlm. between1o/oand1oo/o It is applied to timber in an industrial,controlled treatment process using vacuum pressure impregnation. PROPERTIES materials Colour:CelcureAC-500treatingsolutionis blue. Disposeof surpluschemical,contaminated (includingsawdust)and the empty containersafely Density:3o/omlmsolution: 1.0g/cm"at 20 'C. using a method approved by the waste disposal Odour:Slightlysweet,amineodour. pH:3%m/msolution:9.4 authority. Whenusingdo noteat,drinkor smoke, -rnst\ z:f ta- l r--r l\z-rBS EN ISO 9001 BS EN ISO 14001 FM1724 Et\,4S36409 FM2075 Rn Osmos€ company FORUSE RECOMMENDATIONS Gelcure AC-500 preserved wood Timber shallbe clean,dry,and not Thetimberto be preserved decayedby fungior attackedby insects.The moisture content of the wood shall be appropriatefor the preservative treatmentmethodandend use.At the time the timber moisturecontentmust be of preservation 30 % belowthe fibre saturationpoint (approximately mim). DESCRIPTION Celcure AC-500 preserved wood has been preserved by the applicationof a 1 o/oto 10 o/om/m solution in water of Celcure AC-500 liquid concentrate, in an industrial,controlled treatment process using vacuum pressureimpregnation,and then allowedto dry. Application Preservative CelcureAC-500treatingsolutionshould be applied plantoperated usinga vacuumpressureimpregnation in accordancewith the Osmose Plant Operations Manual. The (COSHH)Controlof SubstancesHazardousto 2002 may applyto the use of this HealthRegulations product at work. Engineeringcontrol of operator practicable in exposuremustbe usedwherereasonably additionto the followingitems of personalprotective controlsmayreplace However,engineering equipment. personalprotective if a COSHHassessment equipment shows they providean equal or higherstandardof protection. gauntlets Wear suitableprotectiveclothing(coveralls), when usingthe productand during and eye protection equipment. of treatment maintenance footwearandan gauntlets, impervious Wearimpervious apronwhenhandlingfreshlytreatedtimber. impervious Celcure AC-500 preserved wood is protected against wood rottingfungi and wood destroyinginsects. Celcure AC-500 preserved wood, treated to an appropriate specification,can be used for structural timber, sole plates, garden furniture, playground equipment,patios,decks,fencing,garden edging,and landscapingstructuressuch as pergolas. Disposal NatureWoodproductswhich are no longer usable such as cutoffs, broken boards, sawdust or treated timber material taken out of service are not considered hazardousand may be disposedof in landfillsor burned in commercial or industrial incinerators or boilers in accordancewith Nationaland Regionalregulations.For up to date information please contact the Technical ServicesDepartment. FOR USE RECOMMENDATIONS For further informationon Celcure AC-500 preserved wood and recommendationsfor use, see the User's of coverallsand launder Guide to CelcureAC-500 PreservedWood (lnformation contamination Avoidexcessive regularly. Take off immediatelyall contaminated Sheet 15/68)and the Osmose Naturewood'lnformation clothing. Sheet. Do not breatheaerosol. * Registered Trademark Washhandsand exposedskin beforeeating,drinking, andafteruse. smoking lf you feel unwell,seekmedicaladvice(showthe label wherepossible). Drying Treatedwoodmustbe helduntilsurfacesare drywithin to prevent a bundedareaon a sitewhichis maintained lossof treatmentproductto the environment Treatedtimberwill dry naturally,but to minimisethe dryingperiod,tightlyboundpacksshouldbe stickered area. and then allowedto stand in a well-ventilated Careshouldbe takennotto despatchtimberwhichstill containsfreeliquidon itssurfaces. Technical Advice Service lnformation and advice is available on all aspects of Osmose preservatives from the Technical Services Department.Tel: 01628 486644. TDS1789April2004 Osmose and Naturercod are registeredtrademarksofPmtim SolignumLtd. Naturewod is a registeredtEdemark of Osnose in the uSA. PROTIM SOLIGNUM LTD. Fieldhouse Lane, Marlow, Bucks, SL7 lLS Tel: +44 (0) 1628 486644Fax: +44 (0) 1628 476757 or 481276 (sales) www.osmose.co.uk protim SolignumLimited'sproductsare sold subjectto its standardTermsand Conditionsof Sale, copies o{ which may be obtainedon request.Whilst Protim or informationit may give is accurateand correct,it cannot,becauseit has no direct specification Solignumendeavoursto ensurethat any advice,recommendation, or continuouscontrolover where or how its productsare applied,acceptany liabilityeitherdirectlyor indirectlyarisingfrom the use of its products,whetheror not or informationgiven by it save as specificallyprovidedby its Termsand Conditionsol Sale. recommendation in accordancewith any advice,specification, DLR Beckton Link Viaduct Confidential Appendix E. DLR/Serco Comments on the AIP 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 34 DLR Beckton