FNQ

TENDER DOCUMENTS FOR MAJOR WORKS PROJECT
using AS 4000 - 1997 General conditions of contract
TITLE JOB FILE NO.
NORTH QUAY: CONSTRUCTION OF A

RAIL LOOP, RAIL BRIDGE, RAIL
TERMINAL AND ASSOCIATED
ROADWORKS PRJ.075
VOLUME 4 PART 3 OF 3
DETAILED SCOPE OF WORK

& TECHNICAL SPECIFICATION
BOOK 3: SERIES 800-1000
OFFICE OF ORIGIN: FREMANTLE PORTS

MARINE & TECHNICAL SERVICES
S ERIES 800
BRIDGES, NOISE WALLS AND

RETAINING STRUCTURES
SPECIFICATION 801 - EXCAVATION AND BACKFILL FOR
STRUCTURES
SPECIFICATION 802 - MECHANICALLY STABILISED EARTH
WALLS
SPECIFICATION 812 - BORED CAST IN PLACE PILES
SPECIFICATION 819 - FALSEWORK
SPECIFICATION 820 - CONCRETE FOR STRUCTURES
SPECIFICATION 821 - FORMWORK
SPECIFICATION 822 - STEEL REINFORCEMENT
SPECIFICATION 827 - PRECAST CONCRETE NOISE PANELS
SPECIFICATION 828 - PRECAST CONCRETE MEMBERS
SPECIFICATION 830 - STRUCTURAL STEELWORK
SPECIFICATION 831 - MANUFACTURE AND SUPPLY OF MINOR
STEEL ITEMS
SPECIFICATION 833 - BRIDGE RAILING AND BALUSTRADES
SPECIFICATION 835 - PROTECTIVE TREATMENT OF STEELWORK
SPECIFICATION 860 - BRIDGE BEARINGS
S PECIFICATION 801
EXCAVATION AND BACKFILL

FOR STRUCTURES
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
801.01 SCOPE...................................................................................................................................... 1
801.02 REFERENCES ......................................................................................................................... 1
OPERATIONS ........................................................................................................................................... 1
801.03 CLEARING.............................................................................................................................. 1
801.04 SURVEY .................................................................................................................................. 1
801.05 EXCAVATION IN GENERAL ............................................................................................... 2
801.06 NOT USED .............................................................................................................................. 2
801.07 FOOTINGS ON SOIL.............................................................................................................. 2
801.08 DEWATERING ....................................................................................................................... 3
801.09 ACCEPTANCE OF FOUNDATION SURFACE.................................................................... 4
801.10 BLINDING CONCRETE......................................................................................................... 4
801.11 BACKFILL .............................................................................................................................. 4
North Quay: Construction of a Rail Series 800

Loop, Rail Bridge, Rail terminal and Specification 801
Associated Roadworks Excavation and Backfill for Structures
SPECIFICATION 801
EXCAVATION AND BACKFILL FOR STRUCTURES
GENERAL
801.01 SCOPE
1. This Specification covers general earthworks not associated with Scope

roadworks. This includes all earthworks required for the construction of abutment and
pier and retaining wall foundations and for the approach embankments all as detailed on
the drawings.
801.02 REFERENCES
1. Australian Standards and MRWA Test Methods are referred to in

abbreviated form (e.g. AS 1234 or WA123). For convenience, the full titles are given
below:
Australian Standards
AS 2868 Classification of machinery for earthmoving, construction, surface

mining and agricultural purposes.
AS 1289 F3.3 (Part F) - Soil strength and consolidation tests, Determination
of the penetration resistance of a soil with a Perth sand
penetrometer.
MRWA Specifications - Cross References
Specification 100 GENERAL MANAGEMENT REQUIREMENTS

Specification 301 CLEARING
Specification 820 CONCRETE
OPERATIONS
801.03 CLEARING
1. Clearing shall be undertaken in accordance with Specification 301, Clearing

CLEARING.
801.04 SURVEY
1. Survey shall be undertaken in accordance with the Survey Control requirements Survey
of Specification 100 GENERAL MANAGEMENT REQUIREMENTS.
2. Prior to excavation, a survey of the existing ground surface shall be carried HOLD POINT
out and approved.
3. Prior to excavation in rock, a survey of the rock surface shall be carried out HOLD POINT
and approved.
North Quay: Construction of a Rail 1 Series 800

801.05 EXCAVATION IN GENERAL
1. Excavation in general shall include:- Scope
a) bulk excavation at bridge site
b) local excavation for installation of substructures, retaining walls and

footings
c) excavation for protection works
all as shown on the drawings.
2. Excavation in rock shall comprise excavation of material in place whether Definition of

solid or not that cannot be ripped and excavated by a tracked excavator (Class 155 as Rock
AS 2868) in good condition. The excavator shall be capable of exerting a minimum Excavation
breakout force of 180 kN at the bottom of the excavation with a 600 mm wide bucket
fitted with rock teeth.
3. Excavation in all other classes of material shall be termed common

excavation.
4. Bore Information drawings included give indications of materials to be Bore

excavated. They also show ground water levels at the date of drilling. The Contractor Information
must expect and allow for seasonal variations to these levels.
5. The drawings show approximate locations of Services in the vicinity of Services

the works. The Contractor shall contact all service authorities to confirm location
before commencing earthworks. All excavation works shall be carried out with caution
and shall comply with all requirements of the service authorities.
6. In general, the actual dimensions for excavation shall be no more than Dimensions
that required for the placement of protective works if necessary and any working space
required.
7. Unless otherwise specified, all surplus excavated material shall become Disposal of
the property of the Contractor and shall be disposed off site to the Contractor’s spoil Surplus
sites or other authorised waste disposal sites. Excavation
8. The Contractor shall give the Superintendent 24 hours notice on

completion of common excavation for confirmation of the rock surface levels.
801.06 NOT USED
801.07 FOOTINGS ON SOIL
1. Unless otherwise shown on the drawings, soil shall be finished

horizontally, care being taken to avoid disturbing material below foundation level. All
loose material shall be removed before placing the concrete.
2. The Contractor shall compact the bottom of the excavation to 99% of Compaction
maximum dry density.
3. When foundations in Perth sands have been excavated the Contractor Perth Sands
shall compact the bearing surface and test the compaction with a standard Perth falling
weight penetrometer in accordance with AS 1289, F3.3. The minimum acceptable blow
count is 10 blows per 300 mm for the whole of the first 750 mm depth for all footings.

801.08 DEWATERING
1. Where excavation for foundations is at or below insitu water table levels Water Table
the excavation shall be dewatered by pumping or well point dewatering prior to Level
commencing construction of any foundations and shall be kept free from water until
foundation work has been completed or sufficiently set or protected and the
construction and backfilling around the structure is far enough advanced to permit
dewatering operations to be discontinued.
2. The Contractor shall avoid damage to existing structures including water

bores or vegetation during the operation of any dewatering system caused by changes to
the water table level.
3. Temporary drainage systems may be required to be installed to carry

surface water away from the areas where excavation and foundation construction work
is taking place or from any other area where the accumulation of water could cause
delay or damage to the work. These drainage systems shall be maintained in proper
working order at all times. The Contractor shall be responsible for the design of all
dewatering systems.
4. Where a wellpoint system is used, care shall be exercised during

dewatering to avoid an upward seepage pressure from the ground water into the
excavation. Adequate standby pumping equipment and continuous supervision shall be
provided to ensure that no uncontrolled rise in the water table level occurs during
construction operations. Following placement of concrete and removal of formwork
the excavation shall be backfilled to approximately normal ground water level and then
flooded using an external source of water prior to shutting down the wellpoint system.
5. Discharge of water from excavations into sanitary sewers will not be WRC Licence
permitted. Silt traps shall be installed to reduce the discharge of silt into existing
drainage systems. To discharge water from excavations into watercourses in
“Proclaimed Areas” requires the Contractor to have a licence obtained from the Waters
and Rivers Commission under the ‘Rights in Waters & Irrigation Act 19 14’
6. The Contractor shall provide for disposal of all water pumped from
excavations or any part of the Works in such a manner that at no time shall waste water
interfere in any way whatsoever with the use of adjacent land by the public or other
persons. Where the Contractor’s method of disposal requires drains to cross existing
roads, the cost of installation and removal of such drains including the resurfacing and
sealing of all affected sections of road shall be met by the Contractor.
7. Prior to the commencement of any dewatering operations, the HOLD POINT

contractor shall provide to the Superintendent details of the proposed method of
water disposal.
8. Prior to the shutdown of any dewatering system the Contractor shall HOLD POINT
provide to the Superintendent details of the proposed shutdown procedure.
9. Any consequence of either ground water or surface water against any

structure or construction process shall be the sole responsibility of the Contractor.
10. If waste water from dewatering plant is discharged into existing water
courses, traps shall be provided to prevent any silt entering these systems. All Water Courses
discharge shall comply with the requirements of all relevant authorities.

801.09 ACCEPTANCE OF FOUNDATION SURFACE HOLD POINT
1. Prior to concrete blinding of the foundation surface the Contractor

shall certify that the foundation complies with specified levels, dimensions and
compaction requirements.
801.10 BLINDING CONCRETE
1. The exposed bearing surface at the bottom of each excavation shall be

adequately protected from disturbance by the Contractor’s operations or by the action
of storm water or ground water.
2. Immediately after the foundation bearing surface has been trimmed, it

shall be covered with a layer of blinding concrete. The blinding layer shall be formed
and placed and screeded off to the level of the underside of the footing.
3. Blinding concrete shall be as specified in Specification 820,

CONCRETE FOR STRUCTURES.
801.11 BACKFILL
1. The Contractor shall backfill around piers, abutments, retaining walls Backfill in
including footings to the levels shown on the drawings using selected granular fill General
material.
2. All fill shall be placed in continuous horizontal layers of not more than
300 mm uncompacted thickness.
3. Selected granular fill shall be supplied by the Contractor and shall be Fill Material
cohesionless sand or sandy limestone complying with the following requirements:-
a) Particle Size distribution WA 115.1
Sieve Size % Passing
37.5 100
19.0 80 – 100
9.5 60 – 100
4.75 45 – 100
2.36 30 – 100
1.18 20 – 100
0.425 5 – 100
0.150 3 – 30
0.075 1 – 10
NOTE: The portion of the total sample retained on the 37.5 mm sieve shall not exceed 15% of the
total sample.
TABLE 801.01 PARTICLE SIZE DISTRIBUTION (GRANULAR FILL)

b) Linear Shrinkage
The portion of the sample which passes the 0.425 mm sieve (soil
mortar) shall have a linear shrinkage not exceeding 1.0%.
c) Oversize Material
The material shall be free from boulders having any dimension

greater than 100 mm. Excavated material shall not be suitable to use
as selected fill.
4. The contractor shall backfill around footings, abutment walls, piers,

retaining walls and approach embankments to the levels shown on the drawings using
selected fill material.
5. All fill shall be placed in continuous horizontal layers of not more than
300 mm uncompacted thicknesses.
6. Backfill shall be placed on all sides of piers, abutment and retaining wall
footings so as not to damage the concrete.
7. All fill including embankment fill material shall be selected fill Compaction
compacted to 96% of maximum dry density or greater.
8. Within three (3) metres of structural members including abutment walls, Hand Operated
piers, retaining walls and footings only hand operated vibratory compacting equipment Equipment
shall be used.

S PECIFICATION 802
MECHANICALLY STABILISED
EARTH WALLS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
802.01 SCOPE...................................................................................................................................... 1
802.02 REFERENCES ......................................................................................................................... 1
802.03 SUBMISSION.......................................................................................................................... 1
DESIGN ...................................................................................................................................................... 2
802.04 DESIGN ................................................................................................................................... 2
802.05 DOCUMENTATION ............................................................................................................... 2
802.06 VERIFICATION ...................................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
802.07 COMPONENT MATERIALS ................................................................................................. 2
802.08 NOT USED .............................................................................................................................. 2
OPERATIONS ........................................................................................................................................... 2
802.09 COMMENCEMENT................................................................................................................ 2
802.10 INSTALLATION ..................................................................................................................... 2

Associated Roadworks Mechanically Stabilised Earth Walls
SPECIFICATION 802
MECHANICALLY STABLISED EARTH WALLS
GENERAL
802.01 SCOPE
1. The work to be executed under this Specification includes design, Scope

manufacture and construction of Mechanically Stabilised Earth (MSE) Walls for use in
bridge abutments and associated retaining walls.
802.02 REFERENCES

below:
AS 1289.F3.3 (Part F) - Soil Strength and Consolidation Tests, “Determination

of the Penetration Resistance of a Soil with a Perth Sand
Penetrometer”.
AS 4678 Earth-Retaining Structures
Specification 801 EXCAVATION AND BACKFILL FOR STRUCTURES
Other Publications
Australian Bridge Design Code
802.03 SUBMISSION
1. The Contractor shall submit sufficient details of the proposed MSE Submission
System to enable a full technical and aesthetic assessment to be made of its suitability.
In particular this should address:
a) anticipated design life (100 years minimum required)
b) anticipated movements over the life of the structure (vertical and

horizontal)
c) safety factors adopted for the design
d) requirements for fill material
e) proposed shape and surface finish of facing panels;
f) proposed reinforcing elements
with independent supporting evidence as appropriate.

DESIGN
802.04 DESIGN
1. The MSE System shall be designed to support the loads from the
abutment sill beam as shown in Drawings and in accordance with the requirements of
the Australian Bridge Design Code and AS 4678 Earth Retaining Structures. Borehole
information is contained in Information for Tenderers.
802.05 DOCUMENTATION
1. The Contractor shall be responsible for the design and preparation of Design
detailed specifications and Drawings for the manufacture and construction of the MSE
structure.
802.06 VERIFICATION
1. The design shall be verified by an independent geotechnical engineer Verification

experienced in this form of construction.
MATERIALS
802.07 COMPONENT MATERIALS
1. Only MSE Systems composed of metallic reinforcing elements in Materials

conjunction with precast concrete facing panels will be acceptable.
802.08 NOT USED
OPERATIONS
802.09 COMMENCEMENT
1. At least 4 weeks prior to carrying out any work on the MSE HOLD POINT
abutments or walls the Contractor shall supply to the Superintendent full details
of the proposed system, including four copies of all Drawings and specifications
and certification that the design has been checked by an independent geotechnical
engineer experienced in this form of construction.
802.10 INSTALLATION
1. The MSE system shall be installed in accordance with the approved

documented design.

S PECIFICATION 812
BORED CAST-IN-PLACE PILES

(WITHOUT PERMANENT
CASING)
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
812.01 SCOPE...................................................................................................................................... 1
812.02 REFERENCES ......................................................................................................................... 1
OPERATIONS ........................................................................................................................................... 1
812.03 BORING AND TEMPORARY CASING................................................................................ 1
812.04 PROTECTION OF ADJACENT PILES.................................................................................. 2
812.05 INSPECTION OF PILE EXCAVATION ................................................................................ 2
812.06 CASTING PILES ..................................................................................................................... 3
812.07 TOLERANCES ........................................................................................................................ 4

Associated Roadworks Bored Cast in Place Piles
SPECIFICATION 812
BORED CAST-IN-PLACE PILES
(WITHOUT PERMANENT CASING)
GENERAL
812.01 SCOPE
1. This section covers the requirements for the construction of reinforced Scope
concrete piles which are bored and cast-in-place without the use of permanent casing.
2. Unless otherwise specified, piles shall be constructed in accordance with

AS 2159 “Piling - Design and Installation”.
812.02 REFERENCES

below:
AS 2159 Piling Design and Installation

AS/NZS 1554.1 Structural Steel Welding - Welding of Steel Structures
AS/NZS 3678 Structural Steel - Hot-rolled Plates, Floorplates and Slabs
Specification 820 Concrete for Structures

Specification 822 Steel Reinforcement
Specification 830 Structural Steelwork
Specification 835 Protective Treatment of Steelwork
OPERATIONS
812.03 BORING AND TEMPORARY CASING
1. Each pile shall be bored to allow the construction of the pile to the size,
position and level shown on the drawings.
2. All excavated material shall be removed from the site and disposed of as
soon as practicable, so that the site of the works is kept in a clean and tidy condition.
3. If excavations are to be left open, the Contractor shall ensure that they are
made safe with appropriate fall protection measures such as guardrails with a footplate
around the full perimeter of the pile hole, a sleeve extending at least 1 metre above
ground level or a secure pile hole cover. Fall protection shall be provided at all times
during excavation and after excavation is completed. The Contractor shall provide
effective measures to protect each pile hole from site run-off and from loose material
falling in.
4. Where necessary, suitable precautions such as temporary casing shall be

used to prevent collapse of holes during the boring operation.

5. If holes are bored prior to placing the steel casing in position, the nominal
size of the drilling bit used to bore the holes shall not be more than 25 mm larger than
the outside diameter of the steel casing and any protective coating.
6. The Contractor shall be responsible for ensuring services or adjacent

structures are not damaged by the piling operations. Where percussion equipment is
used, the level of energy per blow of the drilling bit shall be kept to the minimum
consistent with effective boring, so as to minimize vibration, and avoid damage to
adjacent piles, structures or services.
7. The toes of the steel casings shall be driven into solid rock where
specified on the drawings or suitable alternative material as required to seal them
sufficiently to prevent soil and water entering from outside the casing.
8. The type and thickness of the steel plate used in the temporary casing
shall be selected by the Contractor who shall be fully responsible for its structural
adequacy. The type and thickness of the temporary casings shall be certified by an
Engineer who has qualifications admitting to Corporate Membership of the Institution
of Engineers, Australia as being suitable for its intended purpose which may include
providing safe access for personnel, resisting all superimposed loads from driving,
extraction, earth and water pressures and the effects of any distortion which is likely to
occur to the casing.
9. Where piles are to be founded on rock, they shall extend a minimum of

300 mm into rock of the type and quality shown on the drawings, but shall not finish
above the levels shown on the drawings.
812.04 PROTECTION OF ADJACENT PILES
1. The Contractor shall ensure that the pile construction process does not
result in damage to adjacent newly cast piles due to ground vibration. The following
minimum requirements shall also be met.
(a) no pile construction shall be commenced within 2.5 m clear distance

of a newly cast pile until the concrete in the pile has attained a
strength of 15 MPa;
(b) piles more than 2.5 m clear distance from a newly cast pile may be
installed by boring at any time providing there is no likelihood of
damage to the newly cast piles;
(c) installation of piles by methods which involve driven temporary

casing or result in significant vibration shall not be carried out
within the distance 2.5 m to 9.0 m until the concrete in the pile has
set for 24 hours.
812.05 INSPECTION OF PILE EXCAVATION
1. Prior to inspection, the pile excavation shall be de-watered and the walls
and base of the pile cleaned out, including the internal surface of the casing, to remove
all mud, loose or foreign material.
2. The temporary casing (where used) shall not be removed, nor shall HOLD POINT
reinforcement and/or concrete be placed until the pile walls and base have been
inspected by the Contractor’s geotechnical representative.
3. The Contractor shall provide all plant, equipment, temporary casing or

protective inspection casing/shield, labour and for all other requirements necessary to
provide safe and effective access for the inspection of the pile excavation.

4. No person shall enter the pile excavation unless the appropriate
precautions have been taken in accordance with Occupational Health and Safety
(Confined Spaces) Regulations 1996 and the Code of Practice for Confined Spaces
(March 1997).
5. In the event that the Contractor is unable to de-water the pile hole for
inspection, full details of the proposed method of cleaning out the pile and the pile
inspection shall be submitted to the Superintendent for review.
812.06 CASTING PILES
1. General
(a) The materials used, and the methods of proportioning, mixing and
handling concrete shall comply with the relevant provisions of
Specification 820 Concrete for Structures.
(b) Steel reinforcement shall comply with the requirements of

Specification 822 Steel Reinforcement.
(c) Concrete shall be placed in the dry and shall be compacted with
immersion type, high frequency vibrators.
(d) Concrete shall be placed through a tremie tube and shall not be
dropped from a height greater than 2 m through air. Concrete which
is being discharged from a tremie shall be positively guided away
from the pile reinforcement so that segregation is not caused by the
flow of concrete impinging on the reinforcement.
(e) Alternative methods for placing concrete in the dry from those
specified in this clause may be used subject to a review by the
Superintendent.
(f) The casing shall be withdrawn during casting of the concrete.
(g) Care shall be taken to prevent earth and rock dislodging from the
side of the hole and contaminating the concrete forming the
minimum cover to the reinforcement.
(h) The minimum height of concrete within the casing shall be adjusted
to ensure that water is not permitted to enter from outside the casing,
and that the soil pressure at the toe of the casing is balanced by the
mass of the concrete within the casing. The free surface of the
concrete shall be at least 1.5 m above the bottom of the casing.
(i) If after driving the casing, it is found not possible to seal the
excavated pile from the inflow of water, mud, loose rock or similar
materials, the reinforcement and concrete may be placed under
water, subject to a review by the Superintendent and the
requirements of Clause 812.06(2) of this specification.
(j) Reinforcement and/or concrete shall not be placed until the HOLD POINT
proposed method of removing mud, loose rock or similar
materials, and the method of placement of concrete under water
has been reviewed by the Superintendent.
(k) Piles shall be concreted within 24 hours of completion of the pile

excavation. For delays greater than 24 hours, the Contractor shall
ream the walls and the base of the pile to remove not less than
25 mm thickness of material, or any other foundation material which
has softened in that time.

2. Casting Under Water
(a) Concreting using tremie methods shall not commence until the pile
hole is filled with such head of water as to equalise the external
water pressure from the surrounding ground.
(b) Where a tremie is used, the hopper and pipe of the tremie shall be
steel, smooth bore, clean and water tight throughout. The tremie
pipe shall be sealed with a plate taped to its outlet, to prevent direct
contact between the first discharge of concrete in the pipe of the
tremie and the water. The tremie pipe shall extend to the base of the
pile hole before the tremie is charged with concrete.
(c) Where a pump is used in lieu of a tremie, a sponge shall be inserted

in the discharge line before the discharge hopper is loaded so that
water and air in the line are prevented from mixing with the
advanced column of fresh concrete. The end of the discharge hose
shall be held against the bottom of the hole until the sponge is
released, and the whole operation controlled to ensure that no voids
are trapped in the pile concrete.
(d) Concreting shall not commence until the tremie pipe or pump
discharge hose are fully charged. During concreting the outlet of the
tremie pipe or pump discharge hose shall be kept a minimum of 2 m
below the top surface of the concrete at all times and the Contractor
shall continuously monitor and record the depth of embedment. The
method used for concrete placement shall be such that a continuous
supply of concrete is available at the top of the tremie tube or pump
hopper during the entire process of placing concrete. Concreting
shall be continued until sound concrete appears a minimum of
400 mm above the required cut off level. The pile concrete shall not
be cut back to its required level until a minimum of 24 hours after
completion of placement of concrete.
(e) The proposed mix shall be self-compacting, with a nominated slump

of not less than 180 mm and not more than 200 mm. The tolerance
on slump shall be ± 40 mm.
(f) The concrete shall be of such consistency, and shall be placed in

such a manner, that pockets of air or water or ground materials are
not entrapped in the concrete, and the space between the
reinforcement and the side walls of the hole are completely filled
with compacted concrete.
812.07 TOLERANCES
1. The following tolerances shall apply to completed piles:
(a) pile head shall finish within 75 mm of the specified plan position;
(b) variation from the vertical or the specified batter/rake shall not be
more than 1 in 100;
(c) for piles which develop a curve, the offset from the theoretical
straight pile line shall not exceed 150 mm over a length of 15 metres
or proportionally for greater or shorter lengths.

S PECIFICATION 819
FALSEWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
819.01 SCOPE...................................................................................................................................... 1
819.02 REFERENCES ......................................................................................................................... 1
819.03 DEFINITION ........................................................................................................................... 1
819.04 - 819.10 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
819.11 GENERAL ............................................................................................................................... 1
819.12 PROPRIETARY FALSEWORK ............................................................................................. 1
819.13 - 819.20 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 2
819.21 GENERAL REQUIREMENTS................................................................................................ 2
819.22 SAFETY................................................................................................................................... 2
819.23 DESIGN ................................................................................................................................... 2
819.24 LOAD TESTING ..................................................................................................................... 3
819.25 REMOVAL .............................................................................................................................. 3
819.26 - 819.79 NOT USED ................................................................................................................ 3
SPECIAL REQUIREMENTS................................................................................................................... 3
819.80 SPECIAL REQUIREMENTS FOR STEEL BEAM BRIDGES.............................................. 3

Associated Roadworks Falsework
SPECIFICATION 819
FALSEWORK
GENERAL
819.01 SCOPE
1. The work to be executed under this Specification is the design and erection
of falsework required for the proper construction of the permanent Works and after
completion of these Works the dismantling and removal of falsework.
819.02 REFERENCES
1. Australian Standards and Test Methods are referred to in abbreviated form

(e.g. AS1234 or WA 123). For convenience, the full titles are given below:
AS 3610 Formwork for Concrete
Government of Western Australia Acts
Occupational Safety and Health Act 1984

Occupational Safety and Health Regulations 1996.
819.03 DEFINITION
1. Falsework comprises all temporary supports of any nature that are required
for the construction of the permanent structure.
819.04 - 819.10 NOT USED
MATERIALS
819.11 GENERAL
1. Footings shall comprise concrete bases or timber bed logs or other types of Footings
suitable materials and shall be of a size that will satisfactorily distribute the bearing
pressures under each footing.
2. All standards shall be securely fastened to sole plates and shall be Bracing
adequately braced in every direction necessary to provide rigid and stable support to the Standards
permanent Work. Where standards are used with extending ends the length of unbraced
extensions shall be limited in accordance with the manufacturer's recommendations.
819.12 PROPRIETARY FALSEWORK
1. All proprietary falsework shall be used in accordance with the

manufacturer's recommendations and shall comply in all respects with the Occupational
Safety and Health Act 1984.

819.13 - 819.20 NOT USED
OPERATIONS
819.21 GENERAL REQUIREMENTS
1. Falsework shall be designed and constructed so that on completion of the Allow for
permanent Works the concrete levels are as shown on the Drawings. To achieve this the Settlement
levels of the falsework shall be set to allow for any settlement and deflection
accompanying casting of the concrete.
2. In the event that falsework settles under load to such an extent that the
allowable tolerances on the finished concrete work are exceeded then the concrete shall be
removed and the falsework modified so that the finished work is in accordance with the
Drawings. The cost of such remedial works shall be borne by the Contractor.
819.22 SAFETY
1. All falsework shall comply with the requirements of the Occupational Worksafe
Safety and Health Regulations 1996.
819.23 DESIGN
1. The design of all falsework shall be in accordance with AS 3610 - and be Design by
adequate in every way for the loads it is required to support and to meet the General Contractor
Requirements.
2. Falsework shall be designed to permit shrinkage of concrete and

movements due to temperature and to allow for any special conditions likely to occur
during construction including but not limited to the redistribution of load due to the
effects of staged construction and prestress.
3. Falsework shall be designed and erected in such a manner that the loads are
accepted in accordance with the loading assumptions made. All permanent structures
such as piers and abutments which are adjacent to or surrounded by falsework shall be
adequately protected to ensure that they are not damaged during the Contract.
4. Foundations for falsework shall be designed to prevent excessive settlement

and rotation of supports. Foundation materials which are soft and compressible or which
may be subject to erosion by water shall be removed and replaced with a suitable
foundation. Falsework shall not be supported or braced from the permanent structure
unless it can be shown that such temporary loading will not affect the integrity of the
structure.
5. At least two weeks prior to commencing falsework (including sheet HOLD

piling) erection the Contractor shall supply to the Superintendent design details and POINT
Drawings checked and certified by a qualified structural engineer in accordance
with the Specification.
6. At least two weeks prior to the installation of sheet piling the HOLD
Contractor shall supply to the Superintendent the proposed process description for POINT
installation and removal.

819.24 LOAD TESTING
819.24.01 GENERAL
1. When directed by the Superintendent the Contractor shall carry out load Testing When
tests on representatives areas of the completed soffit formwork. Directed
2. Costs for such testing will be met by the Principal.
3. The purpose of the tests will be to prove the structural adequacy of the
falsework/formwork system under overload.
819.24.02 LOAD TESTING OF FALSEWORK
1. The load shall be applied using kentledge. The load shall be equivalent to Kentledge
1.25 times the actual weight of the concrete plus a construction live load of 0.75 kN per
square metre.
819.24.03 TEST DURATION
1. The full test load shall be applied for at least twenty four hours during Tolerances
which time the Contractor will determine the displacement of the falsework resulting from
the application of the test load. The acceptance of the system shall be subject to it
sustaining no structural damage under the test load and it being adequate such that the
profile of the soffit surface after pouring the concrete shall be in accordance with the
Drawings and the Formwork Tolerances.
819.24.04 NONCONFORMANCE
1. If any section of the falsework under the test load displaces such that the Retesting at
profile of the cast concrete soffit will not be within the tolerances specified or if the Contractor’s
falsework under the test load shows signs of structural distress then the Contractor shall Cost
make the necessary modifications to the falsework tested and to all other areas which
would be similarly defective. The Contractor shall then carry out a further test load on an
area of the modified falsework in accordance with this Specification. The costs of all
retesting shall be borne by the Contractor.
819.25 REMOVAL
1. After completion of the permanent works the Contractor shall dismantle all
falsework and remove it from the site.
819.26 - 819.79 NOT USED
SPECIAL REQUIREMENTS
819.80 SPECIAL REQUIREMENTS FOR STEEL BEAM BRIDGES
1. Steel beams shall be supported on the bearings before casting the deck
elements. The bottom flanges of beams shall be set parallel to the top surface of the
bearings.
2. The Contractor shall provide adequate temporary bracing for the beams to
prevent rotation, lateral and longitudinal movements due to superimposed loads and

temperature during construction. The attention of the Contractor is specifically drawn to
the possibility of temperature differentials across the beams causing lateral displacements.
3. Beams may require pulling into line to conform with the construction
tolerances specified.
4. The welding to or drilling of holes in the beam flanges for attaching

temporary bracings or supports will not be permitted.

S PECIFICATION 820
CONCRETE FOR STRUCTURES

CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
820.01 SCOPE.................................................................................................................................. 1
820.02 REFERENCES ..................................................................................................................... 1
820.03 DEFINITIONS ..................................................................................................................... 2
820.04 SPECIAL PROCESSES ....................................................................................................... 2
820.05 ADDITIONAL QUALITY SYSTEM REQUIREMENTS .................................................. 2
820.06 - 820.10 NOT USED ............................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
820.11 GENERAL ........................................................................................................................... 2
820.12 CEMENT.............................................................................................................................. 3
820.13 AGGREGATE...................................................................................................................... 3
820.14 WATER................................................................................................................................ 4
820.15 ADMIXTURES.................................................................................................................... 4
820.16 ALKALI-REACTIVE MATERIALS & SOLUBLE SALTS .............................................. 4
820.17 - 820.20 NOT USED ............................................................................................................... 4
DESIGN OF CONCRETE MIXES .......................................................................................................... 4
820.21 GENERAL ........................................................................................................................... 4
820.22 DURABILITY...................................................................................................................... 4
820.23 CLASS OF CONCRETE FOR MIX DESIGN .................................................................... 5
820.24 - 820.26 NOT USED ............................................................................................................... 6
820.27 TRIAL MIXES..................................................................................................................... 6
820.28 - 820.30 NOT USED ............................................................................................................... 7
SUPPLY AND DELIVERY OF CONCRETE......................................................................................... 7
820.31 CONCRETING PLANT ...................................................................................................... 7
820.32 BATCHING AND MIXING................................................................................................ 7
820.33 TRANSPORT....................................................................................................................... 7
820.34 TEMPERATURE AT POINT OF DELIVERY ................................................................... 7
820.35 MIX CONSISTENCY.......................................................................................................... 8
820.36 ADDITION OF WATER TO THE MIX AFTER MIXING ................................................ 8
820.37 SAMPLING OF CONCRETE FOR STRENGTH ............................................................... 8
820.38 STRENGTH OF CONCRETE DELIVERED...................................................................... 8
820.39 NOT USED .......................................................................................................................... 9
OPERATIONS ........................................................................................................................................... 9
820.40 GENERAL ........................................................................................................................... 9
820.41 PLACING CONCRETE....................................................................................................... 9
820.42 CONSTRUCTION JOINTS ............................................................................................... 10
820.43 COMPACTION.................................................................................................................. 10
820.44 FINISHING OF UNFORMED SURFACES ..................................................................... 11
820.45 CURING OF CONCRETE................................................................................................. 11
820.46 STEAM CURING .............................................................................................................. 12
820.47 PROTECTION OF CONCRETE SURFACES .................................................................. 14
ANNEXURE 820A ................................................................................................................................... 15
CLASS OF CONCRETE ....................................................................................................................... 15

Associated Roadworks Concrete for Structures
SPECIFICATION 820
CONCRETE FOR STRUCTURES
GENERAL
820.01 SCOPE
1. The work to be executed under this Specification consists of the mix Scope
design, the supply and delivery, placing, compaction, finishing, curing and protection of
concrete for the following structures:
(a) Bridgeworks
(b) Manufacture of Box Culverts
(c) Major structural works involving the use of high strength concrete,
including retaining walls
2. Concrete for general non-structural works is covered in Specification

901, CONCRETE - GENERAL WORKS.
820.02 REFERENCES
1. Australian Standards and Test Methods are referred to in abbreviated

form (e.g. AS1234 or WA 123). For convenience, the full titles are given below:
AS 1012 Methods of Testing Concrete

AS 1141 Methods for Sampling and Testing Aggregates
AS 1379 Specification and Supply of Concrete
AS 2758.1 Aggregates and Rock for Engineering Purposes, Pt 1 - Concrete
Aggregates
AS 3582.2 Slag - Ground Granulated Iron Blast Furnace
AS 3582.3 Silica Fume
AS 3972 Portland and Blended Cement
AS 1478 Chemical Admixtures for Concrete, Mortar and Grout
AS 3799 Liquid Membrane-Forming Curing Compounds for Concrete
MRWA Specifications - Cross Reference
Specification 201 QUALITY SYSTEMS

Specification 819 FALSEWORK
Specification 821 FORMWORK
Specification 822 STEEL REINFORCEMENT
Specification 901 CONCRETE - GENERAL WORKS
Test Methods
WA 910.1 – Chlorides and Total Soluble Salts in Soil and Water

Cement & Concrete Assn of NZ - Report No TR3, Determination of Alkali Content

820.03 DEFINITIONS
1. For the purpose of this Specification the following definitions apply:
a) Concrete in general shall consist of a mixture of cement, water and

coarse and fine aggregate. Unless noted otherwise, blended
cement as defined in Clause 820.12 (paragraph 1) may also be
used.
b) Water/cement ratio is the ratio by mass of the total water content of

the mix available for hydration to the total cement in the mix.
c) Aggregate/cement ratio is the ratio by mass of the total aggregate in

the mix (measured in the saturated surface dry state) to the total
cement in the mix.
d) The compressive strength of concrete shall be defined as the average

28 day crushing strength of a minimum of three standard 100 mm
diameter by 200 mm long cylinders taken from the same sample and
made, cured and tested in accordance with AS 1012.
820.04 SPECIAL PROCESSES
1. The placing, compacting, finishing and curing of concrete are identified Special
as SPECIAL PROCESSES in accordance with Specification 201 QUALITY Processes
SYSTEMS.
820.05 ADDITIONAL QUALITY SYSTEM REQUIREMENTS
1. The information to be submitted by the Contractor as part of their Quality Plan

Quality Plan shall include, but not be limited to, the following:-
(a) Details of the methods to be used in maintaining evidence generated

during each special process. The number of personnel required
together with proof of any relevant training and experience shall be
included.
(b) Verification of the compliance of any proposed heat accelerated

curing method with the Specification requirements (refer to Clause
820.46)
820.06 - 820.10 NOT USED
MATERIALS
820.11 GENERAL
1. Concrete required under this Contract shall be supplied from either an

approved off-site batching plant and delivered by truck agitator or an on-site batching
plant.
2. In its finished state concrete shall be sound and dense and durable and
free from honeycombing and shall have the strength and other properties specified.