Link Viaduct Confidential THIS PAGE INTENTIONALLY BLANK 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 35 DLR Beckton Link Viaduct Confidential Title of Submission: Beckton Link Viaduct AiP Document Number: Revision Number: Comments Sheet Rev No: 01 Date: 26 January 2011 Reviewers: MG – Mandela Govera JC – James Cronje No. 1 1.1 Comment Comment Status Reviewer Doc Section Response Can you please confirm that the dimensions of the sleepers are correct. They are slightly different from what Martin Creighton supplied, i.e 2,600mm(L)X300mm(W)X175mm(D) Comment for Action MG Dimensions are derived from drawing 72816/T/12 and are believed to have been ‘regularised’ to a common dimension to ensure compatibility with the original wrap-around. Dimensions of replacement sleepers may differ. Martin Creighton’s email schedules ‘approx’ dimensions. What is the tolerance on these dimensions. Existing Assets, Bullet no. 2 Subject to confirmation, actual dimensions can be stated in the AIP. 2 2.1 My comments were raised to ensure Motts have checked dimensions against those given by Serco. If dimensions given in the AiP are the correct then there is no further action on this item. Cleared MG Part of Mott MacDonald’s remit is to undertake visual as well as detailed inspection of the BEC viaduct sleepers to establish replacement methodology, (i.e whether spot replacement, or 1 in 4 for e.g). Identification of which sleepers need to be replaced is one of the key deliverables of this project. Can Motts advise when this will be done? Comment for Action MG Site Survey MM inspection remit comprises the following elements: • Visual inspection of the existing installation supplemented by more detailed inspection of selected sleepers with excavation of ballast and partial removal of casing and rubber boot to allow the condition of the sleepers to be determined. The sleepers selected for this treatment to be based on DLR/Serco intelligence. The need for a more intrusive inspection (e.g. coring) would be established at this time. • Spot measurement of track gauge and cant using 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 36 DLR Beckton Link Viaduct Confidential No. 3 3.1 4 4.1 5 5.1 6 6.1 7 7.1 8 8.1 Comment Comment Status Reviewer Doc Section Response digital cant gauge and measurement of rail side and head wear. DLR/Serco to advise when inspection can be carried out. Survey completed 9/10 April 2011. Can Motts liase with Serco and carry out the survey as soon as possible please Cleared MG How do we decide which sleepers are replaced? Comment for Action JC In the first instance, defective sleepers have been identified through inspection. See 5.1 of the AIP. Has any testing been undertaken to prove the 30yr design life claim for the USP and does this include the bond between USP and the sleepers? Comment for Action JC No. Design life is notional. Products are to be covered by suppliers’ warranties. Is there a warranty from Edilon? Comment for Action JC See 4.1. Where will the USP's be bonded to the sleepers? Comment for Action JC To be decided by user in consultation with the supplier at detailed design stage. In the methodology, I don't follow the turning the individual sleeper through 90 degrees. Presumably the track will need to be jacked up high enough to enable the sleepers to be clear the concrete ballast wall and just be slid out to the cess. Comment for Action JC Rotation in the horizontal plane is recommended if clearances to the side are limited. Otherwise, the sleepers may simply be slid out to the side once the track has been jacked up. Data sheets missing. Comment for Action JC Included. 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 37 DLR Beckton Link Viaduct Confidential 279595/RLY/RCR/05/R02 27 June 2011 – FINAL DRAFT C:\Documents and Settings\fif05315\Local Settings\Temporary Internet Files\Content.IE5\P1IN3HUZ\DLR_AiP_replacement%20sleepers_beckton%20link%20viaduct_Rev_1[1].doc 38 Technical Requirement Specification (TRS) Poplar to Westferry Booted Sleepers Up and Down Roads Signature Prepared by Aqueel Zaman Civil & Track Engineer (KAD) Approved by Caitriona Hannon Permanent Way Engineer (DLR) Accepted by Sam Twum-Barima Engineerig Asset Manager (DLR) Date Consulted Name Position Sam Twum-Barima Engineering Asset Manager Ray McGinn Assistantt Civil & Track Engineer Caitriona Permanent Way Engineer Mark Fisher Project Manager Document History Revision Date Summary of changes A 09/01/2015 Draft issue for review B 06/02/15 Final issue Revision: draft Page 2 of 8 ContentsTechnical Requirement Specification (TRS) .................................................. 1 Poplar to Westferry Booted Sleepers .......................................................................... 1 Up and Down Roads ................................................................................................... 1 Consulted ............................................................................................................................................ 2 Document History .............................................................................................................................. 2 1 Introduction ......................................................................................................... 4 2 Brief Description of Work scope ........................................................................ 4 3 Site Location and Limits ..................................................................................... 5 4 Track Support ...................................................................................................... 6 5 Track Alignment .................................................................................................. 7 6 Associated Assets .............................................................................................. 7 7 References ........................................................................................................... 8 Revision: draft Page 3 of 8 1 Introduction As part of DLR’s asset management strategy and in response to the deteriorated condition of booted sleepers between Poplar and Westferry on both the up and down roads, an asset condition assessment [1] was carried out to determine the extent and magnitude of deterioration. The assessment concluded the following results. Road Booted Sleepers Condition 0 Condition 1 Condition 2 Condition 3 Up 471 45 320 99 7 Down 498 38 302 110 8 Total 969 123 622 219 15 % - 12.7 64.2 22.6 1.5 Condition: 0 New type booted sleeper. No requirement for renewal 1 Old type booted sleeper showing very little or no signs of deterioration. No requirement for imminent renewal 2 Old type booted sleeper showing signs of deterioration of one type or another but still structurally sound. A need for renewal is identified but not priority 3 Old type booted sleeper with obvious signs of deterioration and potentially structurally affected. Need for renewal identified as a priority The results above indicate that the majority of the sleepers fall within condition 1 and 2 with no urgent priority for renewal. However, the deficient design of the original booted sleepers causes the following safety concerns (reference taken from Mott Macdonald’s AiP titled DLR Beckton Link Viaduct - Acceptance in Principle of under-sleeper pad [2]): The sleeper and resilient pads installed to the sides and underside of the sleeper cannot be inspected without detaching the non-resilient wrap and therefore an accurate condition assessment cannot be determined, unless intrusive investigation works are carried out The wrap-around traps water which increases the likelihood that the resilient pads will Deteriorate and that the sleeper itself will be subject to decay Therefore, following stakeholder consultation, this site has been identified for trackform renewal only (sleeper and rail replacement). Rail replacement is primarily driven by the renewal methodology (renew track in panels) and side wear levels approaching the maintenance limit. The purpose of this Technical Requirements Specification (TRS) is to define the technical requirements and scope. 2 Brief Description of Work scope Remove existing BS80A rail, hardwood sleepers encased in resilient surround, CEN 33C1 check rails and BS80A guard rails and replace with new hardwood sleepers with under sleeper pads as specified within the AIP for under sleeper pads[2] spaced at 26 per length with new modified BS80A flat bottom rails, and new CEN 33C1 check rail. Replace existing 1139A/B crossover comprising of SV40 right-hand turnouts with semi welded crossings with new SV40 right hand turnouts with cast manganese crossings on new hardwood sleepers with under sleeper pads. Revision: draft Page 4 of 8 3 Site Location and Limits Up 1139A 1139B Down Location Poplar to Westferry Line: West Route Designation: Up and down road Up: Re-rail: Re-rail plain line from ch 5397 to expansion switch CSC 27 at ch 5066. (S&C at 1139 crossover to also be replaced, refer to section 4). Total plain line meterage is 317m. Re-sleeper: Re-sleeper from the 1st booted sleeper at ch 5397 to the last booted sleeper at ch 5069, this includes conditions, 1, 2 and 3 only, condition 0 sleepers are to be re-used, total sleepers 405no (excluding sleepers/bearers over S&C) , refer to Appendix C – Booted sleeper survey[3] for details and location of sleepers. New scarf type adjustment switches (60ft) to be installed as per the DLR standards and procured by the contractor. All as per drawing number ccd-19010776c (see appendix G) Site Limits Which ever staged approach the contractor adopts they shall supply a design