3. Concrete shall comply with AS 1379, except as varied by this
Specification.
820.12 CEMENT
1. All cement used in the Works shall comply with the requirements of Type Testing
GP cement as specified in AS 3972. The Contractor shall provide manufacturer's test
certificates showing all cement has been sampled and tested and conforms in all
respects with the above standard.
2. Blended cement shall be a combination of Ordinary Portland Cement

and ground granulated blast-furnace slag complying with AS 3582.2. The
densified silica fume to be added to the blended cement shall be finely divided and
comply with AS 3582.3.
3. The Contractor shall use cement in approximately the chronological order

in which it is delivered from the manufacturer. Transportation units and storage bins
for bulk cement shall be weatherproof and shall be constructed so that there is no dead
storage. The Contractor shall demonstrate that the storage bins for bulk cement do not
have any dead storage. If dead storage exists the bins shall be emptied completely at
least once every three months. Cement delivered in bags shall be stored in
weatherproof structures having floors raised above the ground. Cement that is more
than three months old shall not be used.
4. Concrete manufactured from cement not conforming to this Specification

or from cement that has deteriorated and become unsuitable for use shall be rejected.
820.13 AGGREGATE
1. Fine aggregates for concrete shall be natural sand and shall comply with Testing
the requirements of AS 2758.1. The maximum amount of water absorption for fine
aggregates shall not exceed 1.5 percent.
2. Coarse aggregates for concrete shall be crushed igneous rock or crushed

or screened river gravel conforming to the requirements of AS2758.1. All coarse
aggregates shall be single-sized. Graded coarse aggregates shall not be used. The
maximum amount of water absorption for coarse aggregates shall not exceed 2.5
percent.
3. The durability of coarse aggregates shall be assessed according to test

methods of AS 2758.1. The acceptance criteria for these tests shall be that for a
concrete exposure classification C unless otherwise specified.
4. In addition all aggregates proposed for use in the Works shall comply
with the requirements of the "Alkali-Reactive Materials" clause of AS 2758.1. The
Contractor shall also demonstrate that measures have been taken to prevent latent Alkali
Reactivity which is not identified by these tests. (See also Clause 820.16 of this
Specification).
5. The Contractor shall provide proper means of storing the aggregates.

Each nominal size of coarse aggregate and fine aggregate shall be kept separated and
suitable precautions shall be taken to prevent the aggregates from being contaminated
by the ground or by wind blown dust or other foreign matter.
6. The gradings of the individual aggregates shall conform to the overall

limits for these materials given in AS 2758.1. Sampling for the purposes of carrying
out tests shall be in accordance with AS 1141.

820.14 WATER
1. Water used in concrete manufacture and curing shall be clean and potable
and free from amounts of suspended material or organic matter or alkali salts or any
other impurities which may adversely affect the properties of the concrete or have
harmful effects on any reinforcement or other fixture embedded therein.
2. Water for concrete shall have a total soluble salts content of not greater Testing
than 1 500 milligrams per litre when tested in accordance with MRWA Test Method
WA 910.1.
3. The Contractor shall arrange that a suitable supply of water is available at Contractor to
the batching plant. Supply
820.15 ADMIXTURES
1. Admixtures may be used in concrete to modify workability but will not

be permitted for the purpose of reducing cement content. However, the admixture shall
have no harmful effect whatsoever upon the quality of the concrete or upon any
reinforcement or other fixture embedded therein.
2. Any admixture shall comply with the requirements of and be used in

accordance with AS 1478.
3. Calcium chloride and other chloride-bearing admixtures shall not be used

in concrete containing any type of steelwork or steel reinforcement.
820.16 ALKALI-REACTIVE MATERIALS & SOLUBLE SALTS
1. The total mass of reactive alkali in the concrete, including any Testing
admixtures, shall not exceed 2.5 kg/m³. The method of determining the alkali content
shall be in accordance with Part 2 of Report No. TR3 by the Cement & Concrete
Association of New Zealand.
820.17 - 820.20 NOT USED
DESIGN OF CONCRETE MIXES
820.21 GENERAL
1. The Contractor shall design a mix for each class of concrete specified and
shown in the Drawings. The locations for these classes are summarised in Annexure
820A.
820.22 DURABILITY
1. The intent of this Specification is to provide durable concrete in the Intent

permanent works.

820.23 CLASS OF CONCRETE FOR MIX DESIGN
1. All concrete for the Works shall be as specified in Table 820.1 except
that blinding concrete shall be Class N20 in accordance with AS 1379.
2. Ordinary Portland Cement only shall be used in all classes of concrete.
3. The combined grading shall be within the limits given in Figure 820.1
and Figure 820.2 after making allowance for the permissible tolerances on individual
aggregate gradings specified in Clause 820.13.
CONCRETE CLASS S35 S35/10 S40 S50 S50/10
Nominated strength 35 MPa 35 MPa 40 MPa 50 MPa 50 MPa
Target strength for mix design 42 MPa 42 MPa 48 MPa 58 MPa 58 MPa
Maximum aggregate size 20 mm 10 mm 20 mm 20 mm 10 mm
Minimum aggregate/cement ratio 4.0 3.2 4.0 3.0 3.0
Maximum water/cement ratio 0.50 0.45 0.43 0.40 0.40
Minimum Cement Content 350 kg/m3 350 kg/m3 400 kg/m3 420 kg/m³ 420 kg/m3
TABLE 820.1
NOTE: Concrete Class S35/10 is to be used in the Manufacture of Precast Parapet Panels only and
concrete class S50/10 is to be used in the concrete restraint blocks only.
P 100
E
R
C
80
E
N
T 65
A 60
G
E
. 42
40 45
P 35
A 31
S 24 30
S 20 23
I 12 16
N 9
2 2
G 0 2
0.075 0.15 0.3 0.6 1.18 2.36 4.75 9.5 19
SIEVE SIZE mm
FIGURE 820.1 AGGREGATE GRADING ENVELOPE 20mm

100
P
E
R
C 80
E
N
T 60
A 60
G
E 46
. 40 37
P
A 28 30
S
S 20
14 20
I 16
N 5 12
G 0 4
0.075 0.15 0.3 0.6 1.18 2.36 4.75 9.5
SIEVE SIZE mm
FIGURE 820.2 AGGREGATE GRADING ENVELOPE 10mm
820.24 - 820.26 NOT USED
820.27 TRIAL MIXES
1. The Contractor shall prepare a trial mix for each class of concrete to be
used in the Works. Each mix shall use such aggregates that have been tested and
approved by the Superintendent. The mixes shall be made using the plant and degree of
quality control proposed for the Works.
2. Where the concrete is supplied by an off-site batching plant the

Contractor shall arrange for the trial mix to be delivered to the site in a truck agitator or
mixer truck of the type to be used for the supply of concrete to the Works. Surplus trial
mix concrete may be placed as blinding concrete.
3. The Contractor shall measure the slump of the trial mix in accordance Slump Test
with AS 1012.3 and the value of the slump shall be agreed by the Superintendent.
4. Once a mix design for a specific class of concrete is adopted the slump of
the trial mix shall be deemed to be the slump for that class of concrete and all concrete
of this class supplied to the Works shall have the same slump, within a tolerance of +
15 mm.
5. The maximum slump of any concrete mix shall be 100 mm unless a

superplasticising admixture is used in which case 100 mm shall be the maximum slump
before addition of the admixture. For concrete containing high range water reducer
(HRWR), the initial slump prior to its addition shall not be less than 40 mm unless
otherwise approved by the Superintendent.
6. The Contractor shall cast not less than nine and not more than twenty-one
compressive strength test specimens from the trial mix which shall be tested to
determine that the strength requirements of this Specification are met.

7. The average 28 day compressive strength of all specimens made from a
trial mix shall be not less than the target strength and 70% of all test results shall have
compressive strengths within 3 MPa of the mean.
820.28 - 820.30 NOT USED
SUPPLY AND DELIVERY OF CONCRETE
820.31 CONCRETING PLANT
1. The batching plant shall be capable of producing the quantities of

concrete at the rates necessary for the efficient and proper placement of concrete in the
Works.
820.32 BATCHING AND MIXING
1. The Contractor shall provide and maintain and operate the batching
equipment so as to accurately determine and control the amount of each separate
ingredient entering the concrete to the tolerances specified in AS 1379. The amounts of
cement and sand and each size of aggregate entering each batch of concrete shall be
determined by weighing and the amount of water shall be determined by weighing or by
volumetric measurement.
2. Mixing of concrete shall comply with the requirements of AS 1379.
820.33 TRANSPORT
1. Concrete shall be transported to the Works in a manner preventing

contamination, segregation or loss of ingredients. Containers for transporting concrete
shall be cleaned at the end of each day's work and whenever concreting is interrupted
for more than 40 minutes.
2. In continuous pours the maximum time lag between truck loads on site
shall not exceed 20 minutes.
3. Concrete shall be continuously agitated from the time of adding water to

the mix until discharge is completed. The use of non-agitating equipment to transport
concrete will not be permitted.
820.34 TEMPERATURE AT POINT OF DELIVERY
1. Placement of concrete will only be permitted providing: Hot Weather

Concreting
(a) The concrete mix temperature during placement shall at no time
exceed 32°C.
AND, EITHER
(b) The ambient shade temperature is less than 38°C and falling.
OR
(c) The ambient shade temperature is less than 38°C and rising, but
placement can be completed before the ambient temperature exceeds
38°C.

2. To keep the concrete maximum temperature below 32oC it may be
necessary to shield and/or wet the aggregate stockpiles, chill the mixing water or
schedule concrete placement at night.
3. When the ambient shade temperature is greater than 32oC suitable means
shall be provided by the Contractor to avoid premature stiffening of concrete placed in
contact with hot dry surfaces. Where necessary the surfaces against which concrete is
to be placed including reinforcement and formwork shall be sprayed with water to
prevent excessive absorption of water from the fresh concrete.
820.35 MIX CONSISTENCY
1. The Contractor shall check the consistency of all concrete by Slump Test
measurement of the slump in accordance with AS 1012.3. A minimum of one full set
of Slump Testing equipment shall be supplied by the Contractor for this purpose for the
period of the Contract. In general, slump tests shall be carried out close to the concrete
discharge point.
820.36 ADDITION OF WATER TO THE MIX AFTER MIXING
1. Excessive over-mixing shall not be permitted and any concrete which has
been retained in the mixer so long that it requires additional water to permit satisfactory
placing shall be rejected.
820.37 SAMPLING OF CONCRETE FOR STRENGTH
1. Sampling procedures for concrete shall conform to AS 1012 and from

each sample of concrete taken for the purpose of checking the 28 day compressive
strength not less than 3 test specimens shall be cast.
2. The Contractor shall have available not less than fifteen steel moulds for
making concrete compression test specimens. For the period of large concrete pours the
Contractor shall supply adequate extra moulds to meet the increased frequency of
sampling required.
3. Where it is required to determine the compressive strength of concrete

prior to 28 days, e.g. to determine stripping times for formwork, the Contractor shall
cast additional test specimens and they shall be cured under similar conditions to the
concrete they represent.
820.38 STRENGTH OF CONCRETE DELIVERED
1. Concrete from any class shall be deemed to conform with the strength
requirements of this Specification if:
(a) Every concrete sample has a 28 day compressive strength greater

than 95% of the nominated strength,
AND
(b) The average 28 day compressive strength for any group of four
consecutive samples is equal to or greater than the nominated
strength.
2. Consecutive samples for the same class of concrete are not restricted to a
single pour.

3. For a group of samples failing to comply with sub-clause 1(b) above that
concrete represented by the lowest strength sample shall be liable to rejection.
4. If at any time during the progress of the Works any mix is found to be
unsatisfactory or it becomes necessary to use materials differing from those originally
approved then the Contractor shall prepare revised mix designs and prepare trial mixes
for testing in accordance with Clause 820.27 prior to their use being approved.
Otherwise for any particular class of concrete the Contractor shall not vary the
properties of the materials used or their relative proportions from those of the approved
trial mix.
820.39 NOT USED
OPERATIONS
820.40 GENERAL
1. Requirements for falsework shall be in accordance with Specification 819 Falsework

FALSEWORK.
2. Requirements for formwork shall be in accordance with Specification 821 Formwork

FORMWORK.
3. Requirements for steel reinforcement shall be in accordance with Reinforcement

Specification 822 STEEL REINFORCEMENT.
820.41 PLACING CONCRETE
1. Concrete shall be deposited as near as possible in its final position and

shall be placed in a manner which will prevent segregation. It shall be spread in
horizontal layers with the first layer not exceeding 350 mm in compacted thickness and
the thickness of subsequent layers limited to 75% of the length of the immersion
vibrators being used. Placing shall be continuous between specified or approved
construction joints.
2. Where chutes are used to convey concrete their slopes shall be such as to
avoid segregation. Concrete shall not be allowed to fall freely more than 2.0 m unless
suitable chutes or baffles or other devices are provided to prevent segregation.
3. Screeding of the deck or top surface of the structure shall progress in a

longitudinal direction with the screed boards operated at right angles to the centreline of
the deck or top surface. Screed guides shall be accurately set and rigidly fixed in
position. Guides shall be of robust construction and shall be capable of sustaining
construction loadings without undue or permanent deflection.
4. Concrete shall not be placed in standing water.
5. All concrete in a batch shall be placed in its final position and compacted
within 90 minutes of adding water to the mix.
6. Prior to the placement of any concrete, the Contractor shall certify to HOLD POINT
the Superintendent that all falsework, formwork, reinforcement and other
embedded items, levels, placement procedures and curing procedures to be
employed comply with the requirements of the Specification.

820.42 CONSTRUCTION JOINTS
1. The location of all construction joints shall be as indicated on the

Drawings. Construction joints shall be made on true vertical and horizontal planes, or
as otherwise shown on the Drawings. The surface of the hardened concrete shall be
treated to remove all laitance and expose the aggregate so as to provide a thorough bond
with concrete cast subsequently. The roughened surface shall be thoroughly cleaned to
remove loose chips and any foreign matter.
2. Immediately before fresh concrete is cast against the joint the hardened
concrete surface shall be thoroughly wetted.
820.43 COMPACTION
820.43.01 MINIMUM EQUIPMENT
1. Before commencement of each concrete pour, sufficient vibrators HOLD POINT

and spares shall be available and tested. The number of working vibrators
required shall be not less than one for each 4 cubic metres of concrete placed per
hour. The number of standby vibrators shall be not less than 25% of the number
of working vibrators with a minimum of 1.
2. The required number of vibrators for a given rate of placing concrete

shall be continuously used during the pour.
3. Immersion vibrators shall be of the rotary out of balance type with a

frequency of not less than 150 Hertz and, where the specified concrete finish is Class 2
or 3, shall be fitted with approved rubber caps. The largest practical size of vibrator
should be used.
820.43.02 OPERATION
1. The concrete shall be properly compacted throughout the full extent of

each layer so as to produce a concrete that is uniformly plastic and dense and free of all
entrapped air and the finished work shall be a dense and uniform mass free of voids and
segregation and honeycombing and showing a uniform face as specified when the
forms are removed. Layers of concrete shall not be placed until layers placed
previously have been thoroughly compacted.
2. Compaction of concrete shall be carried out by approved power-driven

immersion vibrators applied in such a manner as will ensure the concrete is
satisfactorily and uniformly compacted. Immersion vibrators shall penetrate the full
depth of the layer and where the underlying layer is of fresh concrete shall penetrate
that layer a minimum of 100 mm to ensure that successive layers are well knitted
together. Immersion vibrators shall be withdrawn slowly to prevent the formation of
voids. Vibrators shall not be used to work the concrete along the forms or in such a
way as to damage formwork.
820.43.03 ADDITIONAL REQUIREMENTS FOR BRIDGE DECK CONCRETE
1. Compaction of deck concrete shall be carried out using approved

immersion vibrators followed by screeding with a "bull float" and finishing with a
mechanical trowelling machine.

820.44 FINISHING OF UNFORMED SURFACES
820.44.01 GENERAL
1. The type of finish and surface texture required in each part of the Works
shall be as shown on the Drawings.
820.44.02 ALLOWABLE TOLERANCES
1. Unformed concrete surface finishes shall be as designated on the

Drawings with reference to the classifications given in Table 820.2.
Designated Finish Type of Concrete Finish Maximum Allowable Surface

Irregularities
U1 A wood floated finish to produce a uniform 5 mm abrupt or 15 mm in a 3 m

surface without surface pitting or cavities. template.
U2 A high quality steel trowelled finish having a Nil abrupt or 5 mm in a 3 m

dense smooth impervious finish without surface template.
pitting or cavities.
U3 A high quality mechanical steel trowelled finish 2 mm abrupt or 5 mm in a 3 m

having a dense impervious finish without template.
surface pitting or cavities.
U4 A wood floated surface with a broomed finish. 3 mm abrupt or 5 mm in a 3 m

template.
TABLE 820.2 UNFORMED SURFACE FINISHES FOR CONCRETE
820.44.03 BROOMED FINISH
1. Broomed surfaces shall be obtained by finishing with a wood float

followed by brooming transversely to the principal slope direction, or perpendicular to
the edges. The broomed finish shall contain grooves between 1 mm and 3 mm deep
spaced between 2 mm and 6 mm apart so as to provide a non-slip surface.
820.45 CURING OF CONCRETE
1. Freshly placed concrete shall be protected from the sun, wind and rain
and prevented from drying out too quickly.
2. Curing shall commence immediately after the concrete has achieved its
final set.
3. The minimum curing period for structural concrete shall be 7 days. The
minimum curing period for any other concrete incorporating ground granulated blast
furnace slag, silica fume or fly ash shall be 14 days.
4. All concrete surfaces shall be cured by one of the following methods:
(a) By covering with sand or hessian or foam which is kept permanently

wet.

(b) By wrapping with polythene or similar film to provide an airtight
cover.
(c) By maintaining the formwork in position for the required curing

period.
(d) By spraying with an approved curing compound complying with the

requirements of AS 3799. Such curing compound shall be applied in
accordance with the manufacturer's published recommendations.
5. If the Contractor proposes to use a spray-on curing membrane on the top

surface of the bridge deck the Contractor shall prove that the membrane does not inhibit
the bond with any subsequent surfacing or alternatively, shall remove it by an approved
means immediately before application of the surfacing.
6. Concrete deck slabs shall also be treated with an approved aliphatic-

alcohol based evaporation retardant coating applied according to the manufacturer's
recommendations immediately after the surface has been initially screeded.
7. The Contractor shall ensure that the method of curing shall not result in
any staining of exposed surfaces of concrete.
820.46 STEAM CURING
820.46.01 GENERAL
1. This section of the Specification covers the curing of precast concrete

units in an atmosphere saturated with water vapour at a pressure not exceeding
atmospheric pressure.
2. The method of control and the proposed curing cycle to achieve the
specified concrete compressive strength are the responsibility of the Contractor, but
shall be in accordance with this Specification.
3. The Contractor shall take measures to allow for the potential lower 28
day compressive strength obtained from test cylinders cured initially under in-situ
conditions, as compared to those cured in accordance with the requirements of
AS 1012.
820.46.02 STEAM COVERS
1. To prevent drying out, steam covers shall be placed over the units
immediately following the casting and screeding operations in such a manner as to
ensure free circulation of the steam around the concrete mass.
820.46.03 CURING CYCLE
1. After an initial "maturity " of 40°C hours, but not less than two hours
after batching the last batch of concrete for the units, steam shall be admitted to the
steam covers at such a controlled rate that the maximum average temperature rise shall
not exceed 24°C per hour and the temperature rise in any one fifteen minute period
shall not exceed 6°C. (Note: The initial "maturity" period is calculated by dividing
40°C hours by the concrete temperature of the last batch of concrete placed in the unit.
The concrete temperature is as measured on an indicating thermometer).
2. If the admission of steam to the steam covers is delayed by more than the
initial specified "maturity" of 40°C hours after the completion of placing of concrete,
water curing, shall be applied until steaming commences.

3. Steaming shall continue at a rate such that the temperature rise shall not
exceed 24°C per hour, until a temperature under the steam covers of not greater than
70˙C ï 5°C has been reached. The steam supply shall then be reduced to maintain
temperature at 70°C + 5°C.
4. After the elapse of sufficient time at the maximum temperature for the
required concrete properties to have been reached, steam shall be completely shut
down. Steam covers shall not be removed nor any part of the concrete units and test
cylinders disturbed in any way until the temperature under the steam covers has fallen
to within 30°C of the ambient temperature. The rate of loss of temperature under the
steam covers after shutting off steam shall not exceed 24°C per hour.
820.46.04 TEMPERATURE CONTROLS
1. Temperature shall be recorded by means of recording thermometers. The

temperature sensitive parts of the thermometers shall be so positioned under the steam
covers as to record the minimum temperature under the covers. One recording
thermometer shall be used for each unit or group of units in line up to a total length of
25 m. For greater lengths, additional recording thermometers shall be used and the
distance between the temperature sensitive parts of the thermometers shall not exceed
25 m.
2. The recording thermometers shall be set in operation immediately upon

completion of casting and screeding.
3. Charts shall not be removed from any recording thermometers, nor the
recording thermometers disturbed or moved in any way until after the removal of the
steam covers.
4. Charts from temperature recording thermometers shall be retained.
5. The following information shall be recorded on the chart:

(a) date on which steaming commenced;
(b) unique identification and description of concrete unit;
(c) temperature correction, if any;
(d) time correction, if any;
(e) batching of concrete;
(f) temperature of concrete when placed;
(g) ambient temperature at time of removal of steam covers;
(h) name of Contractor or manufacturer.
820.46.05 STEAM DELIVERY
1. Under no circumstances shall steam jets be allowed to impinge upon any

part of the concrete units or of a test specimen, or of their formwork or moulds. Neither
shall any steam delivery pipe be attached directly to any formwork or moulds in such a
manner as may cause localised overheating of the concrete.
2. Sufficient steam jets or steam entry points shall be provided to ensure that
a substantially uniform temperature is maintained under the steam covers such that the
difference in temperature between any two points adjacent to the concrete units is not
more than 10°C.

820.46.06 EXTENT OF STEAM CURING
1. Unless otherwise specified, steam curing shall be continuously applied

until at least the seven day compressive strength for the specified concrete grade is
obtained.
820.46.07 PARTIAL STEAM CURING
1. Where steam curing is used only to obtain sufficient compressive strength

for removal of forms or for lifting, curing shall be continued by one or a combination of
the methods specified in Clause 820.45, for a minimum period of seven days.
820.46.08 CURING OF TEST CYLINDERS
1. Concrete compression test cylinders shall be placed near the concrete

units, and shall be so positioned under the steam covers as to be midway between two
adjacent points of steam entry, subject always to their being no closer to any points of
steam entry than half the width of the concrete units. Test cylinders shall be positioned
in a group at the lower face of the concrete unit and shall in no case be placed on top of
the concrete unit or its formwork.
2. Test cylinders shall remain in position under the steam covers until the
steam curing cycle is complete. Test cylinders shall be suitably covered in such a way
as to minimise moisture and temperature losses between the time of removal from the
steam covers and the time of forwarding to an accredited laboratory for testing.
Cylinders shall be transported in moisture proof containers.
820.47 PROTECTION OF CONCRETE SURFACES
1. The Contractor shall protect all completed surfaces from damage and
staining from any source including rain water and concrete spillage and grout spillage
and contact with hardwoods and ferrous metals. Where a delay is likely prior to casting
the next concrete pour such that reinforcement bars protruding from completed sections
may cause staining to exposed parts of the finished Works, then the bars shall be
suitably treated to prevent rusting.
2. Where any damage or staining has occurred to completed concrete

surfaces the affected section shall be deemed to be non conforming. The method of
repair or removal shall in no way harm or damage the adjacent section of the Works.

ANNEXURE 820A
CLASS OF CONCRETE
Class of Concrete Works Component
S35 Not Used
S35/10 Not Used
S40 Normal superstructures and reinforced

concrete substructures in non-marine
environments
S50 Special superstructures, including precast

deck troughs and in-situ topping
S50/10 Reinforced concrete restraint blocks

S PECIFICATION 821
FORMWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
821.01 SCOPE...................................................................................................................................... 1
821.02 REFERENCES ......................................................................................................................... 1
821.03 - 821.10 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
821.11 GENERAL ............................................................................................................................... 1
821.12 OFF-FORM CONCRETE FINISHES...................................................................................... 1
821.13 TIMBER FORMWORK .......................................................................................................... 2
821.14 OTHER TEMPORARY FORMWORK................................................................................... 2
821.15 - 821.20 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 2
821.21 FORMWORK DESIGN........................................................................................................... 2
821.22 FORMWORK CONSTRUCTION........................................................................................... 2
821.23 REMOVAL OF FORMWORK................................................................................................ 3
821.24 - 820.29 NOT USED ................................................................................................................ 4
821.30 TOLERANCES FOR CONCRETE CONSTRUCTION.......................................................... 4

Associated Roadworks Formwork
SPECIFICATION 821
FORMWORK
GENERAL
821.01 SCOPE
1. The work to be executed under this Specification is the design and

construction of formwork required for the proper construction of concrete for structures
in the permanent Works to the tolerances specified herein.
821.02 REFERENCES
1. Australian Standards and Test Methods are referred to in abbreviated

form (e.g. AS1234 or MRWA 123). For convenience, the full titles are given below:
AS 1761 Helical Lock-Seam Corrugated Steel Pipes

AS 2271 Plywood and Blockboard for Exterior Use
821.03 - 821.10 NOT USED
MATERIALS
821.11 GENERAL
1. Formed concrete surfaces shall comply with the requirements of

Section 3 of AS 3610.
821.12 OFF-FORM CONCRETE FINISHES
1. Surface Finishes shall meet the requirements of AS 3610 to the classes

designated on the Drawings.
2. Particular importance is attached to the achievement of good "off-the- Surface Finish

form" concrete finishes throughout the Works. Formwork shall be designed and
fabricated and erected and dismantled so that all formed concrete surfaces achieve the
specified uniform surface finish and texture without patching or plastering or cement
washing or any treatment after removal of the formwork.
3. All formwork made up from separate panels shall be so designed that the Panel
pattern of exposed panel joints complements the overall geometry of the structure and Arrangement
does not detract from the final appearance of the structure. The Contractor shall detail
proposed soffit and side formwork panel arrangements on the formwork Drawings.
4. In order to minimise the number of joints, formwork panels shall be Panels Plywood
supplied in the maximum practicable width and length. Plywood when used shall be
placed with the grain of the outer plys in the direction of the span.

821.13 TIMBER FORMWORK
1. Timber for formwork shall be well seasoned and free from loose knots Timber
and other defects. Timber which has become warped or unsuitable for use shall be
replaced at the Contractor's expense.
2. Plywood used in formwork lining shall comply with the relevant Plywood
provisions of AS 2271.
821.14 OTHER TEMPORARY FORMWORK
1. Forms made from materials other than plywood will be permitted Steel Forms
provided that the requirements for strength and rigidity and tightness are met and that
all bolts and rivet heads are countersunk and the finished concrete appearance is not
inferior to that obtained with good quality plywood. Steel forms shall be suitably
treated to prevent rusting of the face to be in contact with the concrete. The minimum
thickness required for steel formwork is 4 mm.
2. Polystyrene used as formwork shall be lined with a 3 mm thickness of Polystyrene

plywood on the face that is to be in contact with the concrete to be poured and such
facing shall be glued with a suitable adhesive to the polystyrene.
821.15 - 821.20 NOT USED
OPERATIONS
821.21 FORMWORK DESIGN
1. The design of all formwork shall be in accordance with AS 3610.
2. Formwork shall be so designed and constructed that it can be removed

without damage to the concrete. In the case of prestressed concrete the design of the
formwork shall permit movement of the members to occur during prestressing without
damage to the permanent work. Formwork shall be set to the profiles and precambers
shown on the Drawings and due allowance shall be made in setting the levels of the
formwork to compensate for any deflection or deformation due to the weight of the
concrete. Formwork shall be designed and constructed to withstand the vibration
required during placing of the concrete as specified in Section 820, CONCRETE FOR
STRUCTURES.
3. Where concrete is poured in more than one operation the Contractor shall Construction
take all necessary precautions to hold the formwork tight against the previous pour to Joints
avoid any discontinuities in the finished off form surface.
4. At least two weeks prior to commencing formwork construction the HOLD POINT
Contractor shall supply to the Superintendent design details and Drawings
checked and certified by a qualified structural engineer that the formwork
complies with the Specification.
821.22 FORMWORK CONSTRUCTION
1. Forms shall be built true to line and level and braced in a substantial and
unyielding manner to maintain correct position and shape.

2. On all exposed concrete surfaces the joints and splices in formwork Joints
panels shall be arranged in a manner suitable to the shape and area being formed.
Wherever possible joints in adjoining panels shall be positioned to be either staggered
by half panel lengths or placed in line.
3. Forms shall be mortar tight and the edges of all joints shall be sealed with a Sealing
suitable type of sealant. Forms subject to external water pressure shall be watertight.
4. Forms shall be held in correct alignment and spacing by bolt and rod Bolt and Rod
assemblies designed so that when the forms are removed no metal shall be closer to the Assemblies
surface of the concrete than the minimum cover specified on the Drawings. The rods
shall be held in place by devices capable of developing the strength of the rod attached
to the walings. Bolt and rod assemblies shall be arranged so that cavities caused by
their removal shall form a regular pattern appropriate to the area being formed. All
such cavities shall be wetted and carefully packed with colour matched mortars and
brought to an even surface.
5. The use of wires and/or bolts extending to the surface of the concrete Cover
shall not be permitted except where shown on the Drawings. Wires or bolts or
fastenings for forms or fixing reinforcement shall have the same concrete cover as
specified for reinforcement.
6. All handrail and guardrail sockets and hole formers and all other fittings Fittings
shall be accurately located. Bolts, pipes and bars used to form holes in the structure
shall be well greased and arranged so that they may be removed from the concrete
without excessive jarring or hammering before removal of forms.
7. Form lubricants shall be of the non-staining type which do not adversely Lubricant
affect the surface of the concrete. Lubricants shall be used after the fabrication of
forms and prior to the placing of any reinforcing steel or other embedded item. The
lubricant shall be uniformly applied in a thin film and any surplus shall be removed
prior to placing concrete. Care shall be taken that such coatings do not soil the surface
of reinforcement.
8. Where the bottom of a panel is inaccessible from within then access Access Panels
panels shall be provided to permit thorough removal of rubbish before placing concrete.
9. Prior to concreting all forms shall be clean and free from sand and Cleaning
shavings and tie wire ends and other debris. Surplus water shall be drained and any
temporary openings closed in a proper manner.
10. Forms for re-entrant angles shall be chamfered and forms for corners Chamfers &
shall be filleted. The bevel in each case shall have a width of 20 mm on each side Fillets
unless otherwise shown on the Drawings.
821.23 REMOVAL OF FORMWORK
1. Formwork shall be removed in such a manner as shall ensure that no Removal

damage to the concrete occurs.
2. Formwork support and formwork to reinforced concrete deck soffits and Timing
pier cap beams shall not be removed until a minimum of 7 days has elapsed and the
concrete has achieved a cylinder strength of 30MPa.
3. Not Used.
4. For other parts of the structure other than the deck formwork shall not be Timing
removed until a minimum of 48 hours has elapsed and the concrete has attained a
cylinder strength of 20 MPa.