for acceptance in relation to track alignment. The Design must incorporate our standards and allow for full operational services upon completion of each stage. Down: Re-rail: From expansion switch CSC 25 at ch 5047 to expansion switch CSC 25 at ch 5400. (S&C at 1139 crossover to also be replaced, refer to section 4) 339m. Re-sleeper: Re-sleeper from the 1st booted sleeper at ch 5400 to the last booted sleeper at ch 5052, this includes conditions, 1, 2 and 3 only, condition 0 sleepers are to be re-used, total sleepers 400no (excluding sleepers/bearers over S&C), refer to Appendix C – Booted sleeper survey[3] for details and Revision: draft Page 5 of 8 location of sleepers. New scarf type adjustment switches (60ft) to be installed as per the DLR standards and procured by the contractor. All as per drawing number ccd-19010776c (see appendix G) Which ever staged approach the contractor adopts they shall supply a design for acceptance in relation to track alignment. The Design must incorporate our standards and allow for full operational services upon completion of each stage. 4 Track Support Structures The site is located along the Beckton Link viaduct. The existing low vibration trackform was originally installed to minimise the transmission of vibrations from the track to the viaduct and hence the volume of noise re-radiated by the structure. There is therefore a requirement to retain a resilient trackform The viaduct is lined with ballast mats with a minimum ballast depth of 200mm as shown within the Beckton Extension Contract 1 Alignment and Trackwork drawings [4] within Appendix D. Existing ballast depths to be confirmed by the contractor Rail New BS80a to be used and installed as per the existing configuration of unstressed welded rail between expansion switches. DLR to supply all rail and smalls for the project. Check Rail The existing check rail is functioning as a guard rail (based on 50mm flange way clearance). Therefore derailment containment protection is to be reviewed in conjunction with the requirement for the provision of check rails (with 44mm flange way clearance). Guard Rails Existing field side guard rails at the Westferry end is in place providing additional column protection to the ‘dive under’ viaduct. The existing guard rail system comprises 80a rail fixed to the timber sleepers with coach screws, which is ineffective in providing derailment protection. This shall be replaced with a standard UIC 33 guard rail . New hardwood sleepers fitted with USP (under sleeper pad) to be installed throughout the site limits as stated within section 3. USP’s to be fitted in accordance with DLR Technical Specification DLR-ENG-GENR-SPC-00005. DLR have procured 200 sleepers which will be free issued, the remaining hardwood sleepers are to be procured by the contractor. Sleepers Baseplates Requirement for check rail baseplates have been stated above. SG iron twohole type baseplates to be used for BS80A rail. Ballast Trackform to be laid on existing ballast, ballast depths to be maintained to 230mm. Revision: draft Page 6 of 8 Expansion Switches: 5 6 Location of expansion switches to be reconfigured in accordance with DLR engineering standards. Possible reduction in the number of expansion switches to be reviewed at design stage. Refer to Booted Sleeper Schematic Diagram Issue 1 within Appendix G for locations of expansion switches. Track Alignment Existing design line speed or improvements: The design shall cater for the requirements of speed curve data [6] attached within Appendix F. Particular alignment/clearance requirements Clearances to be assessed against DLR engineering standards. Original alignment is attached within Appendix D [4]. Non compliances to the existing design alignment are to be identified and alternative improved design to be proposed. Associated Assets Conductor rail and associated cables/equipment Re-use/replace existing conductor rail. Signalling and associated equipment All signalling equipment, to be reinstated in their existing location. Drainage N/A Revision: draft Page 7 of 8 7 References Reference 1 2 3 4 5 6 7 Revision: draft Document Booted Sleeper Condition Survey 2013 Report Issue 2 - DRS 2014_IT-0907_69904 AiP titled DLR Beckton Link Viaduct - Acceptance in Principle of under-sleeper pad Booted Sleeper Survey Revision 3 Beckton Extension Contract 1 Alignment and Trackwork drawings Speed Curve Data Booted Sleeper Schematic Diagram Issue 1 Expansion switch on timbers – ccd-190-10776c Page 8 of 8 Appendix A B C D E F G SD signed Booted Sleeper Condition Survey 2013 Report Issue 2 DOC NO: DRS 2014_IT-0907_69904 BOOTED SLEEPER CONDITION SURVEY 2013 REPORT Prepared by Aqueel Zaman Civil & Track Engineer Reviewed by Ray McGinn Assistant Civil & Track Engineer Booted Sleeper Condition Survey 2013 Report Page 1 of 12 A. Zaman Issue 2