821.24 - 820.29 NOT USED
821.30 TOLERANCES FOR CONCRETE CONSTRUCTION
1. The materials for forms and form arrangements shall be such as to result
in finished concrete work complying with the tolerances shown in Table 821.1
Footings to Piers and Abutments:
(a) Variation of dimensions in plan and elevation - 5 mm + 20 mm

(b) Misplacement or eccentricity of centreline + 10 mm
(c) Variation in specified level + 10 mm
Abutment Walls, Columns and Column Cap Beams:
(a) Variation from vertical or specified batter. The lesser of 1:300 or

+ 5 mm in full height
(b) Variation in cross sectional dimensions - 5 mm + 10 mm
(c) Misplacement or eccentricity of centreline + 5 mm
(d) Variations from specified level of surfaces other than + 5 mm
bearing surfaces
(e) Variation from specified level of all bearing surfaces + 3 mm
Bridge Superstructures:
(a) Departure from specified alignment of centreline and + 10 mm

edges
(b) Departure from specified profile + 10 mm
(c) Variation in cross-sectional dimensions − 3 mm + 5 mm
(d) Variation from specified level of all bearing surfaces + 3 mm
TABLE 821.1 TOLERANCES FOR CONCRETE CONSTRUCTION

S PECIFICATION 822
STEEL REINFORCEMENT
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
822.01 SCOPE...................................................................................................................................... 1
822.02 REFERENCES ......................................................................................................................... 1
822.03 CLEAR COVER REQUIREMENT ......................................................................................... 1
822.04 - 822.09 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 1
822.10 STANDARDS .......................................................................................................................... 1
822.11 BENDING AND CUTTING.................................................................................................... 1
822.12 STORAGE................................................................................................................................ 2
822.13 CLEANING.............................................................................................................................. 2
822.14 MECHANICAL SPLICES ....................................................................................................... 2
822.15 - 822.19 NOT USED ................................................................................................................ 2
OPERATIONS ........................................................................................................................................... 3
822.20 FIXING .................................................................................................................................... 3
822.21 WELDING ............................................................................................................................... 3
822.22 LAP SPLICES .......................................................................................................................... 3
822.23 TOLERANCES FOR FIXING................................................................................................. 4

Associated Roadworks Steel Reinforcement
SPECIFICATION 822
STEEL REINFORCEMENT
GENERAL
822.01 SCOPE
1. The work to be executed under this Specification is the scheduling, Scope

supply, delivery and fixing of steel reinforcement to be cast into concrete.
822.02 REFERENCES
1. MRWA Specifications, Australian Standards and Test Methods are

referred to in abbreviated form (e.g. AS1234 or MRWA 123). For convenience, the full
titles are given below:
AS/NZS 4671 Steel Reinforcing Materials

AS 1554.3 Welding of Reinforcing Steel
822.03 CLEAR COVER REQUIREMENT
1. The minimum cover measured from the surface of the concrete to the face
of any reinforcing steel shall be as shown on the Drawings.
822.04 - 822.09 NOT USED
MATERIALS
822.10 STANDARDS
1. Reinforcement used in the Works shall comply with the Australian

Standards listed in Table 822.1.
Reinforcement Specification
Grade 500N Hot Rolled Deformed Steel AS/NZS 4671

Reinforcing Bars for Concrete
Reinforcing Wire AS/NZS 4671
Reinforcing Fabric/Welded Mesh AS/NZS 4671
TABLE 822.1 REINFORCEMENT USED IN WORKS
822.11 BENDING AND CUTTING
1. The Contractor shall prepare reinforcement bending schedules from the Schedule
Drawings.
2. Reinforcement shall be accurately cut and bent to the dimensions and

shapes shown on the Drawings. All bars shall be bent in accordance with Table 822.2
unless otherwise detailed on the Drawings. Pin diameters for bends shall be in
accordance with Table 822.3 and hook and cog allowances in accordance with
Table 822.4.
3. Reinforcement partially embedded in concrete shall not be field bent

unless it is allowed for on the Drawings. Where field bending is required it shall be
carried out by the application of a constant force using a pin diameter as specified in
Table 822.3.
4. Heating of reinforcement shall not be permitted except where indicated

on the Drawings and shall then only be carried out in accordance with the following
requirements:
a) The steel shall be heated uniformly for at least 100 mm each side of
the portion to be bent.
b) For grade 500 steel the heating shall be controlled such that the
temperature does not exceed 450°C and shall be measured with
temperature indicating crayons. Steel heated beyond 450°C shall be
rejected.
c) Grade 250N steel may be heated to a dull cherry red.
d) Heated bars shall not be cooled rapidly by quenching or any other

means.
e) All heating shall be carried out in the presence of the

Superintendent.
5. Prior to heating any reinforcement the Contractor shall supply to the HOLD POINT
Superintendent full details of the proposed heating procedure.
822.12 STORAGE
1. Reinforcing steel shall be stored above ground level and shall be

protected from damage and deterioration.
822.13 CLEANING
1. Reinforcement placed in the Works shall be clean and free from all loose
rust and mill-scale and all dirt and grease and other foreign substances which might
impair the bond between steel and concrete. After being placed in position all
reinforcement shall be maintained in a clean condition until it is embedded in the
concrete.
822.14 MECHANICAL SPLICES
1. Mechanical splices shall be used only where shown on the Drawings.

Alternative mechanical splices to the ones shown on the Drawings may be used
provided that they are capable of developing at least 125% of the specified yield
strength of the bar and meet the dimensional and clearance requirements shown on the
Drawings.
822.15 - 822.19 NOT USED

OPERATIONS
822.20 FIXING
1. Reinforcing steel shall be accurately placed in the positions shown on the

Drawings in accordance with the tolerances given in Table 822.5.
2. The reinforcement shall be secured in position so that it shall not be

displaced during the placement of concrete and the Contractor shall ensure that there is
no disturbance of the reinforcement in concrete that has already been placed.
3. Reinforcing bars intended to be in contact at points where they cross shall

be bound together with 1.6 mm annealed soft iron tie wire. Stirrups shall be wired
securely to the bars they are intended to restrain so as to form an effective
reinforcement cage.
4. All reinforcing steel supported off formwork where the resulting concrete
surface will be exposed, shall be supported on approved special purpose cement bar
spacers.
5. Reinforcement not supported off formwork or where the resulting

concrete surface will be concealed may alternatively be supported on approved concrete
blocks or plastic chairs.
822.21 WELDING
1. Welding or tack welding of reinforcement will not be permitted except

where indicated on the Drawings and shall then comply with the following
requirements:
a) Welding shall be in accordance with AS 1554.3.
b) Welding of grade 500 steel will not be permitted within 75 mm of a

bend.
c) Welds shall not be broken out.
2. Prior to welding any reinforcement, the Contractor shall supply to HOLD POINT
the Superintendent documentation showing that welders to be employed on the
Works are suitably qualified and that the qualification of welding procedures has
been verified by testing in accordance with the requirements of AS 1554.3
822.22 LAP SPLICES
1. Reinforcement shall only be spliced at locations shown on the Drawings.
2. The minimum length of lap shall be as indicated on the Drawings.
3. Welded steel wire fabric shall be lapped as detailed on the Drawings and
where not detailed shall overlap by at least one complete mesh on all sides such that the
end cross wire of one sheet overlaps with the second end wire of the adjacent sheet.
Loose bars shall not be used in conjunction with fabric reinforcement except where
shown on the Drawings. Loose small pieces of fabric shall only be used where they are
essential for fitting into small confined parts of the Works.

822.23 TOLERANCES FOR FIXING
1. The tolerances for fixing of reinforcement are given in Table 822.5.
1 2 3 4
Nominal length Nominal size Tolerance
Condition or Dimension or Diameter of (mm)
L (mm) Bar (mm)
On each overall dimension, or on the overall dimension
of each straight portion, or on that offset dimension,
controlled by concrete cover at both ends for bars
other than fitments. Up to 600 Up to 20 +0 -20
Up to 600 Over 20 +0 -30
Over 600 Up to 20 +0 -40
Over 600 Over 20 +0 -50
Up to 600 Up to 20 -0 +20
Up to 600 Over 20 -0 +30
Over 600 Up to 20 -0 +40
Over 600 Over 20 -0 +50
On that overall dimension controlled by cover at

both ends, for fitments (ties, stirrups, helices,
hoops, and the like) only.
Up to 600 Up to 12 +0 -10
Up to 600 16 to 20 +0 -15
Over 600 Up to 20 +0 -20
Any Length Over 20 +0 -30
Up to 600 Up to 12 - 0 +10
Up to 600 16 to 20 -0 +15
Over 600 Up to 20 -0 +20
Any Length Over 20 -0 +30
On the overall dimension, or on the overall dimension

of each straight portion, or on that offset dimension,
controlled by concrete cover at one end only or at
neither end.
Any length Any size -0 +50
including
allowances
for laps.
On the overall offset dimension of a cranked column bar Any offset Up to 20 -0 +10
On the deviation from square measured in relation to Any bar 24 and over
the end 300mm of the sawn or machined end of a length. ∝=2°
a straight bar intended for use as an end bearing
TABLE 822.2 FABRICATION

Case Material Diameter
a) Reinforcement, other than that specified in All deformed bars 5 db

items(b), (c) or (d) below. Fabric 3 db
b) Fitments Wire and fabric 3 db

Grade 230R bars 3 db
All deformed bars 4 db
c) Reinforcement in which the bend is intended to Size 16 mm or less 4 db

be subsequently straightened or rebent Size 20 mm or 24 mm 5 db
Size 28 mm or greater 6 db
d) Reinforcement which is epoxy-coated or Size 16 mm or less 5 db

galvanised, either before or after bending Size 20 mm or greater 8 db
NOTE: db is the diameter of the bar being bent.
TABLE 822.3 PIN DIAMETERS FOR BENDS
Bar Diam (mm) 6 10 12 16 20 24 28 32 36
Length Allowance (mm) 120 140 160 180 220 260 300 340 380
(assumed pin diameter, 5 db)
TABLE 822.4 HOOK AND COG ALLOWANCES FOR BENT BARS AND FITMENTS

1 2 3
Case Condition Tolerance(mm)
1 Where concrete cover to the 1a. At the end of
reinforcement is the controlling reinforcement.
factor. Tolerances on Dimensions 'C'
-0 +30
1b. At the outside edge of Tolerances on Dimension 'T'

reinforcement or fitment. -0 +20 when compression face
-0 +10 when tension face
Tolerances on Dimension 'B'
-0 +10 when tension face
-0 +20 when compression face
2 Where cover is not 2a. At the end of reinforcement. Tolerance on Dimension 'L'.
controlling. ± 50
(see Case 1)
2b. At the outside edge of Tolerances on Dimension 'E'
reinforcement including ±10
fitments.
3 Lateral spacing of 3a. Beam or column type member.

reinforcement.
Tolerance on Dimension 'S'

+0.1S or ± 15mm
whichever is greater.
3b. Slab or wall type member.
4 Bars in corners, crossing bars Bars to be placed in configuration

starter bars, etc. shown on the Drawings.
Tolerances on location of an
individual bar ± 15mm unless
otherwise limited by cover
requirements of case 1 above.
The tolerances given above are the maximum permissable, but it should be noted that
in some circumstances, where reinforcement is fabricated to maximum tolerance,
they may not be fully available.
NOTE: This table should be read in conjuction with Table 822.2
TABLE 822.5 TOLERANCES ON FIXING REINFORCEMENT

S PECIFICATION 827
PRECAST CONCRETE NOISE

PANELS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
827.01 SCOPE...................................................................................................................................... 1
827.02 REFERENCES ......................................................................................................................... 1
827.03 MANUFACTURE.................................................................................................................... 1
827.04 FORMWORK .......................................................................................................................... 1
827.05 REINFORCEMENT................................................................................................................. 2
827.06 CONCRETE ............................................................................................................................. 2
827.07 MEMBER TOLERANCES...................................................................................................... 2
827.08 MARKING OF MEMBERS .................................................................................................... 2
827.09 STANDARD OF FINISH ........................................................................................................ 3
827.10 HANDLING AND STORAGE................................................................................................ 3
827.11 ERECTION OF NOISE WALLS............................................................................................. 4

Associated Roadworks Precast Concrete Noise Panels
SPECIFICATION 827
PRECAST CONCRETE NOISE PANELS
GENERAL
827.01 SCOPE
1. The work to be executed under this Specification is the manufacture,

supply and installation of precast concrete Noise Wall panels and posts as detailed on
the drawings.
827.02 REFERENCES

below:
Specification 820 CONCRETE FOR STRUCTURES

Specification 908 ANTI-GRAFFITI COATINGS
827.03 MANUFACTURE
827.03.01 GENERAL
1. Manufacture and acceptance shall be in accordance with this

Specification and details shown on the drawings.
The external faces of the wall panels and posts will be exposed surfaces in the
completed works and shall have a finish as described on the drawings. Casting methods
shall be designed to ensure that no damage occurs to the units. The ends of all units
shall be free from any grout loss or honeycombing or cracking or spalling. Units with
defects of this nature shall be rejected.
2. No fixing points will be permitted on the external exposed faces of the

panels.
3. Protect all completed surfaces from damage and staining from any source
including rainwater and concrete spillage.
827.04 FORMWORK
1. The provisions of Specification 821, FORMWORK, shall apply and in

addition:
(a) The formwork used for the units shall be rigid formwork to achieve
a surface finish of Class 2.

(b) The unformed surface of the wall panels shall have a two tone effect
created by a smooth trowelled finish to the top third of the panels
with a broomed finish to the lower portion of the panels as detailed
on the drawings.
827.05 REINFORCEMENT
1. The provisions of Specification 822, STEEL REINFORCEMENT,

shall apply, except that the tolerance on the minimum clear cover specified shall be -0
mm + 5 mm in all cases.
827.06 CONCRETE
The provisions of Specification 820, CONCRETE FOR STRUCTURES, shall apply.

In addition:
(a) Concrete shall be subjected to intense compaction at time of casting. Compaction
(b) Where steam curing is proposed to be used then it shall be low Curing
pressure wet steaming and in accordance with Clause 820.28. Any
other form of accelerated curing will not be permitted. Steaming
shall not commence until at least two hours after the last batch of
concrete has been placed. Subsequent curing shall be in accordance
with Clause 820.27.
827.07 MEMBER TOLERANCES
(a) The precast units shall conform to the dimensions shown on the
drawings and to the Codes specified.
(b) Tolerances applying to the precast units shall be as follows:
Overall panel height +3, -3mm

Overall panel length +0, -3mm
Panel thickness +0, -3mm
Straightness of edges and flatness of surface length / 1000
Warp 3mm
Squareness of corners (cross-diagonal measurement) 3mm
Overall post length +10, -10mm
Overall post cross section dimensions +3, -0mm
Post recess dimensions +3, -0mm
827.08 MARKING OF MEMBERS
1. Each member shall be clearly marked using distinguishing numbers or

letters consistent with those shown on the drawings. The marking location shall not be
visible in the completed structure.

827.09 STANDARD OF FINISH
1. First class concrete with good workmanship is required. Any concrete

which does not meet the approval of the Superintendent because of pour discontinuity,
poor materials, variation in materials, non-uniformity of colour, poor compaction or
mixing, or unsuitable formwork, will be rejected and re-built at the expense of the
Precast Contractor.
2. Prior to commencement of manufacture, the Precast Contractor shall

make a sample panel of minimum size 1000 x 1000 mm x 60 mm thick for the purpose
of indicating the proposed finish. This sample, when approved by the Superintendent
shall form the basis of the standard of finish required for the execution of the work
included in this section.
3. Allow for the approved sample panel to be delivered to site during

construction.
4. No production units shall be produced until the sample panel has been
approved by the Superintendent.
827.10 HANDLING AND STORAGE
827.10.01 GENERAL
1. Temporary storage areas shall be carefully cleared and levelled. The

supports shall be on firm foundations and every precaution taken to prevent subsidence
from occurring and to prevent the units bearing other than at the specified support
positions.
827.10.02 LIFTING
1. Leave precast units in forms until the concrete has attained sufficient
strength and durability to be handled without damage, either structurally or to corners
and surfaces. Damaged units will be rejected.
2. No unit is to carry its own weight or any load until it has gained sufficient
strength to do so. If removed prior to this stage adequately support it and carefully
handle it.
3. Lifting insert locations and rigging system requirements are to be

assessed by the Precast Contractor to ensure that no cracking of the panels occurs
during lifting or transportation.
4. The Precast Contractor shall submit calculation to the Superintendent

related to the lifting of the panels from the mould allowing for the effects of suction. In
particular, details are to be provided on the proposed method of tilting the panels from
their poured position to the vertical.
5. Ensure precast wall panels are lifted and transported in a vertical upright
position.
827.10.03 TRANSPORT
1. The units shall be transported to the Site in a manner that does not
damage the units. Units shall not be transported until they are at least 7 days old and
the concrete shall have reached its 28 day nominated strength.

827.10.04 STACKING
1. Allow to store precast units at the precasting yard or other approved

location until the Contractor progressively takes delivery of the units.
2. Wall panels shall be kept in an upright position at all times and shall only
be lifted from the lifting points specified by the Precast Contractor.
827.11 ERECTION OF NOISE WALLS
1. Handle all precast units with due care to avoid bumping and impact. In
the event of any member sustaining damage in the way of cracking or spalling, set aside
the member and no further work done on it until it has been inspected by the
Superintendent and determined whether the member can be repaired or is to be rejected.
2. Do not lift or support units at other than the designated lifting points. All
wall panels shall be delivered in a vertical position.
3. The delivery sequence of precast units on site shall be scheduled so that

erection can be accomplished directly from the delivery vehicle.
4. Carry out the erection of the precast units in accordance with the lines
and levels shown on the drawings and to the tolerances specified below.
5. Ensure that the posts are adequately braced in position, levelled, aligned
and plumbed prior to concreting the post socket. Provide adequate protection during
post installation and concrete backfilling to prevent side collapse of the hole walls.
Where necessary, provide a temporary steel lining.
6. The following tolerances shall apply to the erected precast units:
Variation in verticality +/- 5mm (in full height)

Level of top of units +/- 10mm
Location in plan +/- 10mm

S PECIFICATION 828
PRECAST CONCRETE
MEMBERS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
828.01 SCOPE...................................................................................................................................... 1
828.02 REFERENCES ......................................................................................................................... 1
828.03 – 828.11 NOT USED ............................................................................................................... 1
828.12 MANUFACTURE.................................................................................................................... 1
828.13 NOT USED .............................................................................................................................. 2
828.14 HANDLING AND STORAGE................................................................................................ 2
828.15 – 828.19 NOT USED ............................................................................................................... 3
828.20 ERECTION AND CONSTRUCTION..................................................................................... 3
828.21 – 828.22 NOT USED ............................................................................................................... 3
828.23 DECK CONCRETE OVERLAY ............................................................................................. 3

Associated Roadworks Precast Concrete Members
SPECIFICATION 828
PRECAST CONCRETE MEMBERS
GENERAL
828.01 SCOPE
1. The work to be executed under this Specification is the supply and

installation of precast concrete members (decking slabs).
828.02 REFERENCES

below:
AS 1554.3 Welding of Reinforcing Steel

828.03 – 828.11 NOT USED
828.12 MANUFACTURE
828.12.01 GENERAL
1. Manufacture and acceptance shall be in accordance with this

Specification and details shown on the Drawings.
2. Casting methods shall be designed to ensure that no damage occurs to the

units. The ends of all units shall be free from any grout loss or honeycombing or
cracking or spalling. Units with defects of this nature shall be rejected.
828.12.02 FORMWORK
1. The provisions of Specification 821, FORMWORK, shall apply and in

addition:
(a) Formwork shall be fabricated from steel with a minimum thickness

of 3 mm.
(b) Unformed surfaces shall be roughened and shall be free from

laitance and loose material which may be deleterious to the bond
with the in situ deck concrete. This shall be achieved after curing by
scabbling or any other suitable method.

828.12.03 REINFORCEMENT
1. The provisions of Specification 822, STEEL REINFORCEMENT,

shall apply, except that the tolerance on the minimum clear cover specified shall be -0
mm + 5 mm in all cases. Any lengths of reinforcement which are left exposed after
manufacture shall be coated with cement grout to prevent rusting.
828.12.04 CONCRETE
1. The provisions of Specification 820, CONCRETE FOR

STRUCTURES, shall apply. In addition:
(a) If the Contractor proposes to use external type vibrators for concrete Compaction
compaction then he shall provide evidence to show that the same
level of compaction can be achieved.
(b) Where steam curing is proposed to be used then it shall be low Curing
pressure wet steaming and in accordance with Clause 820.46. Any
other form of accelerated curing will not be permitted. Steaming
shall not commence until at least two hours after the last batch of
concrete has been placed. Subsequent curing shall be in accordance
with Clause 820.45.
828.12.05 MARKING OF MEMBERS
1. Each member shall be clearly marked using distinguishing numbers or

letters consistent with those shown on the Drawings.
828.13 NOT USED
828.14 HANDLING AND STORAGE
828.14.01 GENERAL
1. Temporary storage areas shall be carefully cleared and levelled. The

precast concrete members shall be supported over their full width at the lifting points
only. Temporary supports shall be of timber of a minimum size 150 mm wide, 100 mm
thick and 1 m long. The supports shall be on firm foundations and every precaution
taken to prevent subsidence from occurring and to prevent the units bearing other than
at the specified support positions.
828.14.02 LIFTING
1. Units shall be kept in the upright position at all times and shall only be
lifted from the specified lifting points. Units shall be lifted using either a full length
steel lifting beam or two cranes to ensure the force at the lifting points is purely vertical.
828.14.03 TRANSPORT
1. The units shall be transported to the Site in a manner which does not
damage the units. Units shall not be transported until they are at least 7 days old and the
concrete shall have reached its 28 day nominated strength.

828.14.04 STACKING
1. Precast concrete members may be stacked on top of each other. Each

layer shall be separated from the next layer by at least 75 mm, by temporary supports
placed in line vertically at the support points.
828.15 – 828.19 NOT USED
828.20 ERECTION AND CONSTRUCTION
1. No precast concrete members shall be positioned in the Works until the

supporting substructure has gained 75% of its design strength. The units shall be
positioned to a tolerance of ±3 mm.
828.21 – 828.22 NOT USED
828.23 DECK CONCRETE OVERLAY
1. Before the deck concrete overlay is placed the top surface of the precast
units shall be thoroughly cleaned with a water jet to remove dust and chips and any
other foreign matter.
2. Immediately prior to commencing of concreting the top surface of the

precast units shall be thoroughly wetted.

S PECIFICATION 830
STRUCTURAL STEELWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 3
830.01 SCOPE...................................................................................................................................... 3
830.02 REFERENCES ......................................................................................................................... 3
830.03 WORKMANSHIP.................................................................................................................... 4
830.04 PROVISION FOR AUDIT INSPECTION .............................................................................. 4
830.05 DEFINITIONS ......................................................................................................................... 4
830.06 QUALITY ASSURANCE........................................................................................................ 4
830.07 - 830.09 NOT USED ................................................................................................................ 5
MATERIALS.............................................................................................................................................. 5
830.10 NOT USED .............................................................................................................................. 5
830.11 SPECIFICATIONS FOR STEEL............................................................................................. 5
830.12 TEST CERTIFICATES AND IDENTIFICATION OF MATERIAL...................................... 6
830.13 TESTING OF STEEL .............................................................................................................. 6
830.14 IDENTIFICATION MARKS................................................................................................... 7
830.15 STORAGE................................................................................................................................ 7
830.16 HANDLING AND STACKING .............................................................................................. 7
FABRICATION ......................................................................................................................................... 7
830.17 GENERAL ............................................................................................................................... 7
830.18 SHOP DRAWINGS ................................................................................................................. 7
830.19 PRECAMBER AND DISTORTIONS ..................................................................................... 8
830.20 STRAIGHTENING AND CORRECTION OF DISTORTIONS............................................. 8
830.21 CUTTING AND EDGE TREATMENT .................................................................................. 8
830.22 NOT USED .............................................................................................................................. 9
830.23 HOLES FOR BOLTING.......................................................................................................... 9
830.24 WELDING ............................................................................................................................... 9
830.25 STUD SHEAR CONNECTORS ............................................................................................ 13
830.26 BOLTING .............................................................................................................................. 14
830.27 HOLDING DOWN BOLTS................................................................................................... 14
830.28 - 830.29 NOT USED .............................................................................................................. 14
830.30 CERTIFICATION OF FABRICATION ................................................................................ 14
830.31 - 830.39 NOT USED .............................................................................................................. 15
830.40 ERECTION ............................................................................................................................ 15
830.41 - 830.49 NOT USED .............................................................................................................. 15
830.50 BOLTED JOINTS .................................................................................................................. 15
830.51 - 830.59 NOT USED .............................................................................................................. 15
830.60 CONSTRUCTION TOLERANCES ...................................................................................... 15
830.61 - 830.79 NOT USED .............................................................................................................. 16
SPECIAL REQUIREMENTS................................................................................................................. 16
830.80 - 830.89 NOT USED .............................................................................................................. 16

Associated Roadworks Structural Steelwork
SPECIFICATION 830
STRUCTURAL STEELWORKS
GENERAL
830.01 SCOPE
1. The work to be executed under this Specification is the supply,

fabrication and erection of steel beams and associated structural steel
work, except for handrailing, guardrailing and minor items which are
covered in Specifications 831 and 833 respectively.
830.02 REFERENCES
1. All metal fabrication and welding shall comply with the current edition of
the relevant Standard or Code of Practice (including amendments)
specified in the Contract Specification or nominated on Contract
Drawings.
The requirements of the relevant Standard / Code are deemed to be the

minimum standard applicable, unless otherwise stated in the Contract
Specification.
Australian Standards and MRWA Test Methods are referred to in

abbreviated form (e.g. AS 1234 or WA123). For convenience, the full
AS 1100 Technical Drawings (Parts as appropriate)

AS 1101.3 Graphical Symbols for General Engineering - Welding and Non-
Destructive Examination.
AS 1163 Structural Steel Hollow Sections
AS 1252 High Strength Bolts with Associated Nuts and Washers for
Structural Engineering
AS 1553 Low Carbon Steel Covered Electrodes for Manual Metal Arc
Welding
AS/NZS 1554.1 Welding of Steel Structures
AS 1554.2 Stud Welding
AS 1710 Non Destructive Testing of Carbon and Low Allow Steel Plate -
Test Methods and Quality Classification
AS 1796 Certification of Welders and Welding Supervisors
AS 1858 Electrodes and Fluxes for Submerged Arc Welding
AS 1966 Electric Arc Welding Power Sources
AS/NZS 1995 Welding Cables
AS 2203 Carbon Steel Electrodes, Cored (for Arc Welding)
AS 2812 Welding, brazing and cutting of metals – Glossary of terms
AS/NZS 3678 Structural Steel Hot Rolled Plates, Floorplates and Slabs
AS/NZS 3679 Hot Rolled Structural Steel
AS 4100 Steel Structures
Austroads Australian Bridge Design Code
Specification 831 MANUFACTURE AND SUPPLY OF MINOR STEEL ITEMS

Specification 833 BRIDGE RAILINGS AND BALUSTRADES
Specification 835 PROTECTIVE TREATMENT FOR STEEL WORK
830.03 WORKMANSHIP
1. All work shall be carried out by competent and qualified personnel

under the supervision of experienced and competent supervisors to fully
satisfy the requirements of this Specification.
830.04 PROVISION FOR AUDIT INSPECTION
1. In addition to the Special Conditions of Contract, the Contractor shall lay

out and arrange the individual members or units to be inspected so that
identification marks on each may be readily distinguished and so that
each member or unit is accessible for audit inspection by the
Superintendent.
2. The Contractor shall assist the Superintendent by turning the members or

parts to permit examination of all sides. The Contractor shall supply free
of charge all labour and tools and scaffolding required to facilitate full
inspection.
830.05 DEFINITIONS
1. ITP - Detailed Inspection and Test Plan(s) for the Works
2. MDR - Manufacturer’s Data Report
3. Welding Service Provider (WSP) - The Contractor as defined in the

Conditions of Contract or an approved Subcontractor (approval in writing
to be obtained from the Superintendent) to undertake the Works.
830.06 QUALITY ASSURANCE
1. The WSP shall:
a. Be responsible for all quality control and assurance activities

necessary to ensure that the completed Works comply with the
specified requirements.
b. Provide prior information to the Superintendent in respect of any

proposed subcontract work to enable the Superintendent to assess
and approve their suitability for that work.
c. Establish and maintain an accredited quality management system to

AS/NZS ISO 9002:1994 and AS/NZS ISO 3834 (or to an approved
alternative) and to ensure that any Subcontractors are subject to the
same requirements.
d. Submit a Quality Plan to the Superintendent detailing how the

Quality Assurance requirements are to be applied to each element of
the Works.

830.07 - 830.09 NOT USED
MATERIALS
830.10 NOT USED
830.11 SPECIFICATIONS FOR STEEL
1. All materials supplied by the Contractor shall be new and shall conform New Steel
to the Standards specified below.
2. Unless otherwise specified, steel plate used in box girders shall meet the Standards
requirement of Grade 250LO in accordance with AS 3678.
3. Unless otherwise specified, all structural steel sections except hollow

sections, shall be Grade 300 in accordance with AS 3679.
4. Structural steel hollow sections shall conform to the requirements of

AS 1163 and shall be grade C350.
5. Bolts, Nuts, Screws and Washers:
a. All bolts, nuts, screws and washers will conform with the relevant
Australian Standards listed in Clause 9.2;
b. High strength bolts, with associated nuts and washers, will comply
with AS4100. The length of the bolt will be as shown on the
Drawings, or, if no length is shown, will be in accordance with
AS4100;
c. All screw threads will conform to the ISO coarse pitch series thread
in accordance with AS1275;
d. Unless shown on the Drawings, nuts other than those for high
strength bolts will be “normal” size. The strength grade of normal
nuts to be associated with each strength grade of the bolt, U-bolt,
screw, stud or other threaded component will be as follows:
Grade of Bolt, U-bolt etc. Strength Grade of Nut
4.6 5
5.8 5
8.8 8
10.9 10
6. The strength grade required for precision bolts and screws will be as
shown on the Drawings.
7. Where stainless steel bolts are shown on the Drawings the stainless steel
used in the manufacture of non high strength bolts, nuts and dowels will
conform to AS2837 Grade 316L for welded components or Grade 316
otherwise. The stainless steel used in the manufacture of high strength
bolts and nuts will conform to SS2343 (American Iron and Steel Institute
Grade 316 Mo+) and have a minimum ultimate tensile strength of 800
Mpa.

8. Where prevailing torque locknuts, also known as “self -locking nuts” are
shown on the Drawings, they will be the insert type having a nylon or
similar plastic insert such as “Nyloc” nuts. Those used with commercial
grade bolts or U-bolts will be strength grade 6 or higher.
9. Unless shown otherwise on the Drawings, the following types of washers

will be used:
a. With precision bolts – bright metal washers, normal series;
b. With commercial bolts – black metal washers, normal series;
c. With stainless steel bolts – stainless steel washers Grade 316, normal
series.
10. Washers are generally not required under socket head cap screws.
11. The Contractor will obtain a Certificate from a laboratory with

appropriate NATA registration stating that the bolt, nuts screws and
washers comply with the appropriate standard.
830.12 TEST CERTIFICATES AND IDENTIFICATION OF MATERIAL
1. Steel shall be identified in accordance with Clause 15 of AS 3678 or Identification

Clause 5 of AS 3679 as appropriate This identification shall be
maintained during all phases of fabrication.
2. The Contractor shall ensure that all materials or parts conform with the
tests required by the Standards and with other tests specified in this Part
of the Specification.
3. Test certificates showing the results of mechanical tests and chemical Certificates
analysis (where applicable) of the material or parts used in the Works
shall be retained by the Contractor, and shall form part of the MDR.
4. All materials or parts used in the Works shall be traceable to the Test
Certificates. The Contractor shall establish and maintain a
comprehensive system of identification records. Copies of all these
records shall be forwarded to the Superintendent on request, and shall
form part of the MDR.
830.13 TESTING OF STEEL
1. If steel manufacturer's certificates in accordance with Clause 830.12 are Testing

not available, then the Contractor shall prepare specimens and carry out
tests in accordance with the relevant Australian Standards.
2. Prior to fabrication, all plates of thickness in excess of 30 mm shall be

tested by the Contractor along all lines where welding will be carried out
using continuous ultrasonic testing to establish that the plates are free
from laminations and defects. The method of testing shall be in
3. A written report on each line tested shall be forwarded direct from the
NATA registered testing laboratory to the Superintendent within 24 hours
of completion of the test. The location and extent of inclusions and/or
laminations shall be detailed and sketched in the report.

830.14 IDENTIFICATION MARKS
1. Each item of structural steelwork shall have its own item mark number Identification
which shall be used on all related schedules and documents. This mark
shall be clearly indicated on all members by durable identification marks
to enable accurate identification on site.
830.15 STORAGE
1. All steel, whether fabricated or not, shall be stored in such a manner that
corrosion is minimised. Generally, storage at least 200 mm above the
ground on timber gluts under cover will be satisfactory. Rusted or bent
or damaged steel will be rejected.
830.16 HANDLING AND STACKING
1. Before and after fabrication and during transit and on the Site all Identification
structural steelwork shall be handled and stacked in such a way that it is
not damaged.
2. All bolts and nuts and washers and plates under 300 mm maximum
dimension and small articles generally shall be packed separately in
watertight containers.
3. Identification marks as specified in Clause 830.14 shall be stencilled on

each package in a conspicuous position.
FABRICATION
830.17 GENERAL
1. All structural steelwork shall be fabricated as shown on the Drawings and

in accordance with the requirements of AS 4100 and AS 1554.1 (SP
quality) unless directed otherwise.
2. The steelwork shall be fabricated where applicable with all necessary

temporary brackets and straps and gussets and cleats and fixings and
lifting eyes and the like necessary for erection and assembly.
830.18 SHOP DRAWINGS
1. The Contractor shall prepare shop Drawings for the fabrication of all
members.
2. Shop Drawings shall show details of fabrication which are not explicit in
the Contract Drawings. Details required include dimensions, angles and
weld preparation details.
3. The details shown on the shop Drawings shall be consistent with the
Contract Drawings and shall comply with the following:-
a) The marking plan shall show the location of each part in the
structure.
b) Shop Drawings shall conform to AS 1100 as appropriate.

c) Welding and cutting definitions shall conform to AS 2812.
d) Welding symbols shall conform to AS 1101.3.
e) Complete information regarding the location, type, size and extent of

all welds shall be clearly shown on the shop Drawings. These
Drawings shall clearly distinguish between shop and field welds.
f) Joints or groups of joints in which it is especially important that the

welding sequence and technique of welding be carefully controlled
to minimise shrinkage stresses and distortion shall be noted on the
Drawings. Joints where no welding is permitted shall also be clearly
indicated. Weld lengths specified on the Drawings shall be the
required effective lengths.
g) Each member shall be clearly identified with the identification marks

shown on the Drawings. Each type of component shall be further
identified to readily distinguish it from all other types.
h) For assemblies, all associated bolting, accessories and/or joining

details shall be shown on the shop Drawings.
4. Four (4) copies of the shop Drawings, certified by the Contractor as

complying with the above requirements, shall be submitted to the
Superintendent seven (7) working days before fabrication commences.
5. Variations of details shown on the Shop Drawings shall not be made

without resubmission of appropriately amended Shop Drawings at least
seven (7) working days before fabrication of any affected component of
the Works.
6. The Contractor shall be responsible for the correctness of the shop

Drawings. Acceptance of the shop Drawings by the Superintendent shall
not relieve the Contractor of his responsibility.
830.19 PRECAMBER AND DISTORTIONS
1. The contractor shall be aware that the specified construction tolerances

require making due allowance for precamber and distortions due to
fabrication and erection processes and for careful matching of angles and
dimensions at field joints.
2. Unless noted otherwise, precamber shown on the Contract drawings is

due to permanently applied loadings. The Contractor shall allow for all
other aspects of his construction method affecting precamber.
830.20 STRAIGHTENING AND CORRECTION OF DISTORTIONS
1. All plates shall be flattened and all sections shall be straightened and
made free from twist before any work is done on them to ensure that
when assembled surfaces shall be flat within specified tolerances and
adjacent surfaces shall be in close contact throughout. The methods
adopted for such flattening and straightening shall be such as not to
damage or mark the material. Heating of plates and all sections will not
be permitted unless written approval is obtained from the Superintendent.
830.21 CUTTING AND EDGE TREATMENT
1. Steelwork shall be cut only by sawing or thermal cutting (abrasive water

jet cutting and laser cutting are also permitted). After cutting, cut edges
shall be ground to remove burrs, dross and slag, and to clean up any
roughness (including gouge marks and unintentional bevel).
2. Unless required otherwise for welding, or where shown differently on the

Drawings, any surfaces produced by cutting shall be finished square
(unless a bevelled edge is called for) and smooth and true to the required
dimensions.
3. Ends of web stiffener plates shall be cut and finished to fit snugly and
uniformly to girder flanges unless otherwise shown on the Drawings.
4. Cut edges shall be finished as specified in AS 4100 Guillotined plates

shall be cut to an oversize sufficient for the correct dimensions to be
achieved after edge finishing. Where galvanizing is specified, the edge
surface preparation shall conform to the requirements specified in this
Specification.
5. Unless shown otherwise on the Drawings, all corners on cut edges shall
be rounded to a radius of approximately 1.5 mm, except where such
edges are subsequently to be welded. Rolled edges need not be rounded
provided the corners have a similar radius.
830.22 NOT USED
830.23 HOLES FOR BOLTING
1. All bolt holes shall be drilled to a diameter 2 mm larger than the diameter
of the bolt unless otherwise shown on the Drawings.
2. Drilled holes shall be cylindrical and perpendicular to the face of the

member. Drilling shall be done by mechanical means.
830.24 WELDING
830.24.01 General
1. All welding shall comply with AS 1554.1 or AS 1554.2 or ANSI/AWS

D1.1 as appropriate. All welding shall be category SP (Structural
Purpose) in accordance with AS 1554.1.
830.24.02 Qualification Of Welding Personnel
830.24.02.01 Welder
1. Welding shall only be carried out by welders meeting the requirements of
Clause 4.11.2 of AS 1554.1
2. Not less than ten (10) working days prior to planned commencement of
welding, the following information on each welder shall be provided to
the Superintendent:
a. Documentary evidence of the qualification/certification currently

held;
b. Trade training background;

c. Duration of employment with current employer;
d. Nature of current employment duties; and;
e. Documentary evidence confirming each welder is qualified for each

welding procedure that they will apply to the Works.
3. The WSP shall:
a. Maintain records clearly identifying the welders to each completed

weld, weld repair and/or fabricated assembly/unit, which records
shall be available to the Superintendent;
b. On completion of the welding work, a weld map showing the welds

completed by each welder shall be part of the MDR.
830.24.02.02 Supervisor / Welding Coordinator

1. All welding shall be carried out under the supervision of the Contractor's
Welding Supervisor who shall be qualified in accordance with the
requirements of Clause 4.11.1 of AS 1554.1.
2. Not less than ten (10) working days prior to commencement of welding,
the WSP shall identify the Welding Supervisor who will be responsible
for the coordination of all operations in respect of the welding work. The
WSP shall provide details of the Welding Supervisor’s qualifications,
certification and experience to the Superintendent. The Welding
Supervisor shall have delegated authority to deal directly with the
Superintendent on all issues relating to the welding work, including:
a. Welding procedure management;
b. Welding quality management;
c. Inspection and testing activities;
d. Sign-off of completed work.
830.24.02.03 Welding Inspector

1. All welding work will be inspected by a suitably qualified Welding
Inspector in accordance with Clause 7.2 of AS 1554.1, and who holds:
a. Current W.T.I.A. Welding Inspection Certification, either as a

Welding Inspector or as a Structural Welding Supervisor; or,
b. Other current qualification / certification acceptable to the

Superintendent.
2. Not less than ten (10) working days prior to commencement of welding,
the WSP shall identify the Welding Inspector who will be responsible for
the inspection of the welding work. The WSP shall provide details of the
Welding Inspector’s qualifications, certification and experience to the
Superintendent.
830.24.03 EQUIPMENT
1. Welding equipment and plant shall conform to AS 1966 and AS 1995,

and shall be maintained at all times in good condition. It shall be of an
appropriate type for the intended purpose and shall only be used in the
circumstances and in the manner recommended by the manufacturer for
size of electrodes, currents, voltages, speeds of travel, position of welding
and fixtures and jigs shall be as laid down for the particular class of work.
2. Where a machine or a method is not of a conventional type, the machine

or method shall be used in the welding procedure qualification.
3. Where welding is required to be done in conditions of a high risk of

electric shock the welding equipment shall be fitted with a Voltage
Reduction Device (VRD).
830.24.04 WELDING CONSUMABLES
1. All welding consumables to be used in welding procedures and for the

Works shall comply with the relevant Standards. Electrodes used for
manual welding shall conform to AS 1553. Flux cored electrodes used
for semi-automatic welding shall conform to AS 2203. Electrodes and
fluxes used for submerged arc welding shall conform to AS 1858.
2. The WSP shall store and handle welding consumables, in particular

hydrogen controlled electrodes, in compliance with the recommendations
in WTIA Technical Note 3.
830.24.05 WELDING PROCEDURES
1. Welding procedures for all fillet and butt welds, or any combination of
either, shall be proven qualified by the WSP, who shall submit to the
Superintendent a schedule of all proposed welding procedure
qualifications, not less than ten (10) working days prior to the planned
commencement of welding work to which the procedures will apply.
2. When the essential variables vary outside the limits specified in Table
4.11(A) of AS1554.1, new procedures shall be qualified by the WSP.
These shall be submitted to the Superintendent for review and release of
the hold point.
3. Suitable run-on and run-off tabs shall be used for all butt welds. The tabs
shall have the same thickness and preparation as the parts to be joined.
Each weld pass shall terminate at least 20 mm beyond the edges of the
parts to be joined. Welds shall be continuous for the full length.
4. All welding for the work shall be shown in a detailed Welding Procedure
Sheet in accordance with AS 1554.1. Each welding procedure shall be
qualified by way of test pieces and/or assemblies in accordance with AS
1554.1.
5. Test pieces and/or assemblies shall represent the actual conditions in the
work in regard to location, weather environment, geometric arrangement,
plate thickness, joint preparation and equipment and be of a minimum
size recommended by AS 1554.1, but of adequate size to carry out all
testing.
6. The Superintendent shall be given at least three (3) working days

notification of the time and place where the welding and testing of all test
pieces and/or assemblies will be carried out.
7. The WSP shall obtain any test and/or Inspection Certificates from a
laboratory with appropriate NATA registration, with all relevant results
shown and a statement that the results comply with AS 1554.1.

830.24.06 CLEANING OF FINISHED WELDS
1. All run-on and run-off tabs shall be removed after the joint has cooled
and the ends of the welds shall be finished smooth and flush with the
faces of the abutting parts.
2. Slag shall be removed from completed welds. The weld and adjacent
base material shall be cleaned by brushing or other suitable means to
remove spatter and foreign material. Welded joints shall not be painted
until after the welds have been inspected and approved.
3. Where butt welds form part of a faying or contact surface, the surfaces of
the butt welds shall be dressed in accordance with Clause 5.12 of AS
1554.1.
830.24.07 INSPECTION AND TESTING OF WELDS
1. Inspection of welds will be carried out in accordance with AS 1554.1.

The WSP shall produce an Inspection and Test Plan (ITP) for all welding
work, which shall contain the necessary elements and hold points to
ensure the completed welding work complies with AS 1554.1 or other
specified requirements. The WSP shall submitted ITPs to the
Superintendent not less than ten (10) working days prior to
commencement of the welding work.
2. The WSP shall ensure that testing of all welds is carried out in
accordance with AS 1554.1. Test Certificates issued by a NATA
registered laboratory shall be available to the Superintendent and shall be
part of the MDR. The testing procedures to be used are:
i) Visual Scanning;
ii) Visual Inspection;
iii) Radiographic Testing;
iv) Ultrasonic Testing;
v) Magnetic Particle Inspection;
vi) Dye Penetration Testing;
vii) Hardness Testing;
viii) Microstructure Replica Examination.
3. The extent of testing and inspection of welds shall generally be in

accordance with the recommendations in Table 7.4 of AS 1554.1, but
also as follows:
a) Visual inspection of all weld preparations prior to welding.
b) Inspection of all weld quality using procedures (i) and (ii).
c) Testing of all full strength butt weld splices in tension and

compression using procedure (iii).
d) For all other butt welds test 10% of the length of all welds longer
than 1 m and one in twenty of all welds which are less than 1 m long
using a combination of procedures (iii) and (iv).

e) 10% of fillet welds tested using procedures (v) and/or (vi).
f) Procedures (vii) and (viii) shall be used where directed by the

Superintendent.
4. The Contractor shall allow for all labour and plant required to lay out and
arrange items for inspection and testing and carry out any necessary weld
preparation including allowance for lost production time.
5. All repaired welds shall be retested and for welds tested under (d) above
two extra samples of either 10% or one in twenty shall be tested as
appropriate. All costs associated with repairing and retesting defective
welds and additional testing shall be borne by the Contractor.
830.24.08 NON-CONFORMING WELDS
1. Any welds not meeting the requirements of this Specification shall be

rejected. The WSP shall document all NCRs and shall submit proposals
to the Superintendent for correcting defective welds. All corrective work
shall be in accordance to AS1554.1.
2. The cost of repairing or correcting defective welds and the cost of any
additional work or material required to repair defective welds shall be
borne by the WSP.
830.25 STUD SHEAR CONNECTORS
830.25.01 GENERAL
1. Stud shear connectors and stud welding shall comply with the
requirements of AS 1554.2 except as varied by this Specification.
830.25.02 OPERATOR QUALIFICATION
1. Operators shall be qualified in accordance with Section 3 of AS1554.2.

Any costs associated with operator qualification shall be at the expense
of the WSP.
830.25.03 WELDING
1. After stud welding, all beams shall comply with the tolerances given in Distortion
Clause 830.60 "Construction Tolerances". Quality control for all stud
welding shall be maintained in accordance with Section 3 of AS1554.2
and shall be at the expense of the WSP.
830.25.04 TESTING
1. The testing of welded studs shall be in accordance with AS 1554.2. In

addition, the Superintendent shall select an additional five per cent of the
remaining studs which shall also be tested. All other studs shall be ring
tested.
830.25.05 CORRECTION OF DEFECTIVE STUD WELDS
1. Any stud welds not meeting the requirements of AS 1554.2 shall be

rejected. Repairs to defective welds, except where allowed for in AS

1554.2, will not be allowed.
830.26 BOLTING
1. Generally:
a. All bolts, nuts and washers are to be hot-dip galvanised unless

otherwise noted. Use one nut only to each bolt. Project the threaded
portion of the bolt a minimum of one thread and a maximum of five
threads through the nut. Use washers, tapered where necessary, to
give nuts and bolts satisfactory bearing. All nuts and washers in each
joint will face in one direction and away from the general view.
2. Designated Types of Bolts:
a. The following types of bolts with their tightening procedures are

designated on structural Drawings when required.
− The following types of bolts with their tightening procedures are

designated on structural Drawings when required.
4.6/S, 8.8/S, 8.8/TF, 8.8/TB, 8.8X/TF, and 8.8X/TB
− where 8.8 bolts are designated, the washers and nuts shall also
be hardened as for the bolt.
− Where 8.8X bolts are designated, keep the thread portion of the
bolt outside the shear plane of the parts being joined.
3. Tightening of Bolts:
a. The tightening of bolts shall be carried out in the following

procedures according to the grade of bolt.
− Bolting procedure 4.6/s refers to commercial bolts of strength

grade 4.6 manufactured to AS 1111, tightened using a standard
wrench to a snug-tight condition.
− Bolting procedure 8.8/S refers to any bolt of strength grade 8.8

tightened using a standard wrench to a snug-tight condition in
the same way as for procedure 4.6/S. the bolts used will be high
strength structural bolts of grade 8.8 to AS1252.
830.27 HOLDING DOWN BOLTS
1. All holding down bolts will, wherever applicable, be welded into a cage
to ensure accurate placement. Bolts, nuts, washers and cage assemblies
will be hot-dip galvanised to give a coating of zinc of not less than 85
microns thickness.
830.28 - 830.29 NOT USED
830.30 CERTIFICATION OF FABRICATION
1. The Contractor shall provide the Superintendent with certification that

each item fabricated conforms to the requirements of the Drawings and
the Specification.

830.31 - 830.39 NOT USED
830.40 ERECTION
1. Where applicable, erection procedures shall comply with the

requirements of Standards Association of Australia Manual MA1 - "Steel
Structures" Part 9 - Erection. The erection sequence assumed in the
design is shown on the Drawings.
2. Upon completion of erection all temporary bracing shall be removed and

holes plugged and steel made good.
3. During erection, no steel shall be cut or heated or welded or drilled.

Drifting may only be used for bringing parts into position and not to
match unfair holes or enlarge holes or distort metal.
830.41 - 830.49 NOT USED
830.50 BOLTED JOINTS
830.50.01 General
1. Unless otherwise shown on the Drawings, all bolts and nuts for field
joints shall be High Strength Friction Grip Bolts, complying with AS
1252 Grade 8.8.
830.50.03 Bolt Installation And Tightening
1. High Strength Bolts shall be installed and tightened in accordance with

AS 4100 and all bolts shall be installed and tightened in accordance with
procedures detailed in the Drawings.
830.51 - 830.59 NOT USED
830.60 CONSTRUCTION TOLERANCES
1. Measurements of length shall be checked with a standard steel measuring

tape or band corrected to a standard temperature of 20°C.
2. The Contractor shall allow in the fabrication of the girders for all weld
distortion so that on completion of erection the dimensions of the
fabricated members shall be correct within the tolerances specified in AS
4100 and in addition shall not exceed the following:
a) Deviation from flatness and straightness of +3 mm in 2m

all exposed plate surfaces and edges straight edge on any
(or from specified surface in the case of direction
curved surfaces).
b) Length of beam +5 mm, -0 mm
c) Deviation from specified alignment at points +5 mm, -0 mm

of support

d) Deviation from specified alignment +10 mm, -0 mm
elsewhere
e) Not Used.
f) Maximum permitted angular rotation of any 0.6°

cross-section relative to its specified location
830.61 - 830.79 NOT USED
830.80 - 830.89 NOT USED

S PECIFICATION 831
MANUFACTURE AND SUPPLY

OF MINOR STEEL ITEMS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
831.01 SCOPE...................................................................................................................................... 1
831.02 REFERENCES ......................................................................................................................... 1
831.03 WORKMANSHIP.................................................................................................................... 1
831.04 - 831.09 NOT USED ................................................................................................................ 2
MATERIALS.............................................................................................................................................. 2
831.10 NOT USED .............................................................................................................................. 2
831.11 STRUCTURAL STEEL FOR PLATES, BARS AND SECTIONS......................................... 2
831.12 BOLTS, NUTS, SCREWS AND WASHERS ......................................................................... 2
831.13 TESTING AND IDENTIFICATION OF MATERIAL ........................................................... 3
831.14 DAMAGED STEEL................................................................................................................. 3
831.15 STORAGE OF MATERIALS.................................................................................................. 3
831.16 ASSEMBLY PROCEDURES.................................................................................................. 3
831.17 ACCEPTANCE OF PROTOTYPE COMPONENTS.............................................................. 4
831.19 - 831.20 NOT USED ................................................................................................................ 4
FABRICATION ......................................................................................................................................... 4
831.22 SPLICES .................................................................................................................................. 5
831.23 HOLES FOR BOLTING.......................................................................................................... 5
831.24 WELDING ............................................................................................................................... 5
831.25 STUD SHEAR CONNECTORS .............................................................................................. 5
831.26 - 831.29 NOT USED ................................................................................................................ 6
831.30 CERTIFICATION OF FABRICATION .................................................................................. 6
831.31 - 831.34 NOT USED ................................................................................................................ 6
831.35 PROTECTIVE TREATMENT................................................................................................. 6
831.36 TRANSPORT, HANDLING AND STORAGE....................................................................... 6

Associated Roadworks Manufacture and Supply of Minor Steel Items
SPECIFICATION 831
MANUFACTURE AND SUPPLY OF MINOR STEEL ITEMS
GENERAL
831.01 SCOPE
1. The work to be executed under this Specification is the supply, fabrication,

protective treatment and delivery of steel expansion joint protection angles, sockets for
guardrails and other minor steel items including dowels, bolts, nuts, screws and washers.
831.02 REFERENCES

abbreviated form (e.g. AS 1234 or WA 123). For convenience, the full titles are given
below:
AS/NZS 1110 ISO Metric Hexagon Precision Bolts and Screws

AS/NZS 1111 ISO Metric Hexagon Commercial Bolts and Screws
AS/NZS 1112 ISO Metric Hexagon Nuts, Including Thin Nuts, Slotted Nuts and
Castle Nuts
AS 1214 Hot-Dip Galvanised Coatings on Threaded Fasteners
AS 1237 Flat Metal Washers for General Engineering Purposes
AS/NZS 1252 High Strength Steel Bolts with Associated Nuts and Washers for
AS 1275 Metric Screw Threads for Fasteners
AS 1285 Prevailing Torque Steel Hexagon Locknuts
AS/NZS 1420 ISO Metric Hexagon Socket Head Cap Screws
AS/NZS 1554 Welding of Steel Structures
AS 1554 Stud Welding
AS 1789 Electroplated Coatings - Zinc on Iron or Steel
AS 1897 Electroplated Coatings on Threaded Components
AS 2837 Wrought Alloy Steels - Stainless Steel Bars and Semi-Finished
Products
AS/NZS 3678 Hot Rolled Structural Steel Plates, Floorplates and Slabs
AS/NZS 3679 Hot Rolled Structural Steel Bars and Sections
831.03 WORKMANSHIP
1. All work shall be carried out by capable personnel under the supervision of
experienced and competent supervisors to fully satisfy the requirements of this Part of the
Specification.

831.04 - 831.09 NOT USED
MATERIALS
831.10 NOT USED
831.11 STRUCTURAL STEEL FOR PLATES, BARS AND SECTIONS
1. Structural steel for plates, bars and sections shall conform to the
requirements of AS/NZS 3678, Grade 250, and AS/NZS 3679 Grade 250 unless noted
otherwise on the Drawings or the Specification.
2. Structural steel hollow sections shall conform to the requirements of AS

1163 Grade 350 unless noted otherwise on the Drawings.
831.12 BOLTS, NUTS, SCREWS AND WASHERS
1. All bolts, nuts, screws and washers shall conform with the relevant
Australian Standards listed in Clause 831.02.
2. High strength bolts, with associated nuts and washers, shall be

manufactured in accordance with AS 1252 and installed in accordance with AS 4100. The
length of the bolt shall be as shown on the Drawings, or, if no length is shown, shall be in
3. All screw threads shall conform to the ISO coarse pitch series thread in
4. Unless shown otherwise on the Drawings, nuts other than those for high
strength bolts shall be "normal" size. The strength grade of normal nuts to be associated
with each strength grade of the bolt, U-bolt, screw, stud or other threaded component shall
be as follows:
Grade of bolt, U-bolt etc. Strength Grade of Nut
4.6 5
5.8 5
8.8 8
10.9 10
5. The strength grade required for precision bolts and screws shall be as
shown on the Drawings.
6. The stainless steel used in the manufacture of non high strength bolts,
nuts and dowels shall conform to AS 2837 Grade 316L for welded components or
Grade 316 otherwise. The stainless steel used in the manufacture of high strength bolts
and nuts shall conform to SS 2343 (American Iron and Steel Institute Grade 316 Mo+)
and have a minimum ultimate tensile strength of 800 MPa.
7. Prevailing torque locknuts, also known as "self-locking nuts", shall be the

insert type having a nylon or similar plastic insert, such as "Nyloc" nuts. Those used
with commercial grade bolts or U-bolts shall be strength grade 6 or higher.

8. Unless shown otherwise on the Drawings the following types of washers
shall be used:-
a) With precision bolts - bright metal washers, normal series
b) With commercial bolts - black metal washers, normal series
c) With stainless steel bolts - stainless steel washers Grade 316, normal
series.
9. Washers are generally not required under socket head cap screws.
10. The Contractor shall obtain a Certificate from a laboratory with

appropriate NATA registration stating that the bolts, nuts, screws and washers comply
with the appropriate standard.
831.13 TESTING AND IDENTIFICATION OF MATERIAL
1. The Contractor shall ensure that all materials or parts conform with the
tests required by the standards and with other tests specified in this Part of the
Specification.
2. Test certificates showing the results of mechanical tests and chemical

analysis (where applicable) of the material or parts used in the Works shall be retained
by the Contractor.
3. All materials or parts used in the Works shall be identified with the tests.
The Contractor shall establish and maintain a comprehensive system of identification
records. Copies of all these records shall be forwarded to the Superintendent on
request.
831.14 DAMAGED STEEL
1. Steel which is bent (except as required for fabrication), damaged or

excessively rusted shall not be used in the Works.
831.15 STORAGE OF MATERIALS
corrosion is minimised. Generally, storage at least 200 mm above the ground on
platforms, slabs, or other supports under cover will be satisfactory.
2. Bolts, nuts, screws and washers not promptly incorporated in the work
shall be stored in a waterproof shelter clear of the ground, and protected from damage.
831.16 ASSEMBLY PROCEDURES
1. Details of the procedures for assembly and fabrication shall be submitted Quality Plan
with the Contractor's Quality Plan. These procedures shall be comprehensive and shall
cover all aspects of the work. The procedures shall include, but not be limited to:-
a) Assembly procedures, including dimensional control and details of

manufacturing jigs
b) Welding procedures
c) Qualification of welds, including stud welding

d) Qualification and identification of welders
e) Qualification of welding supervisors
f) System of identification of welders with work
g) Quality control measures
h) Quality control check lists and forms
i) System for identification of components
j) Procedures for trial assembly
k) Procedures for repair of non-conforming materials, components and

assemblies
l) Procedures for transport, handling and storage, including measures

to prevent distortion and damage to the steelwork and its protective
coating
m) Procedure for Curving
2. The Contractor shall submit a programme showing the proposed

sequence of operations at least one week before fabrication commences.
831.17 ACCEPTANCE OF PROTOTYPE COMPONENTS
1. The Contractor shall give five working days' notice in writing before HOLD POINT
commencing work, and this shall be allowed for in its programme. For the first
item of any component fabricated the Contractor shall make a thorough
dimensional check. The Contractor shall submit to the Superintendent details of
this dimensional check, and certification that the dimensions are in conformity
with the requirement of the Drawings and the Specification. No further
fabrication work on similar items shall be carried out until submission of this
certification.
1. Each component shall be metal stamped with an identification mark Identification

which remains recognisable after protective treatment, but which is located in a hidden
or inconspicuous position after erection. Each type of component shall be designated
with a mark which is readily distinguishable from the marks for all other types.
831.19 - 831.20 NOT USED
FABRICATION
1. Steelwork may be cut by flame cutting, sawing or guillotining unless

specified otherwise. Surfaces produced by such cutting shall be finished square (unless
a bevelled edge is called for) and true to the required dimensions. Shearing by nibbling
action shall not be permitted.
2. Cut edges shall be finished as specified in AS 4100. Guillotined plates

shall be cut to an oversize sufficient for the correct dimensions to be achieved after
edge finishing. Where galvanising is specified the edge surface preparation shall
conform to the requirements specified in this Part of the Specification.
be rounded to a radius of approximately 1.5 mm, except where such edges are
subsequently to be welded. Rolled edges need not be rounded provided the corners
have a similar radius.
831.22 SPLICES
1. Except where shown on the Drawing, splices shall not be permitted.
831.23 HOLES FOR BOLTING
1. The diameters of the bolt holes shall be 2 mm greater than the diameters
of the bolts shown on the Drawings unless otherwise specified.
2. Holes may be either drilled full-size or reamed to full-size after sub-

drilling or sub-punching. In all cases, sub-drilling may be substituted for sub-punching,
and holes may be drilled from the solid metal instead of being sub-punched or sub-
drilled and reamed, provided such drilling is done with the material assembled in the
same manner as is required for reamed work.
3. Sub-punched and sub-drilled holes shall be smaller in diameter than the

nominal diameter of bolts by 3 mm.
4. For sub-punched holes the diameter of the die shall not exceed the
diameter of the punch by more than 1 mm. Holes shall be clean cut, without torn or
ragged edges. Reamed or drilled holes shall be cylindrical and perpendicular to the face
of the member. Reaming and drilling shall be done by mechanical means.
5. Connecting parts shall be assembled and held securely while being

reamed or drilled and shall be match-marked before separating the parts. Burrs on the
outside surfaces shall be removed.
6. Holes for field connections may be sub-punched or sub-drilled and

reamed or drilled from the solid to a hardened steel template not less than 25 mm thick,
and all corresponding holes in the members to which they connect shall be reamed or
drilled to the same template. Alternatively these connections may be reamed or drilled
with the members assembled.
831.24 WELDING
1. All welding shall conform to AS 1554.1 or AS 1554.2 as applicable,

unless otherwise specified.
2. Weld quality shall be as nominated on the Drawings. All weld spatter

shall be removed before protective treatment is applied.
831.25 STUD SHEAR CONNECTORS
1. Stud shear connectors and stud welding shall comply with the
requirements of AS 1554.2 except as varied by this Specification.
2. Operators shall be qualified in accordance with Section 3 of AS 1554.2. Operator

Any costs associated with operator qualification shall be at the Contractor's expense. Qualifications
3. Any stud welds not meeting the requirements of AS 1554.2 shall be

rejected. Repairs to defective welds, except where allowed for in AS 1554.2, will not

be allowed.
831.26 - 831.29 NOT USED
831.30 CERTIFICATION OF FABRICATION
1. The Contractor shall provide the Superintendent with certification that

each item fabricated conforms to the requirements of the Drawings and the
Specification.
831.31 - 831.34 NOT USED
831.35 PROTECTIVE TREATMENT
831.35.01 GENERAL
1. All minor items of steelwork shall be hot dip galvanised unless otherwise Galvanise
specified.
2. All protective treatment including hot dip galvanising shall be in

accordance with Specification 835 PROTECTIVE TREATMENT FOR STEEL
WORK unless otherwise specified.
831.35.02 PROTECTIVE TREATMENT FOR BOLTS, NUTS, ETC.
1. Stainless steel items do not require protective treatment.
2. Unless shown otherwise on the Drawings, all other bolts, U-bolts, screws,
nuts and washers shall be protected with the following protective treatment:-
Item to be Protected Protective Treatment
High strength bolts and Hot-dip galvanised in accordance with

associated nuts and washers, AS 1214
and Commercial bolts, screws
and U-bolts and associated nuts
and washers
Precision bolts and screws and If not shown otherwise on the Drawings,
associated nuts and washers & electroplated with zinc in conformity with
Prevailing torque locknuts the principles of AS 1897, or for sizes
over M16, of AS 1789 - Classification
Fe/Zn 12c Type C
Socket head cap screws Blue-black or chemical black finish plus a

residual coating of light oil. Prior to
placing into position in the bridge, socket
head cap screws shall be de-greased and
coated with approved zinc rich epoxy
based primer.
831.36 TRANSPORT, HANDLING AND STORAGE
1. The Contractor shall ensure that loading, transport, unloading, stacking

and handling operations are carried out in such a way that the items are protected from
distortion and that galvanised surfaces are protected from damage. The Contractor shall
store components in such a manner that the freshly galvanised surfaces are protected
from the attack of "white rust".

S PECIFICATION 833
BRIDGE RAILINGS AND

BALUSTRADES
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
833.01 SCOPE...................................................................................................................................... 1
833.02 REFERENCES ......................................................................................................................... 1
833.03 - 833.09 NOT USED ................................................................................................................ 1
MATERIALS.............................................................................................................................................. 2
833.10 NOT USED .............................................................................................................................. 2
833.11 SPECIFICATIONS FOR STEEL............................................................................................. 2
833.12 TEST CERTIFICATES............................................................................................................ 2
833.13 IDENTIFICATION RECORDS............................................................................................... 2
833.15 STORAGE................................................................................................................................ 2
833.16 HANDLING AND STACKING .............................................................................................. 3
FABRICATION ......................................................................................................................................... 3
833.17 GENERAL ............................................................................................................................... 3
833.18 SHOP DRAWINGS ................................................................................................................. 3
833.19 VERTICALITY OF POSTS AND BALUSTERS ................................................................... 3
833.20 CURVING OF RAILS ............................................................................................................. 3
833.22 SPLICES .................................................................................................................................. 4
833.23 BOLTING ................................................................................................................................ 4
833.24 WELDING ............................................................................................................................... 4
833.25 - 833.34 NOT USED ................................................................................................................ 4
833.35 PROTECTIVE TREATMENT................................................................................................. 4
833.36 - 833.39 NOT USED ................................................................................................................ 4
833.40 ERECTION .............................................................................................................................. 4
833.41 - 833.79 NOT USED ................................................................................................................ 5
833.80 – 833.82 NOT USED ............................................................................................................... 5

Associated Roadworks Bridge Railing and Balustrades
SPECIFICATION 833
BRIDGE RAILINGS AND BALUSTRADES
GENERAL
833.01 SCOPE
1. The work to be executed under this Specification is the supply, fabrication,

protective treatment and erection of steel handrailing, balustrading and guardrailing
except for minor items which are covered in a separate part of the Specification listed in
the references.
833.02 REFERENCES

below:
AS 1100 Technical Drawings (Parts as appropriate)

AS 1101.3 Graphical Symbols for General Engineering - Welding and Non-
Destructive Examination.
AS1111 ISO Metric Hexagon Bolts and Screws
AS1112 ISO Metric Hexagon Nuts
AS1237 Plain washers for metric bolts , screws and nuts for general purposes
AS 1252 High Strength Bolts with Associated Nuts and Washers for
AS 1553 Low Carbon Steel Covered Electrodes for Manual Metal Arc
Welding
AS/NZS 1554.1 Welding of Steel Structures
AS 1554.2 Stud Welding
AS 2203 Carbon Steel Electrodes Cored (for Arc Welding)
AS/NZS 3678 Hot Rolled Structural Steel Plates, Floorplates and Slabs
AS/NZS 3679 Hot Rolled Structural Steel Bars and Sections
Specification 831 MANUFACTURE AND SUPPLY OF MINOR STEEL ITEMS

833.03 - 833.09 NOT USED

MATERIALS
833.10 NOT USED
833.11 SPECIFICATIONS FOR STEEL
833.11.01 GENERAL
1. All materials supplied by the Contractor shall be new and shall conform New Steel
to the standards specified below.
2. Unless otherwise specified all structural steel sections shall be Grade 250 Standards
in accordance with AS 3679.
833.11.02 RHS GUARDRAILS AND POSTS
1. Structural steel hollow sections shall conform to the requirements of RHS

AS 1163 and shall be Grade C350.
833.11.03 NOT USED
833.12 TEST CERTIFICATES
1. The Contractor shall ensure that all materials conform with the tests Certificates
required by the standards.
2. Test certificates showing the results of mechanical tests and chemical

analysis (where applicable) of the material used in the Works shall be retained by the
Contractor.
833.13 IDENTIFICATION RECORDS
1. All materials used in the Works shall be identified with the test Identification
certificates. The Contractor shall establish and maintain a comprehensive system of
identification records. Copies of all these records shall be forwarded to the
Superintendent on request.
1. Each item of steelwork shall have its own item mark number which shall Identification
be used on all related schedules and documents. This mark shall be clearly indicated on
all members by durable identification marks to enable accurate identification on site.
833.15 STORAGE
corrosion is minimised. Generally, storage at least 200 mm above the ground on
platforms, slabs, or other supports under cover will be satisfactory. Excessively rusted
or bent or damaged steel will be rejected.

833.16 HANDLING AND STACKING
1. Before and after fabrication and during transit and on the Site all
steelwork shall be handled and stacked in such a way that it is not damaged.
FABRICATION
833.17 GENERAL
1. All steelwork shall be fabricated as shown on the Drawings and in

accordance with the requirements of AS 4100 except as varied by this Specification.
2. The Contractor shall supply and fabricate and transport and erect all
railing to the deck and approaches of the bridge as shown on the Drawings. The railing
shall be fabricated from steel sections.
833.18 SHOP DRAWINGS
1. The Contractor shall prepare Shop Drawings to show details of

fabrication which are not explicit in the Contract Drawings. Details required include
dimensions, angles, cambering profiles, splice locations, weld preparation details and
all Special Requirements specified in Clauses 833.80 - 833.89.
2. Each item shall be clearly identified with the identification marks shown
on the Drawings. Each type of component shall be further identified to readily
distinguish it from all other types.
3. Four copies of the shop Drawings certified by the Contractor as

complying with the above requirements shall be submitted to the Superintendent seven
(7) working days before fabrication commences.
4. The Contractor shall be responsible for the correctness of the shop

Drawings. Acceptance of the shop Drawings by the Superintendent shall not relieve the
Contractor of his responsibility.
833.19 VERTICALITY OF POSTS AND BALUSTERS
1. All balusters and posts shall be vertical as shown on the Drawings. The
Contractor's attention is drawn to the need to detail individually angled brackets and
joints to ensure that this requirement is met.
833.20 CURVING OF RAILS
1. Where the rails are shown on the Drawings to be curved, they shall be
curved to form that shape without excessive “springing” forces being applied to the
posts. The methods adopted for curving the rails shall be such as not to excessively
distort the section or damage the material.
1. Cut edges shall be finished as specified in AS 4100. The edge surface

preparation shall conform to the requirements specified for galvanising.
be rounded to a radius of approximately 1.5 mm, except where such edges are

subsequently to be welded.
833.22 SPLICES
1. Posts shall not contain splices.
2. The location of any splices required in the rails additional to those shown
on the Drawings shall be subject to approval by the Superintendent.
833.23 BOLTING
833.23.01 HOLES FOR BOLTING
1. All bolt holes shall be drilled to a diameter 2 mm larger than the diameter
of the bolt unless otherwise shown on the Drawings.
2. Reamed or drilled holes shall be cylindrical and perpendicular to the face

of the member. Reaming and drilling shall be done by mechanical means.
833.23.02 BOLT SPECIFICATION
1. Manufacture - Grade 4.6 bolts shall comply with AS 1111 and nuts shall
comply with AS 1112. Plain washers shall comply with AS 1237. Grade 8.8 bolts and
associated nuts and washers shall comply with AS 1252.
Installation – Bolt installation shall be in accordance with AS 4100.
833.24 WELDING
1. All welding shall be in accordance with AS 1554.1. All welds shall be

Category SP unless otherwise shown on the Drawings.
2. All electrodes used for manual welding shall conform to AS 1553. Flux
cored electrodes used for semi-automatic welding shall conform to AS 2203.
833.25 - 833.34 NOT USED
833.35 PROTECTIVE TREATMENT
1. Unless otherwise shown on the Drawings, all steel components covered

by this Specification shall be hot dip galvanised in accordance with Specification 835,
PROTECTIVE TREATMENT OF STEELWORK.
833.36 - 833.39 NOT USED
833.40 ERECTION
833.40.01 GENERAL
1. Erection of steel railing shall comply with the requirements of AS 4100.
2. After fabrication all weld splatter and slag shall be removed by suitable

mechanical means and all sharp edges and rough welds rounded off.
833.40.02 TOLERANCES
1. The finished railing shall be erected to the tolerances set out below:
a) Variation from true plan positions of posts + 5 mm
b) Variation of dimensions in elevation + 3 mm
c) Variation of line of rails from specified

vertical and horizontal profile + 5 mm
2. The final appearance of the bridge will depend very much on the profile
of the railings and therefore in addition to the above tolerances the Contractor shall take
every care to ensure that the railings are erected to smooth curves which reflect the
design profiles of the bridge. In particular the Contractor shall ensure that a smooth
profile is maintained in the top rail after all site connections have been completed.
833.41 - 833.79 NOT USED
833.80 – 833.82 NOT USED

S PECIFICATION 835
PROTECTIVE TREATMENT
OF STEELWORK
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
835.01 SCOPE.................................................................................................................................. 1
835.02 REFERENCES ..................................................................................................................... 1
835.03 DEFINITIONS ..................................................................................................................... 2
835.04 PROCEDURES .................................................................................................................... 2
835.05 SCHEDULE OF SURFACE TREATMENTS..................................................................... 2
835.06 - 835.09 NOT USED ............................................................................................................... 2
MATERIALS.............................................................................................................................................. 2
835.10 COATING SYSTEMS ......................................................................................................... 2
835.11 GENERAL REQUIREMENTS AND INFORMATION TO BE PROVIDED BY
CONTRACTOR....................................................................................................................................... 4
835.12 - 835.19 NOT USED ............................................................................................................... 5
OPERATION.............................................................................................................................................. 5
835.20 SURFACE PREPARATION................................................................................................ 5
835.21 GALVANISING .................................................................................................................. 5
835.22 SHOP PRIMING .................................................................................................................. 6
835.23 INTERMEDIATE COATING ............................................................................................. 6
835.24 FINISHING COATS ............................................................................................................ 7
835.25 FINISH COLOUR................................................................................................................ 7
835.26 APPLICATION.................................................................................................................... 7
835.27 ACCEPTANCE TESTING .................................................................................................. 8
835.28 PROTECTION ..................................................................................................................... 9
835.29 SITE REPAIRS .................................................................................................................... 9
835.30 - 835.79 NOT USED ............................................................................................................. 10
SPECIAL REQUIREMENTS................................................................................................................. 10
835.80 - 835.89 NOT USED ............................................................................................................. 10
ANNEXURE 835A ................................................................................................................................... 11
SCHEDULE OF SURFACE TREATMENTS....................................................................................... 11

Associated Roadworks Protective Treatment of Steelwork
SPECIFICATION 835
835 PROTECTIVE TREATMENT OF STEELWORK
GENERAL
835.01 SCOPE
1. The work to be executed under this Specification is the surface

preparation, galvanising and application of coating systems for the
protective treatment of steelwork.
835.02 REFERENCES

abbreviated form (e.g. AS 1234 or WA 123). For convenience, the full
AS 1214 Hot Dip Galvanised Coatings on Threaded Fasteners

AS 1580 Methods of Test for Paints and Related Materials
AS 1627 Metal Finishing - Preparation and Pre-treatment of Surfaces
AS 1627.1 Part 1: Cleaning Using Liquid Solvents and Alkaline Solutions
AS 1627.4 Part 4: Abrasive Blast Cleaning
AS 1627.5 Part 5: Pickling, De-scaling and Oxide Removal
AS 1627.9 Part 9: Pictorial Surface Preparation Standards for Painting Steel
Surfaces
AS/NZS 2310 Glossary of Paint and Painting Terms
AS/NZS 2312 Guide to the Protection of Iron and Steel Against Exterior
Atmospheric Corrosion
AS 2700 Colour Standards for General Purposes
AS 3750.9 Organic Zinc-Rich Primer
AS 3750.15 Inorganic Zinc Silicate Paint
AS/NZS 4680 Hot-Dip Galvanised (Zinc) Coatings on Fabricated Ferrous
Articles
Australian Paint Approval Scheme
APAS 2908 Inorganic zinc coating for protection of steel

APAS 2911 Polyurethane coating for protection of steel
APAS 2916 Organic zinc rich coating for protection of steel
APAS 2971 Epoxy 2-pack durable primer for protection of steel in atmosphere
Other Publications
BS 3900 British Standard 3900 - Methods of Test for Paints
2. Unless otherwise specified, the applicable issue of a reference standard

shall be the issue current at the date one week before the closing date of
tenders.

835.03 DEFINITIONS
1. Definitions of painting terms contained in AS 2310 shall apply where

used in the Specification or when used in relation to the Works.
835.04 PROCEDURES
1. Unless otherwise specified in the Specification, all work required to

achieve the specified protective treatment of steelwork in the completed
structure shall be carried out in accordance with the recommended
procedures and guidelines set out in AS 2312.
835.05 SCHEDULE OF SURFACE TREATMENTS
1. Annexure 835A lists the approved surface treatments for use in this
contract.
835.06 - 835.09 NOT USED
MATERIALS
835.10 COATING SYSTEMS
835.10.01 GALVANISING
1. Galvanised coatings shall be carried out in accordance with AS 4680

subject to the adoption of surface preparation or other procedures where
necessary to avoid:
a) brittle, uneven and/or loosely adhering coatings on flame cut edges;
b) pin-holes in galvanised coatings along welds; and
c) white rust, ferrous rust and other surface contamination or stains

which diminish the appearance or function of the galvanised coating.
2. At least 7 days prior to the application of the galvanised coating, the HOLD POINT
Contractor shall submit details of procedures which eliminate the
above coating deficiencies.
835.10.02 PAINT COATING SYSTEMS FOR STEEL
1. After priming, permanently exposed surfaces of non-galvanised steelwork

shall be painted with an intermediate coat of epoxy micaceous iron oxide
paint (E-MIO) followed by finishing coats of polyurethane paint in
accordance with APAS 2911.
2. The Contractor shall also carry out protective treatment on site using
epoxy rich zinc primer conforming to AS 3750.9 for areas of steel
members which have been site welded. Refer also Clause 835.29.
3. Each coating type shall be of a different colour or shade to ensure

adequate coverage.
4. Surface treatment shall be in accordance with the requirements of

AS 2312 except as varied by this Specification.
835.10.03 SPECIAL AREAS
1. Areas In Contact With Concrete

Areas of steelwork in contact with concrete in the completed structure
shall receive the same surface preparation and shop applied coatings as
that employed on adjacent exposed areas for a minimum distance of 50
mm from the exposed surface. Areas further than 50 mm from an
exposed surface shall be left unpainted. (Note: Inorganic zinc silicate is
not recommended for casting in concrete).
2. Friction-Type Bolted Joints

The faying surfaces of friction-type bolted connections designed to
AS 4100 shall be treated as follows:
a) Galvanised Members
The faying surfaces on galvanised members shall be abraded by

means of a flexible rubber backed grinding disc prior to on-site
delivery and allowed to weather.
Alternatively, the faying surfaces shall be abraded by a light "brush

off" abrasive blast clean.
b) Painted Members
Irrespective of the coating system used elsewhere on the members,

the coating system used on the faying surfaces shall be the
following:
- Abrasive blast cleaned to AS 1627.4 Class 3

- Surface profile 25 to 35 microns
- Application of 1 coat of inorganic zinc primer conforming to
AS 3750.15 Type 4 and APAS 2908 with minimum dry film
thickness of 75 microns.
3. Hollow Members
The treatment of hollow members shall be as follows:
a) Galvanised Members
Internal surfaces of galvanised members shall be galvanised

according to AS 4680.
b) Painted Members
The inner surfaces of fully sealed hollow sections shall receive no

protective treatment except that all surfaces shall be dry and free of
all loose materials.
4. Site Welded Connections
Where surfaces are to be welded all surface protection shall be removed

for a minimum distance of 100 mm from the edge to be welded in order
to prevent harmful effects to welders or to the quality of welds.
Reinstatement is in accordance with Clause 835.29.

835.11 GENERAL REQUIREMENTS AND INFORMATION TO BE
PROVIDED BY CONTRACTOR
835.11.01 SHOP AND FIELD TREATMENT
1. Shop treatment shall comprise the galvanising or the abrasive blast

cleaning of all surfaces plus the application of all paint coatings specified,
except that:-
a) Areas adjacent to field welds shall be masked to leave an uncoated

margin of 75 mm for the first coat and an additional 50 mm margin
for each subsequent coat.
b) The final finishing coat of a multi-coat system on exterior exposed

surfaces may be applied on site following the completion of all
construction activities that may cause damage to the coatings.
2. Field treatment shall comprise the application of remaining finishing

coats and the repair of the protective treatment at all field weld areas and
at areas damaged in the course of construction.
3. The Contractor shall submit proposed details of work to be carried HOLD POINT
out by shop treatment and that to be carried out by field treatment.
4. The details shall include a program of the work covering the following:
a) The proposed timing for carrying out repairs to the protective

treatment at areas in contact with concrete.
b) The proposed timing for carrying out protective treatment to the

surfaces which are inaccessible in the completed structure and
outside of field welds.
5. The submission of these details shall constitute a Hold Point.
835.11.02 PAINT
1. All paints shall be supplied by a single manufacturer. Paints shall be

Australian Paint Approval Scheme (APAS) approved products
conforming to the nominated APAS Specifications and approved by the
Principal for the specified application.
2. At least fourteen days before commencing the protective treatment of HOLD POINT
steelwork, the Contractor shall submit the following details for the
Superintendent's approval:-
a) Name of paint manufacturer.
b) Product names of paints.
c) Technical data sheets and hazard information for all paints.
d) Documentary evidence from the manufacturer certifying compliance

of paints with relevant APAS Specifications.
835.11.03 TESTING
1. Testing of the paint to assess conformity to Specifications shall be Inspection and

included in the Contractor's Inspection and Test Plan. Test Plan

835.11.04 RECORDS
1. The Contractor shall record details of the paints used on the Works. The
records shall include, but not be limited to, the following:-
a) Paint manufacturer's name.
b) Product names of all paints.
c) Batch numbers of each product.
d) Designation of each member or area where each batch of paint is

used.
835.12 - 835.19 NOT USED
OPERATION
835.20 SURFACE PREPARATION
1. The surface treatment for all steel surfaces except those shown on the
Drawings to be left unpainted or to be galvanised shall be abrasive blast
cleaned followed by shop priming with inorganic zinc silicate paint.
Surfaces which are to be left unpainted shall be thoroughly wire brushed
and solvent cleaned where necessary to remove loose rust and mill scale
and surface contamination.
2. Non-galvanised steel surfaces which are to be painted shall be abrasive

blast cleaned to AS 1627.4 Class 2.5 immediately before application of
the inorganic zinc silicate paint system. The abrasive may be either
metallic or non-metallic but shall be of an approved type to produce a
mean surface roughness in the range 30 to 40 microns with no individual
reading exceeding 80 microns. The use of coarse steel angular grit or
copper slag or any other material which gives a high surface profile or
could contaminate the surface is not permitted.
3. The surface roughness shall be determined using a dial gauge type of

instrument. Once a satisfactory pattern of performance has been
established, as verified using the dial gauge instrument, an optical
comparator may be used to check surface profile.
4. Steel surfaces which are to be galvanised shall be cleaned and degreased

followed by pickling in accordance with AS 1627.5 immediately before
galvanising.
835.21 GALVANISING
1. All hot dip galvanising shall conform with the requirements of AS 4680
and shall be clean and smooth and continuous and free from acid spots
and cracks and laminations and runs and drips. The coating shall have a
minimum thickness of 85 microns for thickness of steel member 6 mm
and greater. The coating thickness shall be in accordance with AS 4680
for all structural member less than 6 mm thick.
2. Galvanising of fasteners shall conform with the requirements of AS 1214.

835.22 SHOP PRIMING
835.22.01 NON-GALVANISED STEEL SURFACES
1. All external surfaces of non-galvanised steelwork which are to be painted

shall be coated with an approved inorganic zinc silicate primer.
2. The primer shall be applied as soon as possible after blast cleaning before
deterioration has taken place and in any case within four hours.
3. Any surface showing deterioration before being primed shall be re-

cleaned at the Contractor's expense.
4. The primer shall be an inorganic zinc silicate conforming to Type 3 of AS

3750.15 and shall have a minimum dry film thickness of 75 microns.
5. The specified dry film thickness of primer refers to the minimum

thickness of primer measured "above peaks" determined in accordance
with Clause 835.27. The primer shall be cured in accordance with the
manufacturer's published recommendations before application of any
subsequent treatment.
6. The primer shall be applied so as to produce a smooth even coating and

shall be double lap sprayed into all corners and crevices and on welds and
seams.
835.22.02 GALVANISED STEEL SURFACES
1. Galvanised surfaces which are to be painted shall be cleaned and receive

one coat of an approved etch primer.
2. The primer shall be a product approved by the Australian Paint Approval

Scheme and shall be to Specification APAS 2971. The primer shall be
applied and cured in accordance with the manufacturer's published
recommendations.
835.22.03 SURFACE PREPARATION BEFORE APPLYING FINISHING

COATS
1. Not more than eight hours prior to application of a finishing coat the
surface shall be washed with fresh clean water to remove any salt, sand,
dust, grit, grease and cement or other contaminants and allowed to dry
thoroughly. If necessary suitable solvents shall be used to remove
contaminants that are not water soluble and the areas concerned re-
washed with water.
835.23 INTERMEDIATE COATING
1. The intermediate coating to all exposed surfaces of steelwork shall be

epoxy micaceous iron oxide paint (E-MIO). The paint used shall be a
product approved by the Australian Paint Approval Scheme and shall be
to Specification APAS 2971.
2. The minimum dry film thickness of the intermediate coating shall be

150 microns.
3. Where the manufacturer's recommended coating thickness for the paint is

less than 150 microns the required thickness shall be built up by the

application of additional coats.
835.24 FINISHING COATS
1. The finishing coats to all exposed surfaces of steelwork shall be a

polyurethane vehicle to Australian Paint Approval Scheme Specification
APAS 2911.
2. The polyurethane top coats shall be built up by the application of at least

two coats of paint with no single application having a minimum dry film
thickness of less than 60 microns.
3. The final finishing coat shall be applied on site after the erection of the
steelwork, placing of in situ concrete, removal of falsework and all site
repairs have been completed.
835.25 FINISH COLOUR
1. The finish colour for all steelwork shall be "Bottle Green" (G11) as
defined by AS 2700.
2. All paint pigments shall be suitable for outdoor exposure.
835.26 APPLICATION
835.26.01 TIE COATS
1. When recommended by the manufacturer tie and/or mist coats shall be

used to ensure compatibility of coatings.
835.26.02 WEATHER CONDITIONS
1. Painting shall not be carried out under the following climatic conditions:
a) When the ambient temperature is below 10oC.
b) When the metal surface temperature is above 55oC.
c) When the relative humidity is above 85%.
d) When the steel temperature is less than 3oC above the dew point
(see Section 8 of AS 2312).
e) When weather conditions are unsuitable such as in high winds or

rain.
835.26.03 METHOD OF APPLICATION
1. Tie and finishing coats may be applied by spray brush or roller except
that the following conditions shall apply:
a) On site application of paint by spray can be carried out only after the
Contractor has taken every precaution to ensure that there is no
danger of overspray damaging property or passing traffic.
b) Special precautions shall be taken to prevent paint staining concrete

surfaces.
c) Paint thickness specified shall be maintained on all edges by stripe

painting.
835.27 ACCEPTANCE TESTING
835.27.01 INTRODUCTION
1. Paintwork shall be subject to visual examination and measurement of the

dry film thickness after the application of each type of coating.
Galvanised surfaces shall be subject to visual examination and
measurement of the galvanising thickness as detailed in this clause.
835.27.02 VISUAL EXAMINATION
1. All surfaces shall be subject to a visual examination after blast cleaning

and after priming and after application of top coats. Each coat of paint
shall be free of cracks and wrinkles and blisters and lumps or any other
defects. Whenever these defects occur the whole paintwork system of the
affected area shall be removed by abrasive blast cleaning as set out in
Clause 835.20 and replaced at the Contractor's expense.
835.27.03 MEASURING INSTRUMENT
1. The Contractor shall measure the dry film thickness using a non-
destructive type film thickness gauge. The gauge shall be either:
(a) A magnetic instrument used in accordance with AS 1580 - "Methods

of Test for Paints and Related Materials" Method 108.1 except that
gauges of the 'Tinsley' type shall not be used.
or
(b) An instrument operating on the eddy current principle and used in
accordance with British Standard 3900 - "Methods of Test for
Paints" Part C5.
835.27.04 PROCEDURE
1. In order to determine the dry film thickness of each coating the following
procedure shall be adopted:
(a) Dry film thickness gauges shall be calibrated using shims of known
thickness set on the blast reference sample. The calibration
procedure shall consist of taking not less than 30 readings on the
shim on the reference blast sample and from these determining the
mean reading. This mean reading shall be subtracted from the
known shim thickness to produce a correction factor which shall be
added algebraically to all subsequent readings of dry film paint
thickness in order to obtain the true "above peaks" value.
Alternatively the gauge itself may be adjusted to yield the

appropriate reading equivalent to the known shim thickness. In this
case not less than 30 readings shall be taken until the gauge mean
reading is equivalent to the known shim thickness.
This calibration shall be maintained throughout the duration of the

contract except where blasting techniques or procedures are varied

in which case the calibration procedure shall be repeated.
(b) Readings shall subsequently be taken of the total dry film thickness
after the application of each type of coating.
(c) At each stage the Contractor shall use the average reading for that
surface.
(d) The dry film thickness for any coating is the difference between the
values obtained for this coating and the average total dry film
thickness at the completion of the preceding coating.
(e) Film thickness measurements will be taken at random to suit the

shape of the area being tested and the number of such measurements
shall be given as below:
(i) For large flat surfaces like the webs and flanges of beams the
number shall be one per square metre.
(ii) For hand railing panels the number shall be six per linear metre.
2. For assessing the compliance of a coating with the thickness requirement
of this Specification all measured values of the dry film thickness on each
surface shall equal or exceed the specified minimum dry film thickness
for that coating. Surfaces not meeting this requirement shall receive
further coats of primer or finishing coat as appropriate to build up the
paint thickness required.
835.28 PROTECTION
1. The paint system shall be fully cured before any components are handled.
It shall be properly protected during all transport and erection procedures
to maintain it in a clean and undamaged condition. In particular proper
precautions are to be taken during lifting operations to ensure a minimum
of damage is caused by slinging or guying or supporting or similar
operations.
835.29 SITE REPAIRS
1. Repairs to areas of damaged paintwork shall be carried out at the time of

application of the final finishing coat except that where corrosion of the
steel may occur adequate cleaning and protective priming shall be carried
out immediately.
2. Areas of paintwork which have been damaged and areas of site welded
connections shall be cleaned by power wire brush to AS 1627 Part 2
Class 3 followed by abrasive paper to provide a surface profile. In
addition the edge of the surrounding undamaged paint shall be feathered
with abrasive paper.
3. In areas of site welded connections all weld splatter and slag shall be
removed by mechanical means and all sharp edges and rough welds shall
be rounded off before cleaning.
4. The damaged areas and areas of site welded connections shall then be
painted as laid down in Clauses 835.22 to 835.24 except that the primer
shall be an approved two pack epoxy-zinc-rich coating conforming to
Type 2 of AS 3750.9. The paint used shall be a product approved by the
Australian Paint Approval Scheme and shall be to Specification APAS
2916. The new paint shall overlap the existing paint by at least 50 mm all

round the affected area.
5. Areas of galvanising which have been affected by welding or otherwise

damaged shall be thoroughly painted with an approved cold galvanised
paint followed by the required amount of finishing paint.
835.30 - 835.79 NOT USED
835.80 - 835.89 NOT USED

ANNEXURE 835A
SCHEDULE OF SURFACE TREATMENTS
Treatment No. Description of Treatment Surfaces to be treated
1. Galvanise All steel unless otherwise specified
2. Not Used.
3. Abrasive Blast Exposed surfaces of structural members

Inorganic Zinc Silicate Prime Coat
Epoxy Micaceous Iron Oxide
Intermediate Coat
Two-pack Polyurethane Top Coat

S PECIFICATION 860
BRIDGE BEARINGS
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
860.01 SCOPE.................................................................................................................................. 1
860.02 REFERENCES ..................................................................................................................... 1
860.03 - 860.12 NOT USED ............................................................................................................... 1
DESIGN AND MANUFACTURE ............................................................................................................ 1
860.13 GENERAL ........................................................................................................................... 1
860.14 PHYSICAL DIMENSIONS AND TOLERANCES OF ELASTOMERIC BEARINGS..... 1
860.15 ACCEPTANCE TESTS FOR ELASTOMERIC BEARINGS............................................. 2
860.16 – 860.17 NOT USED ............................................................................................................... 3
860.18 REJECTION......................................................................................................................... 3
860.19 TRANSPORT AND DELIVERY ........................................................................................ 3
INSTALLATION OF BEARINGS ........................................................................................................... 4
860.20 LOCATION AND FIXING OF ELASTOMERIC BEARINGS.......................................... 4
860.21 – 860.22 NOT USED ............................................................................................................... 4
860.23 INSTALLATION OF ELASTOMERIC BEARINGS ......................................................... 4
860.24 NOT USED .......................................................................................................................... 4
820.25 TOLERANCES FOR INSTALLATION ............................................................................. 4

Associated Roadworks Bridge Bearings
SPECIFICATION 860
BRIDGE BEARINGS
GENERAL
860.01 SCOPE
1. The work to be executed under this Specification is the design,

manufacture, testing, delivery and installation of bridge bearings.
860.02 REFERENCES

below:
AS 1523 Elastomeric Bearings for use in Structures

AS/NSZ 4680 Hot-Dip Galvanised Coatings on Fabricated Ferrous Articles
AS/NSZ 3679.1 Structural Steel – Hot Rolled Bars and Sections
Other Publications
Australian Bridge Design Code
860.03 - 860.12 NOT USED
DESIGN AND MANUFACTURE
860.13 GENERAL
1. Bearings shall comply with the requirements of Section 4 of the

Australian Bridge Design Code, (the Code) except as varied by this Specification.
Acceptance of bearings will depend on satisfactory completion of load tests as set out in
Clause 860.15 for elastomeric bearings.
860.14 PHYSICAL DIMENSIONS AND TOLERANCES OF

ELASTOMERIC BEARINGS
1. Elastomeric Bearings to be supplied under this Contract shall comprise of

laminated rubber elastomeric bearings and are designated on the Drawings by their
SAA Part Numbers as given in Tables C4.1 to 4.20 of the Australian Bridge Design
Code. Bearings shall be of the sizes shown on the Drawings within the tolerances given
in Table 3.1 of AS 1523.

860.15 ACCEPTANCE TESTS FOR ELASTOMERIC BEARINGS
860.15.01 GENERAL
1. The load testing of bearings is part of the acceptance requirements of this

Specification. All tests shall be carried out in a testing laboratory certified by the
National Association of Testing Authorities Australia for the type of bearing and class
of test concerned.
2. Testing shall be carried out on completion of manufacture of all bearings. Testing

Acceptance of bearings will be dependent upon satisfactory completion of the tests
detailed below:
a) Compression test in accordance with Clause 860.15.02.
b) Stability test in accordance with Clause 860.15.03.
c) Proof loading in accordance with Clause 860.15.04.
d) Determination of bearing stiffnesses in accordance with Clause

860.15.05.
3. A full description of the sequence and method of application of loads

shall be recorded by the Contractor.
4. Test loads shall be applied slowly and at a uniform rate. When the
specified loading has been attained it shall be maintained steady sufficiently long for a
physical examination of the bearing or for two minutes whichever is the greater before
unloading. If any damage occurs, then the load and time at which any damage begins to
occur shall be recorded.
860.15.02 COMPRESSION TEST
1. All bearings shall be loaded individually to 1.5 times the rated load at
zero rotation and zero shear given on the Drawings or in the relevant table of the
Australian Bridge Design Code.
860.15.03 STABILITY TEST
1. 50% of bearings of the same capacity and type shall be loaded in pairs
under the rated load at zero shear.
2. Lateral deflections of rectangular bearings shall be recorded in directions

parallel to width and length dimensions. One bearing in the pair shall then be rotated
through 180° in the horizontal plane. The pair shall then be reloaded with the
maximum rated load and the lateral deflection parallel to each dimension again
recorded at the same points on the non-rotated bearing. From these two results the
lateral deflections for each bearing alone shall be calculated.
3. In case of bearings which are circular in plan one bearing shall be rotated
with respect to the other for a series of equal loads until an orientation producing
maximum lateral deflection is located. The bearings shall then be loaded under the
maximum rated load and the maximum radial lateral deflection measured. The bearings
shall be permanently marked and then reloaded with one bearing rotated through 180°
with respect to the other. The lateral radial deflection shall then be measured at the
same point on the non-rotated bearing and the lateral deflection for each bearing alone
shall be calculated.
4. Any bearing in which the lateral deflection in any direction under the test

load is greater than 5% of the vertical height of the bearing shall be rejected.
860.15.04 PROOF LOADING
1. The Contractor shall carry out the tests set out in Table 860.1 on one pair
of bearings of each type and capacity. The bearings shall be loaded in stacked pairs in
the test apparatus.
2. During the test described at (b) or (c) in Table.860.1, the net contact area
shall be not less than 80% of the unloaded bearing area.
(a) The rated load at zero rotation and maximum shear plus 1.5
x the maximum rated shear deflection.
(b) 1.5 x rated load at zero rotation and maximum shear plus 1.0
x the maximum rated shear deflection.
(c) 1.5 x the maximum rated shear deflection plus 0.5 x rated
load at zero rotation and maximum shear.
TABLE 860.1 PROOF LOADING TEST
860.15.05 STIFFNESSES
1. Bearings shall be tested to determine their compressive and shear

stiffnesses.
2. All bearings shall be tested for compressive stiffness in accordance with

Clause 5.3.2 of AS 1523. Testing for compressive stiffness may be carried out in
conjunction with the compression test. The mean compressive stiffness of all bearings
tested shall be within 15% of the value given in the Code and the compressive stiffness
of any individual bearing shall be within 15% of the mean.
3. 50% of bearings of each type, with a minimum of two bearings, shall be

tested for shear stiffness in accordance with Clause 5.3.3 of AS 1523 as modified by
Clause C4.12.13 of the Code. The shear stiffness of any bearing shall be within 20% of
the value given in the Code.
860.16 – 860.17 NOT USED
860.18 REJECTION
1. Where a bearing is rejected the Contractor may elect to test all bearings of
the type represented and only bearings successfully passing the tests will be accepted.
In addition all replacement bearings shall be acceptance tested. The cost of all
additional testing shall be borne by the Contract.
860.19 TRANSPORT AND DELIVERY
1. The Contractor shall take all necessary precautions to prevent damage to

the bearings during handling, storage and delivery to site.
2. All elastomeric bearings shall be marked, packaged and handled in

accordance with Appendix F of AS 1523.

INSTALLATION OF BEARINGS
860.20 LOCATION AND FIXING OF ELASTOMERIC BEARINGS
1. All bearings shall be placed on mortar pads and shall be located in

position on the abutments and piers by steel dowels which shall protrude through the
lower outer steel plate unless otherwise shown on the Drawings.
860.21 – 860.22 NOT USED
860.23 INSTALLATION OF ELASTOMERIC BEARINGS
1. All elastomeric bridge bearings shall be installed to the requirements of

this Specification and the details shown on the Drawings.
2. Grout pads shall be well compacted and shall be constructed with formed
sides as detailed on the Drawings. Bearings may be used to set the levels of the pad but
shall be removed for inspection of the finished pad.
3. The pads shall consist of an approved non shrink cementitious grout with
a minimum of 28 days compressive strength of 30 MPa when tested using a 70 mm
cube. A minimum of two cubes shall be taken from each batch of mortar mixed.
860.24 NOT USED
820.25 TOLERANCES FOR INSTALLATION
1. Bearings shall be installed to the following tolerances:
(a) Misplacement of centre lines + 3 mm
(b) Variation from specified level at centre + 3 mm
(c) Inclination from horizontal 1 in 300

S ERIES 900
MISCELLANEOUS
SPECIFICATION 901 – CONCRETE – GENERAL WORKS
SPECIFICATION 903 - FENCING
SPECIFICATION 908 - GRAFFITI
SPECIFICATION 909 – WATER RETICULATION
SPECIFICATION 910 – SEWER PRESSURE MAINS
S PECIFICATION 901
CONCRETE - GENERAL WORKS

CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
901.01 SCOPE.................................................................................................................................. 1
901.02 REFERENCES ..................................................................................................................... 1
MATERIALS.............................................................................................................................................. 1
901.03 GENERAL ........................................................................................................................... 1
901.04 ADMIXTURES.................................................................................................................... 2
901.05 REINFORCEMENT............................................................................................................. 2
901.06 CLASS OF CONCRETE ..................................................................................................... 2
901.07 FORMWORK ...................................................................................................................... 2
901.08 - 901.29 NOT USED ............................................................................................................... 3
OPERATIONS ........................................................................................................................................... 3
901.30 MIXING OF CONCRETE ................................................................................................... 3
901.31 PLACING OF CONCRETE................................................................................................. 3
901.32 TESTING ............................................................................................................................. 4
901.33 CURING AND PROTECTION ........................................................................................... 4
901.34 CONCRETING IN HOT WEATHER ................................................................................. 4
901.35 CONCRETE SURFACES.................................................................................................... 5
901.36 CONFORMANCE AND NON-CONFORMANCE ............................................................ 5
901.37 - 901.79 NOT USED ............................................................................................................... 6
901.80 - 901.89 NOT USED ............................................................................................................... 6

Associated Roadworks Concrete – General Works
SPECIFICATION 901
CONCRETE - GENERAL WORKS
GENERAL
901.01 SCOPE
1. The work to be executed under this Specification consists of the mix Scope
design, the supply and delivery, placing, compaction, finishing, curing and protection of
concrete for general non-structural works where normal (N) class concrete has been
specified.
2. Concrete for bridgeworks, Manufacture of reinforced concrete box Major

culverts and other major structures is covered in Specification 820, CONCRETE FOR Structures
STRUCTURES.
901.02 REFERENCES

below:
AS 1012 Methods of Testing Concrete

AS 4671 Steel Reinforcing Materials
AS 1379 Specification and Supply of Concrete
AS 1478 Chemical Admixtures for Concrete.
AS 2758.1 Aggregates and Rock for Engineering Purposes Part 1: Concrete
Aggregates
AS 3600 Concrete Structures.
MATERIALS
901.03 GENERAL
901.03.01 DEFINITIONS
1. Concrete in general shall consist of a mixture of cement and water and Constituents
coarse aggregate and fine aggregate.
2. The strength of concrete shall be defined as the average 28 day Strength

compressive strength of a minimum of two standard 100 mm diameter by 200 mm long
cylinders taken from the same sample and made and cured and tested in accordance
with AS 1012.

901.03.02 FINISHED CONCRETE
1. In its finished state the concrete shall be sound, dense, durable, free from Finished State
honeycombing and shall have the strength and other properties specified.
2. The exposed surfaces shall be smooth and dust free and conform to the Exposed
shape tolerances specified. Surface
3. Concrete shall comply with AS 1379 except as varied by the requirements Concrete to
of this Specification. Comply
4. Aggregates shall meet the durability criteria for concrete exposure Aggregate
classification C of AS 2758.1 unless otherwise specified. Durability
901.04 ADMIXTURES
1. Admixtures may be used in concrete to modify workability but will not Admixtures
be permitted for the purpose of reducing cement content. However, the admixture shall Compliance
have no harmful effect whatsoever upon the quality of the concrete or upon any
reinforcement or other fixture embedded therein.
2. Any admixture shall comply with the requirements of and be used in

901.05 REINFORCEMENT
1. Reinforcement used in the Works shall comply with the relevant Reinforcement
requirements of AS 4671. to Comply
2. Steel for reinforcement shall be free from loose or thick rust, loose mill Storage
scale, all dirt, all grease and all other foreign substances which may impair the bond
between steel and concrete. Reinforcement steel shall be stored above ground level and
shall be protected from damage and deterioration due to exposure.
3. Reinforcing steel shall be accurately cut and bent to the dimensions and Cutting &
shapes shown in the Drawings. All bars shall be bent in accordance with AS 3600. Bending
4. Reinforcing steel shall be accurately placed in the positions shown on the Placement
Drawings and the maximum tolerance on all concrete cover dimensions shall be +5 mm Secured
and -0 mm. The reinforcement shall be secured in position so that it will not be
displaced during the placement of concrete and the Contractor shall ensure that there is
no disturbance of the reinforcement in concrete that has already been placed.
901.06 CLASS OF CONCRETE
1. The Class of concrete shall be as specified on the Drawings or in the Concrete Class
relevant Specification.
2. Unless otherwise noted aggregate size and slump is as follows:
a) Maximum aggregate size 20 mm Aggregate Size
b) Maximum slump 100 mm Slump
901.07 FORMWORK
1. All formwork used to form and support the concrete shall conform to the

requirements of AS 3610.
2. The tolerances shall be as follows: Tolerances
a) Variation in cross-sectional dimensions + 5 mm
b) Variation in overall dimensions + 10 mm
c) Variation in surface level + 5 mm
901.08 - 901.29 NOT USED
OPERATIONS
901.30 MIXING OF CONCRETE
1. Production and delivery for the concrete shall be in accordance with the Batch Plant &
requirements of AS 1379 except that additional water shall not be introduced into a Transit Mixers
mixed batch of concrete and the period for completion of discharge from the
commencement of mixing shall not exceed ninety (90) minutes.
901.31 PLACING OF CONCRETE
1. Prior to the placement of any concrete the Contractor must certify to HOLD POINT
the Superintendent that all falsework, formwork, reinforcement, levels, placement
procedures and curing procedures to be employed comply with the requirements
of the Technical Specification.
2. Before commencement of each concrete pour the Contractor must HOLD POINT
ensure that sufficient vibrators and spares are available and tested. The number of
working vibrators required must not be less that one for each 4 cubic metres of
concrete placed per hour. The number of standby vibrators must not be less than
25% of the number of working vibrators with a minimum of one.
3. Concrete shall be conveyed from on site mixers to its final position Transport &
without delay and by methods which will not permit segregation and/or loss of material. Placing
All the concrete shall be placed in its final position within ninety minutes of the
materials having been placed in the mixer.
4. During placing, all concrete shall be vibrated with a mechanical or Vibration

pneumatic immersion vibrator to remove all voids and air bubbles.
5. Care shall be taken during placing to see that no foreign substances are Foreign
included in the concrete. Substances
6. The location of all construction joints shall be as indicated on the Construction

Drawings or approved by the Superintendent. Construction joints shall be made on true Joints
vertical and horizontal planes and the surface shall be roughened to remove all laitance
and expose the aggregate to provide a thorough bond with concrete cast subsequently.
The roughened surface shall be thoroughly cleaned with water to remove loose chips
and any foreign matter. Immediately before fresh concrete is cast against the joint the
hardened concrete surface shall be thoroughly wetted.

901.32 TESTING
901.32.01 GENERAL
1. All sampling and testing of concrete specimens shall be in accordance Sampling

with AS 1012 Parts 1 to 18. Concrete test cylinders shall be 100 mm diameter by 200 Testing
mm long. Rubber caps may be used for the capping of test cylinders, as allowed in AS
1012.9.
2. The Contractor shall have available not less than six concrete moulds,
slump cone and tray, and rod.
901.32.02 COMPRESSIVE STRENGTH ANALYSIS
1. Any batch of concrete shall be deemed to comply with the strength Compliance
requirements of this Specification if:
(a) Every concrete test specimen in the batch has a 28 day compressive
strength greater than 90% of the characteristic strength; and
(b) The average 28 day compressive strength of the concrete test

specimens in the batch is equal to or greater than the characteristic
strength.
901.33 CURING AND PROTECTION
1. Freshly placed concrete shall be protected from the elements and

prevented from drying out too quickly.
All concrete surfaces shall be cured by one of the following methods for not less than
five (5) days:
(a) Continuous wetting.
(b) Spraying with an approved curing compound complying with the

requirements of AS 3799. Such curing compound shall be applied in
accordance with the manufacturer's published recommendations.
(c) Wrapping with polythene or similar film to provide an airtight cover.
(d) Maintaining the formwork in position for the curing period.
The Contractor shall ensure that the method of curing shall not result in any staining of
exposed surfaces of concrete.
901.34 CONCRETING IN HOT WEATHER
1. The requirements of AS 1379 for temperature of the concrete at the point Placement
of discharge shall be met for all concrete works undertaken in hot weather. In addition, Temperature
placement of concrete shall only be permitted providing:
a) the concrete mix temperature during placement shall at no time Mix

exceed 35°C, Temperature
AND, EITHER
b) the ambient shade temperature does not exceed 38°C and is falling, Shade
Temperature

OR
c) the ambient shade temperature is less than 38°C and rising provided
that the placement can be completed before the ambient temperature
exceeds 38°C.
2. Achievement of temperature requirements may necessitate the shielding Methods

and/or wetting of aggregate stockpiles, the chilling of mixing water and/or the
scheduling of concrete placement at night.
901.35 CONCRETE SURFACES
1. Surface finish of concrete shall conform to the following requirements: Surface Finish
(a) The quality of surface finish and tolerances for exposed formed Quality of
surfaces of concrete shall be as specified in Section 3 of AS 3610 for Finish
a Class 2 finish unless otherwise shown on the Drawings.
(b) The quality of surface finish and tolerances for concealed formed Concealed
surfaces of concrete shall be as specified in Section 3 of AS 3610 for Formed
a Class 3 finish unless otherwise shown on the Drawing. Surfaces
(c) Unformed concrete surface finishes shall be as designated on the Unformed

Drawings with reference to the classifications given in Table 901.35 Surfaces
below
Designated Type of Concrete Finish Maximum Allowable Surface

Finish Irregularities
U1 A wood floated finish to produce a uniform 5 mm abrupt or 15 mm in a 3 m

surface without surface pitting or cavities template
U2 A high quality steel trowelled finish having a Nil abrupt or 5 mm in a 3 m

dense smooth impervious finish without template
surface pitting or cavities
U3 A high quality mechanical steel trowelled 2 mm abrupt or 5 mm in a 3 m

finish having a dense impervious finish template
without surface pitting or cavities
U4 A wood floated surface with a broomed finish 2 mm abrupt or 5 mm in a 3 m

template
TABLE 901.35 UNFORMED SURFACE FINISHES FOR CONCRETE
901.36 CONFORMANCE AND NON-CONFORMANCE
1. Concrete that shows evidence of poor workmanship such as Non-

honeycombing or is porous due to inadequate compaction or due to segregation or Conforming
concrete that fails to comply with this Specification in regard to strength or tolerances
or finishes or other requirements, shall be deemed to be non-conforming.
2. If at any time the concrete fails to meet any of the requirements of this Operations
Specification, concreting operations shall be suspended until corrective measures are Suspended
taken, at no cost to the Principal.

901.37 - 901.79 NOT USED
901.80 - 901.89 NOT USED

S PECIFICATION 903
FENCING & GATES

CONTENTS
Clause Page
FENCING & GATES................................................................................................................................. 1
GENERAL .................................................................................................................................................. 1
903.01 SCOPE...................................................................................................................................... 1
903.02 REFERENCES ......................................................................................................................... 1
GROUNDWORK ....................................................................................................................................... 1
903.03 WORK NEAR TREES............................................................................................................. 1
903.04 PROTECTION OF TREES TO BE PRESERVED................................................................. 1
903.05 DAMAGE ............................................................................................................................... 1
903.06 WORK UNDER TREES.......................................................................................................... 2
903.07 CUTTING AND TREATING LARGE ROOTS...................................................................... 2
903.08 SITE CLEARING .................................................................................................................... 2
903.09 EXISTING SERVICES............................................................................................................ 2
903.10 FOOTINGS .............................................................................................................................. 2
MATERIALS & CONSTRUCTION........................................................................................................ 2
903.11 CONCRETE ............................................................................................................................. 2
903.12 METALWORK ........................................................................................................................ 3
903.13 BOUNDARY FENCES IN THE ELECTRIFIED AREA........................................................ 6
ANNEXURE 903A ..................................................................................................................................... 7
BOUNDARY FENCES IN THE ELECTRIFIED AREA ....................................................................... 7
REMOVAL AND REPLACEMENT OF A FENCE PANEL ................................................................. 7
NEW FENCES......................................................................................................................................... 8

Associated Roadworks Fencing
SPECIFICATION 903
FENCING & GATES
GENERAL
903.01 SCOPE
1 This Specification details the fencing and gates to be installed on the Public
Transport Authority Railway Reserve of the Perth Urban Railway Network.
2 1800 mm high chain link fence with a triple row of barbed wire on cranked
posts applies to the fence along the rail easement, the ACS Section 15 Boundary and the
Intermodal Terminal area, and boundary between the Intermodal terminal and Port Beach
Road. Chain link fence is to be Black Powder Coated finish. A minimum offset of 1.0m
should be provided if used along cycle-paths as per Austroads Part 14 - Bicycles. This
fencing should be in accordance with the following Main Roads standard drawings with
the exception that posts are to be cranked:
• 9331-0385 Assembly Details
• 9331-0386 Gate and Post Details
3. The fence adjacent to the electrified areas of rail line should generally be
1800mm high chain mesh with 3 strands of barbed wire above (not cranked).
903.02 REFERENCES

abbreviated form (eg. AS 1234 or WA 123). For convenience, the full titles are given
below:
AS 1379-1997 Specification and Supply of Concrete.

AS 1450-1983 Steel Tubes for Mechanical Purposes.
AS 1725-1975 Galvanised Rail-Less Chain Wire Security Fences and Gates.
AS 2423-1991 Galvanised Wire Fencing Products.
Specification 901 CONCRETE - GENERAL WORKS
GROUNDWORK
903.03 WORK NEAR TREES
1. Trim, cut back or otherwise modify trees and shrubs on the Reserve
encroaching within one metre of the fence line, as approved by the Superintendent.
Protect trees that overhang or are not on Public Transport Authority property
903.04 PROTECTION OF TREES TO BE PRESERVED
1. Protect trees that are nominated for preservation by the Superintendent, with
high visibility tape.
903.05 DAMAGE

1. Prevent damage to tree bark. Do not attach stays, guys and the like to trees.
903.06 WORK UNDER TREES.
1. Remove topsoil from within the drip line of trees unless otherwise directed.
Excavations under tree canopies shall be dug by hand and filled in as quickly as possible
to minimise root damage.
903.07 CUTTING AND TREATING LARGE ROOTS
1. Do not cut roots exceeding 50 mm in diameter unless permitted by the

Superintendent. Use a chain saw or similar to make a clean cut and avoid disturbing the
remaining root system. Immediately after cutting, apply an approved bituminous
fungicidal sealant to the cut surface
903.08 SITE CLEARING
1. Clear a strip generally 1 metre wide for fences, plus other specified
areas occupied by the works or shown on the Drawings.
903.09 EXISTING SERVICES
1. The Contractor shall be responsible for locating and protecting other

parties’ services affected by the Works. The Superintendent shall arrange for Public
Transport Authority services to be located and marked prior to commencement of
groundworks.
2. The contractor shall not excavate by machine within 1 m. of any
underground services without prior approval of the appropriate Authorities and Public
Transport Authority.
903.10 FOOTINGS
1. Excavate for footings to the minimum dimensions and depths in Table 2.
MATERIALS & CONSTRUCTION
903.11 CONCRETE
903.11.01 GENERAL
1. Footings shall be filled with pre-mixed or site mixed concrete, maintaining

at least 75mm. of cover over any embedded metal components.
903.11.02 TESTING
1. Ready-mixed concrete shall be designed, mixed and tested in accordance

with AS 1379.
903.11.03 CONCRETE MATERIALS AND MIX PROPORTIONS

1. Concrete is to be supplied as follows:-
a) Ready-Mixed
Strength Grade N20, Slump 80 mm., Maximum Sized Aggregate 20mm.,
Direct Discharge, from an approved supplier. Concrete to be delivered in
agitating trucks. Concrete is liable to rejection if the elapsed delivery time
exceeds 1 hour from batching time. Class N20 is accordance with
Specification 901 CONCRETE - GENERAL WORKS.
b)Site Mixed
Use Type ‘A’ Portland cement, clean sharp sand, potable water and coarse
aggregate passing not less than 5 mm. and not greater than 20 mm. sieve
sizes. Mix in the ratio of not less than one part cement to two parts sand
and four parts coarse aggregate by volume (1:2:4 mix), with sufficient
water to provide a water/cement ratio by volume between 0.8 and 0.9.
If additional water is required for workability, the water/cement ratio shall
be maintained by adding a corresponding volume of cement.
903.11.04 PLACEMENT
1. Place concrete in layers not more than 200mm. deep, each layer being
tamped with a rod or vibrated with a poker vibrator to blend into the preceding layer.
2. Where formwork is required to support excavations, the formwork is not to
be removed without prior written approval of the Superintendent.
903.11.05 EMBEDDED ITEMS
1. Fence posts and braces are to be located centrally in the concrete,

maintaining at least 75 mm. cover on sides and ends.
903.11.06 FINISHES
1. Concrete surfaces are to be wood float finished, flush with or above the
surrounding ground surface. Concrete splashes are to be cleaned off metal components
before initial setting.
903.12 METALWORK
903.12.01 GALVANISED COATINGS
1. All posts, fittings, threaded fasteners, cable wires, ties and mesh shall be
heavily zinc coated to a minimum coating mass of 200g./m2 in accordance with the
Standards in Table 1 that may supersede those referenced in the Standards above: -
Component Appropriate Standard Specification

Posts AS 4792:1999 ILG200 or ZB 200/200
Fabricated Fittings AS 4680:1999
Bolts and Nuts AS 4680-1999
Wire and Mesh AS 4534:1998 W10Z or W10DZ
Table 1. Galvanised Coating Specifications
903.12.02 POSTS

1. Posts shall be steel tubes to AS 1450 with nominal bore and wall thickness
according to type as in Table 2. Exposed ends shall be fitted with galvanised caps. End,
corner and gateposts are 3050 mm long, and intermediate posts are 2900 mm long. Posts
shall be made in one piece and butt weld joints are not permitted. Posts shall be machine
indented to a depth of 4.6 mm. with a round nosed die of 2.4 mm. radius to suit the
required barbed wire spacings.
NB= Nominal Bore, OD= Outside Diameter, WT= Wall Thickness

TYPE SIZE SPACING FOOTINGS
DIA DEPTH
INTERMEDIATE NB 40 4000 mm. 300 mm. 600 mm.
OD 48.3 mm. Maximum
WT 2.3 mm
END, CORNER NB 50 as required 300 mm. 750 mm.
OD 60.3 mm.
WT 3.6 mm
GATES NB 50 as required 300 mm. 900 mm.
UP TO 4 m. OD 59 mm.
OPENINGS WT 4.5mm.
GATES NB 80 as required 300 mm. 900 mm.
BETWEEN 4 m. OD 89 mm.
and 8 m. WT 4.5mm.
OPENINGS
BRACING NB 32 as required 300 mm. 600 mm.
OD 42.4 mm
WT 2.6 mm
Table 2 - Post Sizes, Spacings and Footing Details
903.12.03 FASTENINGS AND FITTINGS
1. Compression fittings, caps, bolts, washers and nuts, shall be of approved

type, all heavily galvanised as per Table 1 and fit the sizes of components to be joined.
903.12.04 CHAINMESH
1. Height: 1800 mm.

Apertures and Wire Dimensions: 50 mm. aperture x 2.5 mm. dia.
Selvedges:
On fences: Barbed and barbed
On gates: Knuckled and barbed
2. Chainmesh shall be placed on the outside of posts and adequately strained
and secured to each wire and all posts, except end posts and gate posts, with tie wires at
intervals of not more than 450 mm. The chainmesh shall be laced to end posts and gate
posts. The space between the bottom selvedge of the chainmesh and the ground shall be
not more than 90 mm.
903.12.05 BRACES AND STAYS OF FENCES

1. Braces shall be provided as required by AS 1725.Braces are required at
changes of direction (greater than 1 in 10), ends and gateposts. One stay is required at the
ends of all fence runs. Two stays are required at all corners, gateways and/or significant
changes of direction/elevation.
903.12.06 TYPES OF BRACING:
1. Diagonal Braces:
Gooseneck Stays clamped to posts with steel
compression fittings and embedded in concrete footings.
2. Boxed Strainers
A 32NB horizontal brace fixed approximately 300 mm below top selvedge
of chain mesh with steel compression fittings and double twisted 3.15 mm. dia. wire and
turnbuckle for tensioning. Boxed Strainers are to be used where sandy soil prevails.
3. Back Stays -
To be fitted to gate posts at 45o to the vertical for gates with a leaf width
greater than 1.80m.
4. Horizontal Stays -
at each location of corner back stays.
Attachment of Double Cable Wires to Posts.

1. Double twisted 3.15 mm. dia. wires or single strand 4 mm. dia.
Helical, galvanised as per Table 1.
2. Tensioning of the cable wires shall not be commenced until concrete post
footings have cured for a minimum period of 24 hours.
3. Positions: -
Top Wire: One half diamond below selvedge
Centre Wire: Centre of mesh
Bottom Wire: One diamond above bottom selvedge.
903.12.07 ATTACHMENT OF DOUBLE CABLE WIRES TO POSTS.
1. The first cable wire shall be tied to the post, carried across the outside face
of the next post in line and then looped around the second post so that the wire leaves the
post on the outside face.
2. The second cable wire shall be tied to the first end post, looped around the
first post so that the wire leaves the post on the outside face, and is then carried across the
outside face of the second post.
3. This operation shall be continued along the fence, looping each cable wire
around alternate posts, finally tying each wire to the end or gatepost.
4. The two cable wires shall be twisted together at intervals between posts to
form a tight spiral pitch and so provide adequate tension to the cable wires.
903.12.08 ATTACHMENT OF SINGLE HELICOIL WIRE TO POSTS.
1. The helicoil cable wire shall be looped twice around the first end post and
then twisted around itself four times. It shall then be passed along the outside of the line
posts and attached to other end, gate or strainer post in the same manner as for the first
post. Each run of cable wire shall be tensioned so as to support the weight of the chain
mesh, without sagging. Each run of cable wire shall be securely tied to each line post.
903.12.09 ATTACHMENT OF CHAINMESH.
1. Lacing wire:
2.0 mm Dia. wire fully laced through each diamond at end, gate and corner
posts.
2. Tie wire:
2.0 mm Dia. wire with two full twists and neatly cut off. Chain mesh may
be fastened with Garrard Ring fasteners. (Or similar approved).

903.12.10 BARBED WIRE..
Three rows of two 3.15 mm dia, wire twisted together with four point barbs
at nominally 90 mm centres, heavy galvanised and attached to posts above chain mesh
fencing at 150 mm vertical spacing. Barbed wire shall be strained between all posts until
taut and secured with tie wire on to each post.
903.12.11 GATES.
1. All gates shall be to AS 1725 Table 3 with 3 strands of barbed wire to

match adjacent fencing. Install two part galvanised hinges with attachments as required.
2. All gate framework joints are to be cold galvanised after fabrication.
3. Nominal gate width.

Double gate: 2 x 2000 - ie. 4000 opening
Gate framework: Outer frame 25 NB galvanised tube
Inner frame 20 NB galvanised
tube
Fit two16 mm. dia. galvanised tower bolts, one to each double gate, with corresponding
ferrules set into concrete.
903.12.12 LOCKING CHAINS

1. Provide all gates with heavy galvanised 6mm. Long Proof Coil chain to
pass around the adjacent posts and be closed with padlocks supplied by the
Superintendent. One link is to be welded to the gate and cold galvanised after.
903.12.13 INSULATED PANELS
1. Since fences may run parallel to live 25 KV overhead traction equipment,

care must be taken to prevent induced currents taking different paths to traction earth and
developing potential differences between adjacent sections of fencing. To avoid the risk
of a person bridging the gap between two sections of fence, Public Transport Authority
may instruct the contractor to allow for an insulating fence panel. This is done by placing
two end posts, adequately braced and not less than 2 metres apart, with the cable wires of
the fence each side strained to these posts. The contractor shall provide separately
strained cable wires, barbed wires and mesh across the gap.
2. Insulated panels are normally installed not more than 200 metres apart.
903.12.14 TRACTION EARTH BONDING.
1. Allowance must be made for the contractor to attach threaded studs to

posts, and provide electric cables to bond the fence to traction earth in accordance with
Public Transport Authority Earthing and Bonding Guidelines. Wires wrapped around
each horizontal cable and barbed wire and attached to the studs are also required.
903.13 BOUNDARY FENCES IN THE ELECTRIFIED AREA
1 Contractor to seek advice from PTA on locations.
2 Refer to Annexure 903A for details of boundary fences in the electrified

area.

ANNEXURE 903A
BOUNDARY FENCES IN THE ELECTRIFIED AREA
All fence panels in the electrified area are either bonded to or insulated from traction earth.The traction
return rail forms part of the traction earth.
Metallic items within 3 metres of the vertical plain formed by live 25 000 volt conductors are bonded to
the traction rail so that in the event of a fault a direct earth will be available for protection equipment to trip
the circuit breaker(s) feeding that section of overhead line. The ECO will usually reclose the circuit
breakers in an attempt to power the section up again. Even when the circuit breakers are open for an
electrical section the Overhead Line Equipment may still be charged due to induced voltage or residual
charge.
Fences and other metallic items are therefore bonded to the traction return rail to bleed off
voltages induced from the live overhead line.
A fence section should only be earthed at one point in order to prevent circulating current
between multiple earths.
Where a fence deviates away from the railway track and there is a distance of more than 3 metres from the
vertical plain formed by the live 25 000 volt conductors, an insulated fence panel is installed. This
insulated fence panel is at least 2.5 metres wide to ensure that a person cannot bridge across the panel and
make contact with a portion of a fence at traction earth and one that may be at Supply Authority earth.
In order to maintain electrically safe fences in the electrified area it is important that these insulated fence
panels are never electrically shorted with a jumper cable, temporary traction bond, cable etc and never
shortened in length.
An insulated fence panel is sometimes installed to give at least 2.5 metres separation between equipment at
traction earth and that at Supply Authority earth.
Example: a communications location case at Supply Authority earth may be located close to a fence at
traction earth. In order to make the situation electrically safe, an insulated fence panel may be installed
opposite the communications location case.
Insulated fence panels are also installed approximately every 100 or 200 metres along a fence that is at
traction earth, this is done to cut down the electrical length of the metal work that is parallel with live
overhead line equipment. This reduces the voltage induced into the fence.
Under fault conditions there may be up to 1000 volts difference between an item at traction earth and one
at Supply Authority earth in the vicinity .
REMOVAL AND REPLACEMENT OF A FENCE PANEL
Where there is a need to remove a fence panel, the installation must first be checked to see what type of
panel it is. Fence panels can be considered to be one of the following:
• NORMAL PANEL: Is neither insulated from nor bonded to traction earth and may be at Supply
Authority earth or close to equipment that is at Supply Authority earth.
• BONDED PANEL: A panel that is secured to a post that has a traction bond connected to it.
• SERIES PANEL: A fence panel that is bonded indirectly to traction earth via another bonded panel
• INSULATED PANEL:Has insulated fittings to electrically isolate two sections of bonded fence or
maintain a minimum of 2.5 metres separation from equipment at Supply Authority earth.
Renewal of a normal fence panel will require no special precautions other than to ensure that any adjacent
bonded or insulated panel is not disturbed.

The ECO must be contacted prior to removing a bonded or series fence panel. The ECO will need to know
the exact location of the panel to be removed, who is in charge of the work and when the fence will be
restored to normal.
Where a bonded post has to be removed, a temporary traction bond must be installed between the traction
return rail and the remaining fence panels prior to removing the permanent bond. The temporary traction
bond must be maintained until the fence has been fully restored and permanent bonding replaced.
Temporary traction bonds must not be coupled together. Prior to use, a temporary traction bond must be
inspected to ensure that the cable and fittings are in good order. Any faulty unit must not be used, but must
be forwarded to the Overhead Catenary Foreman for repair or replacement. An appropriate length
temporary traction bond must be used. A temporary traction bond must not be connected to anything other
than the traction return rail and the appropriate fence post per the job requirements.
NOTE: The traction return rail is generally the one closest to the masts. This rail is sometimes
transposed for signalling purposes. The web of the traction return rail is painted with a patch of light
blue paint opposite each mast.
A temporary jumper cable must be installed around a series fence panel prior to its removal. This jumper
cable must be left in place until the fence has been fully restored.
Jumper cables must not be coupled together, Prior to use, a jumper cable must be inspected to ensure that
the cable and fittings are in good order, Any faulty unit must not be used, but must be forwarded to the
Overhead Catenary Foreman for repair or replacement, An appropriate length jumper cable must be used,
A jumper cable must not be connected to anything other than the traction return rail and the appropriate
fence post or from one fence panel to another per the job requirements.
An insulated fence panel is only to be removed by Overhead Catenary Staff, An insulated fence panel must
not be bonded nor bridged.
After completing work on a bonded or series fence panel, the person in charge of the work must advise the
ECO that the work has been completed and the installation has been restored, The ECO will make
arrangements to have the installation electrically tested.
NEW FENCES
The Electrical Manager must be advised of any proposed new fence installations or replacements in the
electrified area, Any new fence must be assessed to determine bonding and insulating requirements.

S PECIFICATION 908
GRAFFITI
CONTENTS
Clause Page
GENERAL .................................................................................................................................................... 1
908.01 SCOPE.................................................................................................................................... 1
908.02 REFERENCES ....................................................................................................................... 1
MATERIALS................................................................................................................................................ 2
908.03 GENERAL ............................................................................................................................. 2
908.04 ANTI-GRAFFITI COATINGS .............................................................................................. 2
908.05 GRAFFITI REMOVAL MATERIALS.................................................................................. 3
908.06 PAINT .................................................................................................................................... 4
908.07 - 908.10 NOT USED ................................................................................................................. 4
ANTI-GRAFFITI COATINGS ................................................................................................................... 4
908.11 SUBSTRATE SURFACE PREPARATION .......................................................................... 4
908.12 APPLICATION ...................................................................................................................... 5
908.13 ANTI-GRAFFITI COATING SYSTEMS.............................................................................. 5
908.14 - 908.20 NOT USED ................................................................................................................. 6
GRAFFITI REMOVAL............................................................................................................................... 6
908.21 GENERAL ............................................................................................................................. 6
908.22 GRAFFITI REMOVAL ......................................................................................................... 7
908.23 PAINTING OVER GRAFFITI............................................................................................... 7
908.24 - 908.30 NOT USED ................................................................................................................. 8
INSPECTION AND TESTING................................................................................................................... 8
908.31 EFFECTIVENESS OF ANTI-GRAFFITI COATINGS......................................................... 8
908.32 SURVEILLANCE OF CONSTRUCTION WORKS............................................................. 8
908.33 REPORTS............................................................................................................................... 9
908.34 - 908.40 NOT USED ................................................................................................................. 9
SPECIAL REQUIREMENTS ..................................................................................................................... 9
908.41 - 908.50 NOT USED ................................................................................................................. 9
ANNEXURE 908A ..................................................................................................................................... 10
APPROVED ANTI-GRAFFITI COATINGS .......................................................................................... 10
ANNEXURE 908B...................................................................................................................................... 11

Associated Roadworks Graffiti
SPECIFICATION 908
GRAFFITI
GENERAL
908.01 SCOPE
1. The works to be executed under this specification consist of the provision Anti-Graffiti
of graffiti prevention measures by the application of anti-graffiti coatings to roadside Coatings
furniture and structures including bridges, noise walls, retaining walls, traffic controller
boxes, and similar features.
2. The scope also includes the removal of graffiti and/or the painting over of Graffiti
graffiti. Removal
3. The scope excludes the application of anti-graffiti coatings to the faces of Signs Excluded
traffic signs. The use of a protective overlay film for the protection of sign faces is
described in Specification 601 SIGNS.
908.02 REFERENCES

abbreviated form (eg. AS 1234 or WA 123). For convenience, the full titles are given
below:
AS 1580.205.1 Methods of Test for Paints and Related Materials - Brushing

AS 1580.205.2 Methods of Test for Paints and Related Materials - Air Spraying
AS 1580.205.3 Methods of Test for Paints and Related Materials - Roller Coating
AS 1580.205.4 Methods of Test for Paints and Related Materials - Airless
Spraying
AS 1580.408.5 Adhesion Pull-off Test
AS 1627.1 Cleaning Using Liquid Solvents and Alkaline Solutions
AS 1627.4 Abrasive Blast Cleaning
AS 2311 Painting of Buildings
AS 2700 Standard Colours
ASTM D6132-97 Standard Test Method for Non-Destructive Measurement of Dry
Film Thickness (DFT)
Materials Institute of WA (MIWA) Specifications & Test Methods
Graffiti Removers
Non-Sacrificial Anti-Graffiti Coatings
Sacrificial Anti-Graffiti Coatings
Test Methods for Effectiveness of Graffiti Removers:
Non-Sacrificial Anti-Graffiti Coatings
Sacrificial Anti-Graffiti Coatings
Copies of the Materials Institute of WA specifications can be obtained from Graffiti
Program, Ministry of Premier and Cabinet, PO Box 877, BALCATTA, WA 6914, or
by Telephone on 08 9240 5555

MATERIALS
908.03 GENERAL
1. Materials required to complete the Works shall be supplied, delivered and

applied by the Contractor.
2. Product Data Sheets and current Materials Safety Data Sheets HOLD POINT
detailing the properties of the proposed products shall be provided to the
Superintendent prior to the use of any materials on works within the Contract.
3. All coatings and treatments shall be applied in accordance with good

painting practice and in accordance with the manufacturer’s specifications.
908.04 ANTI-GRAFFITI COATINGS
908.04.01 DEFINITIONS
1. “Sacrificial Anti-Graffiti Coatings” shall indicate those coatings normally

applied to highly porous substrates, such as natural limestone or limestone derivatives,
and can also apply to lower porosity substrates.
2. “Non-Sacrificial Anti-Graffiti Coatings” shall indicate those coatings

intended to be resistant to graffiti removers.
908.04.02 GENERAL
1. Anti-graffiti coatings shall be selected from the list of approved coatings

at Annexure 908A.
2. The selected anti-graffiti coating system used shall carry a guaranteed Guaranteed
"Graffiti Removal" life of not less than ten years from the date of application. Life
3. Anti-graffiti coatings shall satisfy the requirements given in

“Specifications for Sacrificial Anti-graffiti Coatings” or “Specifications for
Non-sacrificial Anti-graffiti Coatings” as published by the Materials Institute of WA.
4. The coatings shall be able to fulfil the claims of the manufacturer with
respect to coating properties for the particular surfaces on which it is designed to be
used.
5. The anti-graffiti coating shall be applied in accordance with the Effectiveness

manufacturer’s specifications. Coatings shall be assessed in accordance with “Method
for Assessing the Effectiveness of Sacrificial Anti -graffiti Coatings” or “Method for
Assessing the Effectiveness of Non-sacrificial Anti -graffiti Coatings” as published by
MIWA, and shall achieve a minimum rating of 4 in accordance with the following
scale:

Rating Result
0 No graffiti removed
1 Some graffiti removed but no more than 30%
2 Between 30% and 70% graffiti removed
4 Most graffiti removed with only shadowing remaining
5 Graffiti completely removed
6. Alternative anti-graffiti coatings will only be considered upon submission

of a written request to vary the approved anti-graffiti coating.
7. The written request for the nominated coating shall include the
Manufacturer's Specification, Recommendations and Materials Safety Data Sheets and
the Materials Institute of Western Australia’s (MIWA) testing and approval for use on
public buildings.
8. The Contractor may be required to provide test samples or panels Test Samples
accompanied with NATA certification of colour, gloss, thickness and adhesion. The
panels shall be compressed cement sheet, and shall be used for testing in accordance
with MIWA assessment methods.
908.05 GRAFFITI REMOVAL MATERIALS
1. Graffiti removal materials selected by the Contractor shall be used in

accordance with the Manufacturer's specifications and Material Safety Data Sheets.
2. Chemical graffiti removers shall satisfy the requirements given in

“Specifications for Graffiti Removers” as published by the Materials Institute of WA
(MIWA).
3. The remover shall be able to fulfil the claims of the manufacturer with
respect to removal properties for the particular surfaces on which it is designed to be
used.
4. The graffiti remover shall be applied in accordance with the Effectiveness

manufacturer’s specifications. Removal shall be assessed in accordance with “Method
for Assessing the Effectiveness of Graffiti Removers” as published by MIWA, and shall
achieve a minimum rating of 4 in accordance with the following scale:

Rating Result
0 No graffiti removed
1 Some graffiti removed but no more than 30%
4 Most graffiti removed with only shadowing remaining
5 Graffiti completely removed
908.06 PAINT
1. Paint shall be of the colour and type as specified by the Superintendent

and in accordance with AS 2311.
908.07 - 908.10 NOT USED
ANTI-GRAFFITI COATINGS
908.11 SUBSTRATE SURFACE PREPARATION
1. The surface to be treated shall be prepared in accordance with AS 2311

and the anti-graffiti coating Manufacturer's Specification.
2. All dust, dirt, grease and oil contaminants, including remnants of curing
membranes, and other surface contaminants shall be removed by non-destructive means
followed by water washing.
3. Where a clear anti-graffiti coating system is specified, the substrate shall

be free of all graffiti, graffiti shadows, paints or any other surface contaminants which
would be visible through the coating unless the substrate or steel work is intentionally
painted.
4. Where shadows of previously removed graffiti are likely to be clearly

visible through a coating the Contractor shall advise the Superintendent prior to the
application of the anti-graffiti coating.
5. Some of the smoother concrete surfaces may require whip blasting with a
fine grade garnet or surface etching with an approved acid wash followed by a water
wash in order to provide adequate adhesion of the coating system. Whip blasting
operations shall be carried out in accordance with the appropriate regulations.
6. Excess materials shall be disposed of to the Contractor’s spoil site.

908.12 APPLICATION
908.12.01 GENERAL
1. Anti-graffiti coatings shall be applied in accordance with the

Manufacturer's Specifications and AS 2311.
2. Anti-graffiti coatings shall NOT be applied under the following Restrictions to

conditions: Application
(a) the site of work is exposed to a wind speed exceeding 20km/hr;
(b) where wind borne debris may contaminate the uncured surface of the
freshly applied coating;
(c) when the ambient temperatures exceeds 35°C or is below 15°C;
(d) when the relative humidity exceeds 85%;
(e) when there is any chance of rain spatter, or run off, including leakage
through deck joints, contaminating the surface and adversely
effecting the adhesion to the substrate;
(f) where the surface temperature of the substrate is less than 3°C above
the dew point or exceeds 40°C;
(g) where the substrate surface is wet or damp.
2. Not Used.
908.13 ANTI-GRAFFITI COATING SYSTEMS
1. The coating system shall be a non-sacrificial (except where the coating is Type of
to be installed on a limestone substrate) clear or pigmented coating to a specified colour. Coating

2. The coating system shall be an acrylic co-polymer, polyurethane or
polyurea type and shall be non-yellowing and UV-resistant for the guaranteed life of the
coating system. The coating shall be impermeable to chlorides, carbon dioxide and
water but allow the transmission of water vapour.
3. The coating system shall not affect the re-coat ability of the substrate
material.
4. Where a prime or tie-coat is required as part of the anti-graffiti system,

the primer or tie-coat shall be a different colour to that of the final nominated colour.
5. Nominated colours shall be as specified by the Superintendent and in Colour

accordance with AS 2700. The coating pigments shall be colourfast, and not subject to
fading or discoloration.
6. The finished coating system shall be of uniform thickness, colour, and

appearance and shall be free of any defects that may impair the performance or
appearance of the coating for the life of the coating.
7. The finished cured coating system shall have a minimum installed Dry Film
thickness of 175µm encompassing a minimum anti-graffiti coating dry film thickness Thickness
(DFT) of 100µm. The dry film thickness shall be measured in accordance with
ASTM D6132-97 using a digital coating thickness gauge suited for single or multiple
coating layers, which has been calibrated for use on concrete, steel and similar surfaces
to which the coatings are applied.
8. The installed coating system shall have an adhesion value to the substrate Adhesion
exceeding one (1) MPa in accordance with AS 1580.408.5. Value
9. Natural limestone and limestone derivatives shall be coated with a

sacrificial anti graffiti coating system conforming to “Specifications for Sacrificial Anti-
Graffiti Coatings” as published by MIWA.
908.14 - 908.20 NOT USED
GRAFFITI REMOVAL
908.21 GENERAL
1. Where Works in progress have been subjected to graffiti attack, the

Contractor shall remove the graffiti without damage to the substrate.
2. Typical graffiti removal methods shall include but not be limited to:
(a) Abrasive blast cleaning
(b) Chemical cleaning
(c) Steam cleaning
(d) Pressurised liquid blast cleaning
3. The Contractor shall be responsible for ensuring the compatibility of the

proposed cleaning method without injurious effect to any installed coatings, paint
systems and uncoated substrates (except sacrificial coatings for limestone).

908.22 GRAFFITI REMOVAL
908.22.01 GENERAL
1. Where the nature or composition of the graffiti is such that the HOLD POINT
Contractor's selected removal treatment may cause damage to the substrate, the
Contractor shall seek written authorisation from the Superintendent prior to
commencing the treatment.
2. For coated substrates the standard of graffiti removal shall be no residual

graffiti being visible.
3. For uncoated substrates the complete removal may not be possible due to
the absorbency of the substrate material. Under these circumstances the Superintendent
may allow some residual paint staining or shadowing to remain.
4. The graffiti message, tag, or configuration shall not be intelligible or

clearly visible from:
(a) a distance of 3m from a substrate to pedestrians
(b) a distance of 20m to a roadway.
5. Chemical removers used for the cleaning of sacrificial coatings shall

conform with Clause 908.05.
6. Damage to the substrate or substrate coating caused by the Contractor

shall be rectified at the Contractor's expense.
7. Excess material shall be disposed of to the contractor’s spoil site.
908.23 PAINTING OVER GRAFFITI
1. Where removal of graffiti is inappropriate or impractical, graffiti shall be

painted over with paint in accordance with AS 2311.
2. The surface to be painted over shall be prepared in accordance with

AS 2311.
3. The paint shall be 100% acrylic. The colour and level of gloss shall be
specified by the Superintendent.

908.24 - 908.30 NOT USED
INSPECTION AND TESTING
908.31 EFFECTIVENESS OF ANTI-GRAFFITI COATINGS
1. Non-sacrificial anti-graffiti coatings shall be certified for effectiveness in

accordance with “Method for Assessing the Effectiveness of Non-Sacrificial Anti-
Graffiti Coatings” as published by the Materials Institute of WA (MIWA). Sacrificial
anti-graffiti coatings shall be certified for effectiveness in accordance with “Method for
Assessing the Effectiveness of Sacrificial Anti-Graffiti Coatings” as published by
MIWA. Certification of the coating shall include the results of:
(a) Graffiti removal after 24 hours and 72 hours after application;
(b) Graffiti removal after artificial weathering;
(c) Graffiti removal after artificial salt spray exposure;
(d) Attack by alternate removal agents;
(e) Adhesion to selected substrates;
(f) Scratch resistance;
(g) Burn resistance;
(h) Weathering resistance.
2. The Contractor shall provide test certificates from a NATA registered

testing laboratory for the thickness and adhesion of the applied coating.
3. The frequency of adhesion testing shall be one (1) test per 25m2 of coated
area for each coating system layer.
4. The Contractor shall produce certification that the coating system has
been applied in accordance with the Manufacturer's published recommendations.
5. Original copies of these certificates are to be retained by the

Superintendent.
6. Coating materials shall be subject to examination by the Superintendent

and shall be accompanied by certificates of supply stating the place, date, and quantity
of manufacture including appropriate batch numbers to permit full traceability of
product.
908.32 SURVEILLANCE OF CONSTRUCTION WORKS
1. The Contractor shall systematically inspect road and bridge construction Inspections
Works for Graffiti at least on a weekly basis during the Contract period, including
immediately after weekends or public holidays. Particular attention shall be given to
obvious graffiti targets such as bridges and other major structures with a large surface
area.

2. Where an inspection discovers graffiti on completed Works, or on those Cleaning and
parts of the Works that would normally be left for some time before completion, Removal
cleaning shall be initiated and completed within 48 hours. Graffiti that is of a sensitive
nature (defined as including the following: racist, sexist, obscene, etc.) shall be
removed within 24 hours.
3. Cleaning and removal of graffiti shall comply with the requirements of

the section GRAFFITI REMOVAL (Clauses 908.21 to 908.30).
908.33 REPORTS
1. The Contractor shall produce and submit a graffiti report upon completion Reporting
of each instance of graffiti removal. The report shall contain a comprehensive
photographic display of all graffiti supported with written detail as to the location,
description, area and treatment and removal cost of the graffiti.
2. Photographs shall be of nominal size 150mm x 100mm and imprinted Photographs

with the date and shall clearly show the graffiti and a gauge scaled at one metre
intervals.
3. The gauge shall be used in all photographs depicting graffiti and shall not
be permanently fixed or drawn on the defaced surface.
4. The photographs shall be accurately labelled and presented in A4 size

clear photo pockets.
908.34 - 908.40 NOT USED
908.41 - 908.50 NOT USED

ANNEXURE 908A
APPROVED ANTI-GRAFFITI COATINGS
PRODUCT TYPE OF COATING MANUFACTURER
Enviroshield “F” Sacrificial Enviroshield Coatings
Graffiti Shield Sacrificial Guardian Protective Coatings
Graffiti Off Non-Sacrificial Acryline Coatings Technology
Enviroshield “G” Non-Sacrificial Enviroshield Coatings
Anti Graffiti Coating Non-Sacrificial Guardian Protective Coatings
Texcote Non-Sacrificial Parbury Industries
Enduroshield Non-Sacrificial Universal Sealants
Barakade Sacrificial for Limestone, Crommelin Chemicals

Rammed Earth,
Reconstituted Limestone
Universal 601 Sacrificial for Limestone, Universal Sealants

Rammed Earth,
Reconstituted Limestone
Imperite 300 Non-Sacrificial Jotun
GARDALL 2000 Clear Non-Sacrificial Wescote Paints
GARDALL 2000 Grey Non-Sacrificial Wescote Paints
NOTE: Alternative anti-graffiti coatings will only be considered upon submission of a written request
to the Superintendent to vary the coating, together with supporting data and test panels, in accordance
with Clause 908.04.

ANNEXURE 908B
Not used

S PECIFICATION 909
WATER RETICULATION
CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
909.01 SCOPE...................................................................................................................................... 1
909.02 INSPECTION........................................................................................................................... 1
909.03 HYGIENE ................................................................................................................................ 1
MATERIALS.............................................................................................................................................. 2
909.04 GENERAL ............................................................................................................................... 2
909.05 HANDLING OF MATERIALS ............................................................................................... 6
909.06 ALIGNMENT .......................................................................................................................... 6
9 6
9 7
909.09 EXCAVATION AND BEDDING ........................................................................................... 7
PIPE LAYING AND JOINTING ............................................................................................................. 9
909.10 PIPE LAYING AND JOINTING............................................................................................. 9
909.11 INSTALLATION OF VALVES, FITTINGS, HYDRANTS & FLUSHING POINTS ......... 11
909.12 THRUST BLOCKS................................................................................................................ 13
909.13 TESTING OF MAINS AND SERVICE CONNECTIONS ................................................... 13
909.14 BACKFILLING ..................................................................................................................... 13
INCIDENTAL WORKS .......................................................................................................................... 15
909.15 COVERS AND BOX ASSEMBLIES.................................................................................... 15
909.16 MARKER POSTS .................................................................................................................. 15
909.17 VALVES ................................................................................................................................ 15
909.18 CONNECTIONS TO EXISTING CORPORATION MAINS ............................................... 15
909.19 WATER RETICULATION MAINTENANCE ..................................................................... 15
COMPLETION ........................................................................................................................................ 16
909.20 PRACTICAL COMPLETEION............................................................................................. 16
909.21 FINAL CERTIFICATE.......................................................................................................... 16

Associated Roadworks Water Reticulation
SPECIFICATION 909
WATER RETICULATION
GENERAL
909.01 SCOPE
The water reticulation works shall be constructed in accordance with the Drawings and
this Specification and will be subject to the inspection and approval of the Western
Australian Water Corporation who will be referred to as the “Corporation” for the
remainder of this specification.
909.02 INSPECTION
909.02.01 SHOP INSPECTION
The Contractor shall ensure that all pipes, fittings and sluice valves supplied by the
Contractor have been manufactured, tested and inspected in accordance with the
relevant Australian Standard and the Corporation's requirements. The Superintendent
may be present at these tests. Certificates and test results shall be obtained from the
manufacturer by the Contractor and presented to the Superintendent upon request.
909.02.02 FIELD INSPECTION
The Superintendent will inspect the constructed works and any faulty workmanship or
materials will be rejected and the work rectified in accordance with the Specification or
Drawings. All rejected materials shall be promptly removed from the site by the
Contractor.
The Contractor shall ensure that the Corporation's representative has full access to the
site at all times to inspect the work during the period of the contract. Any instruction
from the Corporation pertaining to the works will be issued to the Superintendent.
909.03 HYGIENE
The Contractor shall take every precaution to prevent contamination of the water supply
works. The Contractor shall also ensure a high standard of hygiene with respect to the
Contractors' employees and all materials, tools etc. used in the construction of the
works. In particular no materials, tools etc. previously used on live sewerage work
shall be used.

MATERIALS
909.04 GENERAL
All materials used on the job shall be subject to the approval of the Corporation. The
Corporation may require from time to time manufacturers certificates, test results and
guarantees. Second hand pipes and fittings shall not be used. Materials shall be
handled and stored to avoid damage. Damaged materials shall not be used. All
materials, which will be in contact with the water supply, shall satisfy the Corporation
that the material is approved for use in contact with drinking water.
The specification of materials for construction shall be in accordance with Parts 2 & 3
of the Corporation’s Water Reticulation Manual, this specification and as defined in the
Drawings.
909.04.01 PIPE GUARANTEE
The Contractor shall obtain a certificate from the pipe manufacturer stating that all
pipes, joints and joint rings used in the works are covered by a guarantee identical to
that applying to pipes, joints and joint rings supplied under contract to the Corporation
at the time of manufacture. The certificate shall be passed to the Superintendent on
request.
No pipes, joints or joint rings shall be used in the works unless covered by the
guarantee.
909.04.02 SLUICE VALVES
a) General
The valves shall be manufactured generally in accordance with AS 2638 - 2002. They
shall also conform in all respects with the current Corporation specification for sluice
valves.
General features of the Corporation specification are:-
Class 12 valves with Table C flanges;
Suitable for use in terminal, in-line and unsupported positions;
Double flanged;
Counter-clockwise rotation for closing;
Removable cast iron caps;
Maximum working head 120 m static head;
To pass the open end test;
Cement lined.
b) Variations
The Contractor shall be required to supply to the Corporation a full description together
with detailed drawings, specifications and weights of valves the Contractor proposes to
use, should the Contractor be proposing valves, which have not previously been
supplied to the Corporation under a Water Corporation Sluice Valve Supply Contract.

c) Inspection
The Superintendent or the Superintendents Representative shall be at liberty at all times

to inspect the materials and the manufacture of the valve at the foundry and may reject
without testing any valve which in the Superintendents' opinion is not in conformity
with the Drawings and Specification.
When the valves are ready for internal lining, the Contractor shall give the
Superintendent due notice in writing to this effect and nominate who will perform the
work so that the Superintendent may inspect the valves during the lining process.
d) Lining & Coating
The lining of the internal surface of valves shall be cement mortar in accordance with
AS 2544 - 1995 (heavy type). The lining shall be smooth and free from pinholes or
surface deposits. The internal surface of the body and bonnet of the sluice valve shall be
lined.
Before assembly, the various castings shall be coated externally with “Bitumastic
Super-Service” (black in colour) or similar approved protective coating. The surface
shall be sufficiently hard to resist damage from handling. Any valve imperfectly coated
or upon which the coating is damaged, will be rejected.
e) Testing
The valves shall be tested after completion of the internal lining in accordance with the
requirements of the “open end test” of AS 2638 - 2002 at a test head of 240 m. If the
valves are manufactured elsewhere than in the Perth metropolitan area, the
Superintendent will arrange for inspection, testing and branding of the valves under the
supervision of the inspector of the local Water Supply Corporation in the locality where
the valves are manufactured. All supervision charges incurred in such testing etc, will
be paid by the Principal for the Contract.
The Contractor shall supply to the Superintendent a certificate showing that the valves
have been duly inspected, checked for cement lining and tested as specified. No valve
will be accepted which has not passed the specified test.
e) Marking
The identification or marking required to be cast on the body of the valve is as follows:
Nominal diameter of the valve in mm;
Manufacturers name or trade mark;
Maximum working head, i.e. 120 m;
Standard flange table, i.e. Table C.
909.04.03 HYDRANTS
Hydrants shall be 100 m nominal size cast iron of the screw down type, complete with
bayonet top for standard standpipe as approved by the Corporation. Where required
standard fire hydrant risers (sized to suit) shall be supplied and installed as required on
the Standard Drawings.
All items associated with the supply and construction of hydrants and associated
incidentals shall be to the Western Australian Fire Brigades Board standard requirement
and to the approval of the Superintendent.

909.04.04 MECHANICAL JOINTS
Mechanical joints used shall be of the long body type either "Fergusons", "Gibaults",
"DNR's", "MFJ's" or other type approved by the Corporation. They shall be installed in
accordance with the manufacturer's specifications.
909.04.05 STOP TAPS
Stop taps shall be 20 mm nominal size, right angle pattern, ferrule type with female
BSP connections, manufactured from dezincification resistant brass and complying with
all relevant Australian Standards.
909.04.06 COVERS AND BOXES
All covers to sluice valves, bronze gates valves, hydrants and flushing points shall be
cast iron and manufactured to the Corporation's standard patterns and Drawings (refer
Standard Drawings).
In addition all “sluice valve covers” (except those in a roadway or pathway) shall be
installed with a reinforced concrete “valve surround” to the dimensions shown on the
Standard Drawing.
All “valve liners” shall be of 150 mm diameter PVC pipe (or some other suitable
material) and length to suit.
All “hydrant boxes” shall be reinforced concrete to the dimensions shown on the
Standard Drawings.
All “bronze gate valve boxes” shall be of timber or reinforced concrete to the
dimensions shown on the Standard Drawings.
All “flushing point boxes” shall be of timber or reinforced concrete to the dimensions
shown on the Standard Drawings.
909.04.07 CORROSION PROTECTION
A petrolatum paste, “Denso 300”, “Taki” or similar approved product shall be used to
protect from corrosion all exposed nuts and bolts on all fittings, valves, hydrants,
mechanical joints, tapping bands etc.
In areas of corrosive soil, if directed by the Superintendent or the Corporation, a

protective system shall be applied to all buried ferrous materials including valves,
hydrants, tees, bends, tapping bends. The protective system shall comprise “Denso
300” paste, “Denso 600” tape and “Denso 901” overwrap tape, or an equivalent
approved system, applied in accordance with the manufacturers recommendations.
909.04.08 TIMBER
Timber for bronze gate valve and flushing point boxes, marker posts and thrust blocks
shall be jarrah, and to the dimensions shown on the Standard Drawings.
909.04.09 CONCRETE
Concrete used for in-situ work shall conform to AS 3600 - 1994 and be provided by a
pre-mix concrete supplier conforming with AS 1379 - 1991 or mixed on site using
materials as specified and plant to the approval of the Superintendent.
Concrete for thrust blocks, hydrant boxes etc. shall have a minimum compressive

strength of 20 MPa.
The slump shall not exceed 70 mm or be less than 30 mm.
909.04.10 CEMENT
All cement used shall be Portland Cement Type A in accordance with AS 3972 - 1997
and obtained from an approved manufacturer.
Cement shall be delivered to the site fresh and in sealed bags and there stored in a
waterproof shed until such time as it is to be used. Any bag showing signs of
deterioration or setting is to be rejected.
909.04.11 AGGREGATE
Fine aggregate shall be well graded, clean sharp and free from clay and organic
impurities in accordance with AS 1141.0 - 1999 and AS 2758.1 - 1998.
Course aggregate shall be crushed granite or diorite, clean and free from all impurities
and dust in accordance with AS 1141.0 - 1999 and AS 2758.1 - 1998.
The maximum particle size shall not exceed 20 mm.
909.04.12 SAND
Sand for mortar shall be crushed stone or natural sand free from all deleterious
substances and have a uniform grading.
Sand for bedding or backfilling shall be clean sand free from roots, clay or any
deleterious matter.
909.04.13 CEMENT MORTAR
Cement mortar for internal lining of fittings and sluice valves shall consist of one part
metal dust to one part cement.
909.04.14 STEEL REINFORCEMENT
Steel reinforcement fabric and steel reinforcing bars for concrete shall comply with the
requirements of AS 1302 - 1991, AS 1303 - 1991 and AS 1304 - 1991 and be free from
loose rust or matter likely to impair the bond with concrete.
909.04.15 WATER
Water from use in concrete and mortar shall be of potable quality free from any
impurities harmful to concrete, mortar or steel.
Water for filling constructed mains shall only be drawn from existing Corporation
mains at locations nominated by the Corporation's representative.
909.04.16 DISINFECTANT
The disinfectant used when filling constructed mains shall be Calcium Hypochlorite
(powder form) or Sodium Hypochlorite (liquid form).

909.05 HANDLING OF MATERIALS
All pipes, fittings, sluice valves, hydrants, mechanical joints etc. shall be loaded and
unloaded by lifting (by hand or hoist) or by skidding, in such a manner so as to avoid
shock or damage.
Likewise they shall be carefully lowered into the trench in such a manner as to prevent
damage to the materials and the protective coatings and linings. Under no
circumstances shall such materials be dropped, dumped or scraped along hard
pavements, which may cause scoring of the pipe.
Pipe handled on skid-ways shall not be skidded or rolled against pipe already on the
ground.
909.06 ALIGNMENT
909.06.01 ROAD RESERVES
All pipes and fittings shall be laid on an alignment of 2.1 m from the centre of the pipe
to the road reserve boundary.
Pipes and fittings shall be laid true to line and shall not deviate by more than 100 m
from their correct alignment, except where noted in this specification or where some
obstacle prevents access to the 2.1 m alignment. The Superintendent shall consult the
Corporation's representative for a direction on what action shall be adopted to remove
the obstacle or vary the alignment. Any such variation shall be fully documented on the
“As Constructed” Drawings.
909.06.02 OTHER RESERVES
In the case of mains constructed in Public Access Ways, Public Open Space and other
reserves, all pipes and fittings shall be laid parallel to and on an alignment of 2.1 m
from the side boundary. Where reserves are less than 4.2 m in width the main shall be
laid in the centre of the reserve.
Pipes and fittings shall be laid true to line and shall not deviate by more than 100 mm
from their correct alignment, except where noted in this specification or where some
obstacle prevents access to the alignment. The Superintendent shall consult the
Corporation's representative for a direction on what action shall be adopted to remove
the obstacle or vary the alignment. Any such variation shall be fully documented on the
“As Constructed” Drawings.
909.07 DEPTH
The depth of the pipe, including road crossings ducts shall be in accordance with the
Standard Drawings.
In the event of a conflict with the requirements of the Standard Drawings or the need to
avoid other utility services, the Corporation's representative shall be contacted for
instructions.
Generally pipes shall be as straight as possible in the vertical alignment. Where

changes of grade occur the deflection shall be a smooth transition over a number of
pipes with the maximum deflection at each joint not exceeding that given in this
specification.
Where pipes cross or adjoin other existing or proposed services, the water main shall
have a minimum clearance of 100 mm.
Water service pipework shall have a minimum cover of 450 mm within the road reserve
and 500 mm within private property and shall have a maximum cover of 600 mm.
909.08 SURVEY AND SETTING OUT
On completion of road reserve clearing and road earthworks, when finished levels are
achieved on lot boundaries, the Licensed Surveyor shall provide sufficient survey pegs
for the construction of the water reticulation, and that all ducts and service pipework
can be installed on the correct alignment. The Licensed Surveyor will also provide
sufficient temporary pegs on curved lot boundaries to enable the proper construction of
the water reticulation. All pegs shall be clearly marked with lot numbers (or other
means) so as to be clearly identifiable.
The Contractor shall ensure that all survey pegs installed for the water reticulation
works remain uncovered and undisturbed. If so directed by the Superintendent, the
Contractor shall uncover any pegs that are not visible, or pay the Licensed Surveyor to
reinstall any pegs that have been disturbed by the Contractor.
909.09 EXCAVATION AND BEDDING
909.09.01 GENERAL
No excavation shall be commenced until the corresponding survey pegs are in position.
Excavation of road crossings shall not commence until the road levels have been
established and subgrade excavation completed. Trenches shall not be opened in
advance of the installation or road crossings and pipe laying more than is necessary to
enable the work to proceed without delay.
Trenches excavation shall normally commence after the completion of major site
earthworks but shall be carried out prior to pavement, footpath and final landscaping
operations.
The Contractor shall be responsible for carefully locating the position of all mains,
pipes, cables and other equipment belonging to Public Utility Authorities.
The Contractor shall provide, erect and maintain all temporary works necessary to
support exposed mains, pipes and cables to the satisfaction of the relevant Public Utility
Authority to ensure that the operation of such services is not interrupted in any way.
The Contractor shall be responsible for the cost of any repairs to such services arising
out of the Contractors' work.
Excavation material shall be deposited in an area causing the least interference to

vehicular or pedestrian traffic and to the approval of the Superintendent.
Trenches shall be kept free of groundwater until each section of main has been
completed and tested. Groundwater shall not be permitted to enter pipes.

909.09.02 TRENCH DIMENSIONS
The trench width shall be as shown on the Standard Drawings. The depth shall be the
minimum required to achieve the correct cover on the pipe, as defined on the Standard
Drawings.
All trenches shall be neatly excavated to provide an even bed with a uniform grade.
Over-excavation of the bed of the trench shall be corrected with compacted bedding
material.
909.09.03 BEDDING
Bedding material shall be sand, gravel or other similar approved granular material.
Bedding material shall be free from all stones retained on a 6 mm sieve.
Bedding procedure shall be in accordance with the Standard Drawings.
If the soil condition of the natural trench bed is non-granular or if the equivalent density
is less than 5 blows per 300 mm with a standard penetrometer (9 kg, 600 mm drop, 16
mm diameter rod), the trench shall be over excavated by at least 150 mm, backfilled
with bedding material (as defined) and compacted.
In all cases the trench bottom shall be hand trimmed immediately before placing the
pipe to enable the pipe to be supported evenly over the whole length of the pipe barrel
as shown on the Standard Drawings. Road crossings are to be true to line for their full
length with a maximum box of 100 mm in any duct crossings.
Under all trafficable pavements (roads, driveways, carparks etc.) the trench bottom will,
irrespective of natural soil condition, be levelled and compacted before hand trimming.
Holes shall be dug at each joint to allow the pipe to be supported on the barrel and to
enable the next joint to be properly made.

PIPE LAYING AND JOINTING
909.10 PIPE LAYING AND JOINTING
909.10.01 PREPARATION OF PIPES
All pipes shall be carefully examined for cracks and other defects immediately before
being installed. Spigot ends shall be examined with particular care. Defective pipes
shall be rejected.
Care shall be taken to remove all sand and other material from the inside of the pipes
before they are lowered into the trench.
The inside of the pipe spigots shall again be carefully brushed immediately prior to
jointing to remove any sand that may have entered when the pipe was lowered into the
trench.
Immediately before jointing the outside of the pipe spigots, the inside of the socket and
the rubber joint rings shall all be carefully wiped clean to prevent scoring of the pipe
surface.
909.10.02 JOINTING OF STEEL PIPES AND FITTINGS
Elastomeric seal jointed steel pipes shall be installed in compliance with the
manufacturer’s instructions. Fittings shall be welded as for weld-jointed steel pipes.
Where steel pipes are weld-jointed, installation shall be in accordance with the Steel
Pipeline System Handling and Installation Manual and the following requirements:
• All pipe welding shall be in accordance with AS 4041 Pipework Class 2P,
Corporation Welding Specification WS-1 and the Drawings;
• Pipe flanges for valve connections shall be welded to pipes in accordance with
the Drawing AY58-15-1 of the Pipe Fittings Manual;
• Welding procedures and qualification of each welder and welding operator

shall be in accordance with AS 4041 and the requirements of Corporation
Welding Specification WS-1;
• Where the cement mortar lining of a pipe or fitting cannot be readily reinstated
at the welded joint, a convex band shall be welded over the joint. When the
band has cooled, it shall be fully injected with cement grout through a hole in
the bottom or side which is then sealed with a welded cap once the grout has
set;
• All cut ends and welded areas shall be protected as required by the sub-clause
909.10.04
909.10.03 PE TO PE PIPES AND FITTINGS
PE pipes and pipe fittings and their jointing shall comply with the requirements of, and
including limitations in Table 2.1 of Part 2 of the Corporation’s Water Reticulation
Manual.
Where butt fusion weld jointing is expressly permitted, the pipes shall be prepared for
welding in accordance with pipe manufacturer’s recommendation.

909.10.04 PROTECTION OF STEEL PIPES FROM CORROSION
Damaged pipe coating shall be primed, filled with butyl mastic and wrapped with a
2mm thick reinforced bitumen mastic with PVC backing (Densopol 80, Rockrap 4000
Tape System or approved equivalent), in accordance with the manufacturer’s
application specification.
All welded joints, bands, bends, tees, flanges, flange and valve body assembly bolts
shall be primed and wrapped with a butyl mastic tape and PVC overwrap system
(Denso or approved equivalent) in accordance with the manufacturer’s application
specification.
For pipes emerging from below ground, the tape wrapping shall extend to 100mm
above the finished ground level.
Where a protective coating system is used, pipeline and valve surfaces shall be prepared
so that rust and any other deleterious materials are removed in accordance with the
coating manufacturer’s requirements.
In all circumstances, the minimum surface preparation requirements shall be degreasing

and mechanical wire brushing to obtain a Class 2 cleanliness in accordance with AS
1627 Part 2.
909.10.05 LAYING OF PIPES
At the end of each day’s work or at any time when pipe laying is suspended, every open
end of each incomplete pipeline shall be plugged with a tapered stopper or an
acceptable end cap matching the pipe. No tools or any construction materials shall
remain in the pipes.
a) PE Pipeline System
PE pipelines shall be laid in accordance with manufacturer’s instructions and practices

recommended in the PE butt-welding accreditation course.
Allowance shall be made for the likely pipe movement due to temperature changes
during installation and commissioning. A final service temperature of 20°±5°C may be
assumed unless otherwise specified in the Drawings. Pipe lengths and bend locations
shall be adjusted for changes in length that will occur when the temperature stabilises at
the final service temperature.
The trenches shall not be backfilled unless the ambient temperature is within ±5°C of
the final service temperature.
PE pipes within the trench may “snake” if the final “snaked” alignment at the final
stabilised service temperature is within 100mm of the correct alignment.
b) Railway Crossing
The pipes crossing shall not have elastomeric seal or mechanical joints and shall be in
conduit or sleeve only if required by the relevant authorities.
Minimum clearance between pipe and pipe sleeve shall be 100mm. The Corporation in
certain circumstances may require larger clearances.
The pipeline shall be supported within the pipe sleeve on saddles or support blocks
acceptable to the Corporation or on sand bedding installed after the pipeline has been
laid through the pipe sleeve.

909.10.06 PIPELINE BENDS AND CURVES
a) Deflecting Pipes on a Curve
A pipeline required to follow a long curve may be laid and jointed with deflections at
the joints. The maximum angular deflection at a pipe joint shall not exceed the pipe
manufacturer’s recommendations. Bending of pipes to achieve a curve for any other
purpose is prohibited, except for PE and CU pipes.
PE pipes may be laid in a curve of radius that is not less than the manufacturer’s
recommendations.
b) Bends
Where the required angle change exceeds the permissible joint deflection, standard
bend fittings shall be used.
Bends shall be installed opposite cadastral survey pegs unless otherwise shown on the
Drawings or accepted by the Corporation.
Where a bend is required on a truncation at which a valve is also required, a 800mm

minimum length of straight pipe shall separate the bend and the valve.
909.10.07 TEMPORARY DEAD ENDS
The Contractor shall be responsible for ascertaining by careful excavation, the precise
location of all existing Corporation mains and to lay at the correct depth and alignment
to ensure a simple connection. The Contractor shall take particular care not to disturb
the existing mains or thrust blocks.
The dead ends shall be within 4 m of the existing main and clear of any pavement.
Mains shall be plugged with a suitable end cap or blank flange and adequately anchored
to take the full test pressure.
909.10.08 INITIAL BACKFILLING – SELECTED FILL
Initial backfilling shall be done using selected fill, being defined as sand, gravel or
other approved granular material being free of all stones retained on a 25 mm sieve.
Initial backfilling at the sides and for 150 mm above the top of the pipe shall be hand
tool placed and compacted ensuring that no joints or pipes are disturbed or damaged.
Refer to Standard Drawings.
The joints shall be left fully exposed for inspection during testing.
909.11 INSTALLATION OF VALVES, FITTINGS, HYDRANTS &

FLUSHING POINTS
909.11.01 GENERAL
All sluice valves, fittings and hydrants shall be carefully examined for cracks, damage
or defects immediately before being installed. Defective items shall be laid aside for
inspection by the Superintendent, who will prescribe corrective repairs or rejection.
All fittings will be installed according to the pipe manufacturers specifications.
Care shall be taken to brush clean the inside of all sluice valves, fittings and hydrants
immediately prior to installation. The outside of the spigot ends and the inside of the
collars and rubber rings shall likewise be carefully brushed clean before jointing.
909.11.02 INSTALLING SLUICE VALVES
a) Timber Bearers
All sluice valves shall be seated on a 300 mm x 230 mm x 40 mm timber bearer in

accordance with Standard Drawings.
b) Branch from 200 mm main to 150 mm and 100 mm mains
Where the branch main from a 200 mm is a 100 mm or 150 mm main, the sluice valve
shall be bolted directly onto the flanged branch of the Tee piece.
All nuts and bolts shall be thoroughly smeared with a corrosion protection petrolatum
paste.
c) Branches in Other Cases
In all other cases, the sluice valve shall be installed opposite the truncation point.
If necessary a pipe shall be neatly cut to enable the sluice valve to be installed in the
correct position.
All nuts and bolts shall be thoroughly coated with a corrosion protection petrolatum
paste.
d) Valve Sizing
The nominal diameter of each valve shall be the same as the nominal diameter of the
pipe in which the valve is being installed.
e) Backfilling to Valve
The excavated trench within 1.0 m of the installed sluice valve shall be backfilled in
150 mm layers and firmly tamped.
909.11.03 INSTALLING HYDRANTS
All hydrant tees shall be seated on a 300 mm x 230 mm x 40 mm timber bearer in

accordance with the Standard Drawings.
Hydrant tees shall be installed in the main as near as possible to the centre of the lot or
according to the dimensions shown on the Detailed Drawings.
The excavated trench within 1.0 m of the hydrant shall be backfilled in 150 mm layers
and firmly hand tamped.
When the final verge level above the hydrant tee has been established, a double-flanged
hydrant riser of the appropriate length shall be bolted to the tee. The hydrant
installation shall then be completed in accordance with the Standard Drawings.
All nuts and bolts shall be thoroughly coated with a corrosion protection petrolatum
paste.

909.11.04 INSTALLING FLUSHING POINTS
Flushing points shall be installed as shown in accordance with the Standard Drawings
on all copper mains, on all dead ends that for the purpose of this contract are considered
as permanent, or any location designated on the Detailed Drawings.
909.12 THRUST BLOCKS
Thrust blocks shall be provided at all bends, tees and blank ends. A suitable temporary
thrust block shall be provided at temporary blank ends for pressure testing. Suitable
anchorage shall also be provided at reducers. Alternatively, bolted flanged reducers
and fittings may be used to rigidly connect reducers to the nearest suitably anchored
fitting.
Thrust blocks may be timber or concrete and as shown on the Standard Drawings.
Multiple bends shall be supported with concrete thrust blocks only, and as shown on the
Standard Drawings.
All bolts shall be protected with a corrosion protection paste prior to pouring of
concrete thrust blocks. All bolts shall be installed with the head facing away from the
concrete block. Bolts, nuts and flanges shall not be encased in the concrete.
Joints shall not be encased in the concrete blocks, but be protected by foam or similar
blockouts or other approved means.
A suitable bond breaker shall be provided between the fitting and the concrete (PVC
film or similar).
Thrust blocks shall not extend outside the 1.8 m to 2.4 m alignments. Where a conflict
exists the Corporation's representative shall be contacted for instructions.
909.12.01 STEEL PIPE ANCHORAGE
Where buried steel pipes are used, thrust supports may be replaced by welded pipeline
sections installed on both sides of the fittings as indicated in Table 4-1 of the
Corporation’s Water Reticulation Manual.
909.13 TESTING OF MAINS AND SERVICE CONNECTIONS
909.13.01 GENERAL
After the mains have been laid to form a continuous main the main or any section as
selected by the Superintendent, shall be subjected to a hydraulic test.
All testing preparation, equipment and procedure shall be in accordance with Section
4.7 of the Corporation’s Water Reticulation Manual.
909.14 BACKFILLING
909.14.01 GENERAL
Initial backfilling shall be in accordance with Clause 909.10.08 of this specification.
Final backfilling of pipe trenches shall not be carried out until mains have passed the
hydraulic test and measured by the Superintendent for as constructed purposes.
The fact of any such work being refilled does not relieve the Contractor in any way of
his responsibilities and the Contractor may be called upon to uncover and repair at the
Contractors' own cost, any main declared by the Superintendent as unsatisfactory at any
time until the end of the maintenance period. Any such repair work shall be subject to
retesting at the Contractor's expense.
909.14.02 MATERIAL
The material excavated from the trench may, subject to the approval of the
Superintendent, be used for ordinary backfill, provided it is free of rocks and vegetable
matter. Material in verge within 100 mm of water service pipework and in private
property shall be soil material with a maximum particle size of 10 mm. The remaining
backfill material in the verge comprising the excavated trench material shall be levelled
to the surrounding verge level and compacted.
Material in the pavement area shall be compacted granular material meeting the
specification for road construction.
Where there is a deficiency of suitable backfill material (ordinary or selected), the

Contractor shall supply the required amount of sand, gravel or other approved material
to make up the deficiency.
909.14.03 PROCEDURE (REFER TO STANDARD DRAWINGS)
The joint holes left open for the pressure testing, shall be carefully refilled and hand
compacted with selected fill up to the top level of the initial backfill material. Care
shall be taken not to damage or disturb the joints.
For trenches in verges, the ordinary backfill material shall then be placed, compacted
and neatly trimmed off to the final verge level.
Backfill under pavements shall be entirely of sand, free of clay, vegetable, petrol, diesel
fuel, lubricating oil, hydrocarbon products or foreign material, and compacted as shown
on the Standard Drawing. If the Superintendent deems the compaction to be
insufficient, the Contractor shall re-excavate the trench for a distance and depth as
determined by the Superintendent. The trench shall then be refilled and compacted as
specified.
909.14.04 RESTORATION OF ROAD RESERVES AND ACCESSWAYS
After refilling, trenches in road reserves or accessways are to be maintained in a safe

condition for traffic and pedestrians. The final surface treatment shall be to the
standard required by Fremantle Ports and a letter from Fremantle Ports shall be
obtained indicating its approval of the final surface treatment. The Contractor shall
submit a copy of this letter to the Superintendent, upon request.

INCIDENTAL WORKS
909.15 COVERS AND BOX ASSEMBLIES
The contractor shall place all sluice valve, hydrant, bronze gate valve and flushing point
cover and box assemblies, flush with their final surface level.
909.16 MARKER POSTS
Marker posts shall be provided and installed to the details shown on the Standard
Drawing. They shall be used to indicate the position of valves, hydrants, flushing
points, bronze gate (fullway) valves and where otherwise directed on the Detailed
Drawings. Metal marker posts shall be used in preference to wood where termites are
prevalent.
Markings of “SV”, “H”, “FP” & “FW” shall be black painted letters approximately 150
mm high, on white background.
The marker posts, except where varied, shall be placed adjacent to the fittings, after
final verge trimming.
909.17 VALVES
All sluice valves and bronze gate section “fullway” valves shall be left open and all
hydrants, flushing points and tappings at temporary dead ends left shut.
Sluice valves will have extension spindles installed where required by the Standard
Drawings
909.18 CONNECTIONS TO EXISTING CORPORATION MAINS
The Corporation shall make all connections to Corporation mains.
909.19 WATER RETICULATION MAINTENANCE
The maintenance period shall be 12 months from the date of Practical Completion.
The Corporation will carry out operational maintenance in accordance with their normal
practice. The Corporation shall have full and unrestricted use of the works without
interference from the Contractor.
Any leaks or bursts in the works due to faulty workmanship or materials, shall be
repaired by the Corporation at full cost to the Contractor. The Contractor shall also be
responsible for any consequential damage arising from the leaks or bursts.
Any other defects due to faulty workmanship or materials but of a non urgent nature
and not affecting the supply to consumers may be rectified by the Contractor at the
discretion of the Corporation.
The Corporation may require the retesting of repaired sections and the cost shall be
borne by the Contractor.
The Contractor shall immediately reinstate any subsidence over trenches occurring at
any time during the maintenance period.
Tappings or service pipework found to be more than 200 mm from the standard or
agreed service location in the road reserve or 100 mm within a property shall be
deemed defective unless the Corporation decides that the tapping or service can be used
in the incorrect location without detriment to the Corporation of the owner of the
affected property.
COMPLETION
909.20 PRACTICAL COMPLETEION
The Certificate of Practical Completion will not be issued by the Superintendent until
all mains and prelaid water services have been laid, tested and backfilled in accordance
with the Drawings and this Specification and to the satisfaction of the Superintendent
and the Corporation.
909.21 FINAL CERTIFICATE
Not less than 14 days before the end of the Maintenance Period, a final inspection shall
be made by the Superintendent and the Contractor to determine any items of
maintenance work to be done by the Contractor, which should be carried out to make
the scheme acceptable.
The Final Certificate will not be issued until these items have been completed to the
satisfaction of the Superintendent and the Corporation.

S PECIFICATION 910
SEWER PRESSURE MAINS

CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
909.01 SCOPE...................................................................................................................................... 1

Associated Roadworks Sewer Pressure Mains
SPECIFICATION 910
SEWER PRESSURE MAINS
GENERAL
909.01 SCOPE
The sewer works shall be constructed in accordance with the Drawings and this
Specification and will be subject to the inspection and approval of the Western
Australian Water Corporation who will be referred to as the “Corporation” for the
remainder of this specification.
All works by the contractor shall be carried out in accordance with the most recent
version of the Corporation’s Wastewater Manual Volume One and the Sewage
Pumping Station Code of Australia.

Associated Roadworks Sewer Pressure Mains
S ERIES 1000
RAIL WORKS
SPECIFICATION 1001 - SIGNALLING
SPECIFICATION 1002 - TRACKWORK
SPECIFICATION 1003 - OHLE
S PECIFICATION 1001
SIGNALLING
CONTENTS
Clause Page
GENERAL................................................................................................................................................... 1
1001.01 SCOPE.................................................................................................................................. 1
1001.02 REFERENCES ..................................................................................................................... 2
1001.03 AMENDMENTS TO STANDARDS................................................................................... 4
OPERATIONS ........................................................................................................................................... 4
1001.04 DESCRIPTION OF EXISTING SIGNALLING SYSTEM................................................. 4
CONSTRUCTION REQUIREMENTS & MATERIALS ...................................................................... 5
1001.05 WORKS INCLUDED .......................................................................................................... 5
1001.06 DESIGN AND DOCUMENTATION.................................................................................. 5
1001.07 INTERLOCKING ................................................................................................................ 6
1001.08 TRAIN CONTROL ROOM ................................................................................................. 6
1001.09 TRAIN CONTROL CONSOLE AND DIAGRAM ............................................................. 6
1001.10 TELEMETRY AND ROUTE SETTING SYSTEMS .......................................................... 7
1001.11 OPERATION UNDER FAILURE....................................................................................... 7
1001.12 LEVEL CROSSING PROTECTION................................................................................... 7
1001.13 EQUIPMENT HOUSINGS.................................................................................................. 7
1001.14 FIELD SIGNALLING EQUIPMENT.................................................................................. 7
1001.15 SIGNAL POWER DISTRIBUTION AND ALTERNATIVE SUPPLIES .......................... 9
1001.16 CABLE ROUTE................................................................................................................... 9
1001.17 CABLES............................................................................................................................... 9
1001.18 COMMUNICATIONS ......................................................................................................... 9
1001.19 LIMITS OF WORK ............................................................................................................. 9
1001.20 INTERFACE WORKS....................................................................................................... 10
1001.21 PRELIMINARY WORKS ................................................................................................. 10
1001.22 STAGE WORKS................................................................................................................ 10
1001.23 TESTING AND COMMISSIONING ................................................................................ 10
1001.24 REDUNDANT EQUIPMENT, MATERIAL AND CLEAN UP....................................... 11
1001.25 MAINTENANCE AND OPERATIONS MANUALS AND TRAINING......................... 11
1001.26 SPARES AND TEST EQUIPMENT ................................................................................. 11
1001.27 MATERIAL/EQUIPMENT TO BE SUPPLIED BY FREMANTLE PORTS AUTHORITY
11
1001.28 SIGNAL SIGHTING ......................................................................................................... 11
WORKS NOT INCLUDED..................................................................................................................... 12
1001.29 GENERAL ......................................................................................................................... 12
MAINTENANCE ..................................................................................................................................... 12
1001.30 WORKING LIFE & RELIABILITY ................................................................................. 12
ANNEXURE 1001A ................................................................................................................................. 13
BACKGROUND....................................................................................................................................... 13
1001A.01 GENERAL ..................................................................................................................... 13
EXISTING SIGNALLING ARRANGEMENTS................................................................................... 13
1001A.02 GENERAL ..................................................................................................................... 13
NEW SIGNALLING SYSTEM .............................................................................................................. 13
1001A.03 OVERVIEW................................................................................................................... 13
1001A.04 ASSUMPTIONS ............................................................................................................ 14
1001A.05 NEW AND ALTERED SIGNALS AND POINTS........................................................ 15
1001A.06 TRAIN OPERATIONS .................................................................................................. 16
Associated Roadworks Signalling
1001A.07 LEVEL CROSSING....................................................................................................... 18
1001A.08 CONTROL CENTRE ALTERATIONS ........................................................................ 20
1001A.09 TESTING AND COMMISSIONING ............................................................................ 20
REFERENCES ......................................................................................................................................... 21
APPENDIX 1 .............................................................................................................................................. 1
STAGING DIAGRAMS .......................................................................................................................... 1

SPECIFICATION 1001
SIGNALLING
GENERAL
1001.01 SCOPE
1. This specification consists of the signal design and construction work

requirements for the resignalling of the new spur line from North Fremantle to the new
freight terminal at North Quay and the abolition of the existing Leighton Yard including
connections to the mainline and the removal of the existing Tydeman Road level
crossing protection equipment.
2. The new signalling works proposed for the North Quay Rail loop shall be
controlled from PTA’s train control centre located on Level 4 of the Public Transport
Centre (PTC), West Parade, East Perth.
3. The proposed operation of the rail loop is contained in REP83461-S001

“North Quay Rail Loop Signalling Operational Specification” SEE annexure 1001A.
4. This specification gives an overview of the signalling works involved and

is to be read in conjunction with the concept and detail plans for:
• track work
• level crossings;
• civil works including the new bridge over Tydeman Road;
• over head
• lighting and power
• Terminal paving, electrical and mechanical works
• Victoria Quay signalling works
5. The contractor shall in programming the signalling works, identify

dependencies and interfaces with the above works and program his activities to
facilitate progression of this project.
6. This signalling and telecommunications portion of the project includes,

but is not limited to:

• Design of the new rail signalling system including all interfaces and
necessary stage works as indicated on Signalling Arrangements Plans
R-001-F-001, R-001-F-002 and R-001-F-003 and REP83461-S001
“North Quay Rail Loop Signalling Operational Specification”
(Annexure 1001).
• Installation of new signal Nos. 342 and 344 located on the down side
of Tydeman Road level crossing;
• Relocation of Signal No. 335 towards Fremantle to new location in
advance of Points No. 880 and fitment of a shunt signal light unit and
a position 1 “feather” type route indicator;
• Provision of point machines on points Nos. 880 and 880K (mixed
gauge turnout from mainline) and catch points No. 884.
• Installation of a new level crossing protected by boom barriers at
Tydeman Road;
• Decommissioning of existing Tydeman Road level crossing once the
Rail Loop is commissioned
• Modifications to the bi-directionally signalled up/down mainline to
allow for signalling freight trains into and out of the rail loop;
• Changes to the associated PTC control centre to allow remote control
and indication of the new rail loop signalling;
• Stage and preliminary works to facilitate implementation of the
project without compromising the existing infrastructure or train
service
• Installation and / or removal of insulated rail joints indicated on the
signalling plans or as required as part of the detailed signalling
design;
• Installation of any required extended sleepers, bearers and / or
foundations for point machines, point machine rodding or other
signalling equipment.
• Removal of all signalling associated with Leighton yard including
mainline point motors 876B, 876K and catchpoint motors 876A and
874;
• Clip and padlock of turnouts 876B and catchpoints 876A and 874
• Removal of existing protection equipment, (booms, flashing lights,
track circuits, control boxes, power supplies etc) at the existing
Tydeman Road level crossing.
• Removal of Standard gauge rail between 880 turnout and turnout
876, except shared crossing work through 878A.
• Crossover 878 is to remain with reverse moves being unsignalled as
per ES-P-2951 Rev A.
1001.02 REFERENCES
1. The whole of the work covered by this specification and the material and
the equipment used shall, unless otherwise specified, be in accordance with the relevant
sections of the most recent issues of the following:
PTA Standards
8110-600-001 Rev 1.01 Technical procedure for signal design

8190-600-004 Rev 0.04 Signalling design principles urban
8110-600-004 Rev 1.01 Procedure for the type approval of signalling equipment
8103-600-001 Rev 1.01 Design principles for level crossing warning systems
8190-600-007 Rev 1.00 Code of practice for signal equipment software

8190-600-002 Rev 1.00 Code of Practice for Signal System Testing and
Commissioning
8110-600-017 Rev 1.01 Colouring of a urban Systems Drawing
8110-600-011 Rev 1.04 Preparation of a computer aided drafting (CAD) drawing for
urban systems
8110-600-005 Rev 3.0 Signal Sighting procedure
8110-600-009 Rev 1.01 Construction of Signalling Installations
8190-600-005 Rev 1.0 Signalling construction Principles
8110-600-007 Rev 1.01 Witness testing of Contractor performed signal
commissioning
8110-600-008 Rev 1.02 Procedure for the signal system testing and commissioning
process
8190-600-006 Rev 1.02 Code of Practice for Signal Bonding
8110-600-017 Colouring of a drawing for control and communication
systems
8190-600-005 WAGR code of practice for signalling construction
8110-600-002 PTA procedure - Issue of keys to contractors
8880-70-640 Cabling
734M (Battery chargers) PTA technical specification
632M Signalling and Communications Equipment Earths -
Technical and Performance Specification"
• Guidelines for Bonding and Earthing (Parts 1 to 4 including 228E/1 to 228E/4)

• PTA procedure for changing signal and associated infrastructure including
software
• PTA technical circular No. 43E for railway signalling symbols
• Technical Symbols library
• List of type approved materials and equipment
PTA Standard Drawings
• Equipment location case specification and earthing (PTA standard 750 or 1400 and
drawings ES-HE-887, ES-HE804 to ES-CE-810)
• Signal mast drawings ES-KE-404 to 406, ES-HE-619, ES-FE-943, ES-CE-910,
ES-CM-51
• Level crossing equipment - ES-KE-328&356, ES-FY-41 to 43
• Level crossing signage - ES-HE793 to 795
• Boom barrier equipment - ES-FY-27 to 29, ES-CE 909, ES-HE-779 to 881, ES-
FE-1726, ESHE-870, ES-FE-569, ES-CE-70, ES-HE-791, ES-KE-352, ES-KE-
359,ES-FE-655, ES-FE-637, ES-HE-793 to 795, ES-HE-84, ES-CE-1550, ES-HE-
779 to 881, ES-FE-1726, ES-HE-463, CE81663 Sheet 012, Technical instruction
No. 249E
CE81663 Sheets 001, to 013/3, ES-FE-1823, ES-FY-93 to 95, 99 & 100
• Point machines and fittings - ES-KE-403
• Track circuits - ES-HE-618, 638, 801, 873
2. In all cases where Australian, British or American standard specifications,

rules or codes of practice are referred to, such reference shall always be taken to include
the latest issue of such specification, rules and codes together with the latest
supplements and addenda, relating thereto and in force on the twenty eighth day prior to
closing of tenders.
3. When reference to specific standards is made within this Specification,

these shall be adhered to unless listed in 1001.03 below.

1001.03 AMENDMENTS TO STANDARDS
1. The following items are changes to the standards listed above:-
a. No jointing of cables shall be permitted under this contract, unless

the Fremantle Ports Authority representative otherwise directs the
contractor in writing.
b. Equipment boxes shall be installed on stable ground, clear of

culverts, flood prone areas, drains and services e.g. telephone,
electricity, sewage, water.
OPERATIONS
1001.04 DESCRIPTION OF EXISTING SIGNALLING SYSTEM
1. Currently the line between Fremantle and North Fremantle is double track
fitted with unidirectional automatic colour light route signalling. Fremantle and North
Fremantle / Leighton yards located on either end of the automatic signalling section are
relay based interlockings.
2. The signalling is controlled from a VDU signal control workstation

located in the Public Transport Centre.(PTC) Indications are displayed on a large
overview mimic panel.
3. There is currently a project being managed by the PTA to provide bi-

directional signalling on the current down mainline from North Fremantle to Victoria
Quay as part of the Victoria Quay Freight Line Alterations project. The Contractor
shall not commence the design until the Contractor has obtained “Approved for
Construction” drawings for the Victoria Quay project from the PTA
4. The Fremantle line is fully track circuited using single rail AC immune
DC track relays.
5. The power supply system comprises a 600-volt, 50-hertz location case

distribution system with distribution switchboards, transformers and 110-volt
distribution contained in the equipment location cases fed from a local Western Power
supply (from the consumer mains (240V) via step up / step down transformers at the
relay rooms. There is a back up generator located at the North Fremantle relay room.
6. There are no existing level crossings on Fremantle line between

Fremantle and North Fremantle.
7. There is an existing level crossing on Tydeman Road on the current line

from Leighton Yard to the North Quay rail sidings, which will become redundant once,
the new terminal and rail loop is commissioned. Removal of the level crossing
equipment, power supply and associated signalling equipment is included in the scope
of works.

CONSTRUCTION REQUIREMENTS & MATERIALS
1001.05 WORKS INCLUDED
1. The contractor while fulfilling his obligations under this specification

shall not allow any works under his control to have a detrimental effect on the service
delivery of any portion of the train network. The Contractor shall closely liaise with all
stakeholders to ensure their inputs are considered and requirements met.
2. Unless specified otherwise the Contractor shall in accordance with this

specification supply a Design and Construction service and deliver a “Turn Key”
Project including:
• Design, draft, check and independent review of the complete system,

including factory acceptance tests;
• Supply of plans including construction, stage work, temporary,
maintenance, design, review and “As in Service” copies;
• Supply and deliver all material and services. All signalling materials
shall be currently type approved;
• Provide complete installation, testing and commissioning;
• Provide all preliminary, staging and final works;
• Provide full documentation of the system;
• Participate in Signal Sighting Committee inspections and meetings
with Stakeholders;
• Resource, organise and coordinate all:
− Occupations and Flagging
− Road traffic management
− Permits
− Commercial electricity supplies
− Safe Working Inspectors
− Signal Maintenance Staff
− Notices of intent
− Access to infrastructure
− Test trains
Works shall include but not be limited to the requirements outlined in the following Clauses
1001.07 - 1001.29.
1001.06 DESIGN AND DOCUMENTATION
1. The Contractor shall design, draft, check and supply all drawings and
documentation of the entire signalling system including:
• Site surveys;
• Data preparation and calculations;
• Control Tables;
• Software development or modification;
• Circuit books;
• Signalling scale plan and signalling diagram;
• Design, training and training manuals;
• Level crossing controls;
• Power supplies, earthing arrangements and calculations;
• Boundary interfaces;
• Stage and preliminary work;
• Amendment of all plans and documentation;
• Printing, compiling and issue of files and plans

• Weekly Notice Inserts
• Signal Sighting Forms
• Earthing and Bonding diagrams
2. Design shall be undertaken in accordance with PTA standard 8190-600-
004 Rev 0.04. All signalling shall be made immune from the effects of the 25 KV AC
traction system.
1001.07 INTERLOCKING
1. The contractor shall design, check, supply, install and commission all
relay and / or Computer Based Interlocking (CBI) components necessary to ensure safe
operation of the signalling systems.
2. Should a CBI system be provided: -
a. Software shall be developed, tested and commissioned in accordance

with PTA standard 8190-600-007 Rev 1.00.
b. The following alarms shall be provided to the North Fremantle Relay
Room for objects controlled by the CBI:
− CBI failure
− Point failure
− Signal failure
− Track circuit failure
− Light current unit proving for all LED signals
− Power failure
− Pedestrian gate failure
− Level crossing failure
c. The Contractor shall provide an interface from the CBI to allow

connection to the future telemetry system being installed by the PTA
under the “Single train control system project” for controls,
indications and alarms.
d. Testing and diagnostic facilities shall be provided.
1001.08 TRAIN CONTROL ROOM
1. The contractor shall modify the wall mounted indication diagram and
associated equipment and wiring to include:
a. Additional signal, point, track circuit, and level crossing indications

required; and
b. Deletion of indications representing field equipment that is to be

removed.
1001.09 TRAIN CONTROL CONSOLE AND DIAGRAM
1. There are currently no indications shown on the controller’s workstation.
2. The Contractor shall modify the VDU based control console to allow
operation of the new points and signals including any route setting or software blocking
functions and remove any controls including changes to wiring, software and associated
equipment that will not be required as a result of the works.

1001.10 TELEMETRY AND ROUTE SETTING SYSTEMS
1. The Contractor shall modify the existing PTA ICS telemetry system to
allow for:
a. The additional controls and indications required to remotely control

the new rail loop from the PTC, and
b. The deletion of controls and indications associated with equipment

being removed.
2. The Contractor shall modify the ICS route setting equipment located in
the North Fremantle relay room:
a. To enable route setting into and out of the rail loop and freight
terminal, and
b. To remove route setting associated with signalling equipment being

removed.
1001.11 OPERATION UNDER FAILURE
1. Under point failure conditions, the train driver or safe working person
will manually operate the point machines using the crank handles coded in accordance
with the signalling arrangements. When in manual operation all routes affected by that
point machine shall be set to stop.
1001.12 LEVEL CROSSING PROTECTION
1. The contractor shall install level crossing protection equipment at the new
Tydeman Road level crossing as indicated on plans R-01-Z-001 and R-01-Z-002
including:
a. Boom barrier masts, mechanisms, arms, bells, catches, flashing light

lights and cross arms, line marking, signage and associated cabling;
b. Installation of automatic pedestrian gates, fencing, signage, pedestrian

warning sign units.
2. The level crossing shall operate in accordance with the Signalling

operational Specification REP83461-S001 (Annexure 1001A).
3. The Contractor shall provide facilities for observing and determining the
status and condition of the level crossing equipment and associated field devices
remotely via the PTA Communications system.
1001.13 EQUIPMENT HOUSINGS
1. The contractor shall design, supply, install and commission all field
equipment boxes located to minimise the extent of local wiring.
1001.14 FIELD SIGNALLING EQUIPMENT
1. The Contractor shall design, supply, install and commission all field
signalling equipment including:

• Signal masts, single and multi lens LED colour light signal units,
illuminated LED feather type indicator units, ladders, landings,
foundations, number plates and associated fittings. All LED style
light units shall include light current unit proving. Filament proving
shall be used where applicable;
• Relocation of existing signals, track circuits, ATP transponders and
cabling, bonding, etc where required in accordance with the
signalling arrangements;
• If required by the PTA for signal sighting reasons a new signal mast,
ladder and landing is to be provided for Signal 335 with the mast
height and distance from the track to be specified by the PTA Signal
Sighting Committee;
• Level crossing activation pushbuttons in stainless steel telephone
cabinets on home signals as indicated on the signalling arrangements;
• Permanent magnet motor point machines style WSA 84M complete
with all point fittings, insulations, point numbering, rodding, cranks
or foundations and bearers or extended sleepers;
• Immunised DC track circuits including trackside units, earthing,
boxes, mounting posts, foundations, associated track connections,
cabling, signal and traction head and cross bonding, spark gaps and
cabling to new or relocated overhead traction and signal structures,
equipment cases and point machines;
• Signal and traction head and cross bonding of turnouts and
crossovers;
• All insulated rail joints;
• Temporary bonding of insulated rail joints and all track circuit
alterations and bonding associated with preliminary and stage works;
• In service plans to FPA in accordance with PTA procedures;
• Power supplies, batteries, chargers, transformers, medium voltage and
low voltage switch gear assemblies, low voltage switch boards,
change over contactors, circuit breakers, fuses, terminals and bus
bars;
• Upgrading of the power supply should this be required to cater for the
additional load associated with the new works;
• All accommodation including housings and boxes;
• Supply, fabricate and assemble all equipment housing components
including mounting frames and rails, stackable terminals, power
distribution bus bars and labelling;
• Supply and install all BR type miniature relay and plug bases;
• Earthing, earth mats, earth stakes and surge protection equipment;
• All through signalling, signal power, communications and vital CBI
cable by direct burial, in conduits and pits through platforms and in
conduits through roadways and under tracks and crossings unless
excluded specifically in clause 1001.29;
• All local and through cabling;
• Any modifications to the existing Tydeman Road level crossing to
allow the construction of the new terminal;
• Modifications to racking, cable tray, or additional mechanical fit out
of the North Fremantle relay room, and,
• Modification of gauge discrimination and bi-directional running
circuits from Victoria Quay to No 880 points to ensure standard
gauge trains are not incorrectly signalled over 880points normal;
• Removal of gauge discrimination and bi-directional running circuits
between Points 880 and Leighton Yard
• Signal maintainer access from Tydeman road to the track via a
suitable stairway to replace the existing access ladder on the up side
of Tydeman Road that will be foul of the new track.

1001.15 SIGNAL POWER DISTRIBUTION AND ALTERNATIVE
SUPPLIES
1. The contractor shall provide a local Western Power supply to the new
Tydeman Rd level crossing which shall be used to power the level crossing and
adjacent signalling.
2. A back-up power supply shall be provided that is independent of the

local street supply. The backup supply maybe provided by the existing generator at
North Fremantle should the Contractor check that adequate capacity is provided without
exceeding voltage drop constraints.
3. Should a CBI system be installed it shall be fed by an uninterruptible

power supply.
1001.16 CABLE ROUTE
1. The Contractor shall install a new cable route from the mainline cable
route to Signal 344 departing the North Quay Rail terminal. The new cable route shall
connect to the existing main line main cable route. Cables wherever possible shall be
direct buried. Where direct burial is not feasible the cables shall be installed in ground
level troughing or in conduits. Steel trunking may be used for attachments to bridge
structures and on walls as per the bridge drawings, in but shall not be used elsewhere
without the approval of Fremantle Ports Authority.
2. The Contractor shall design, supply and install any clamping

arrangements on over-bridges, under-bridge, viaducts and any new cable entries. The
cable route shall be clear of future bridge piers for the Curtin Avenue road extension
under the rail loop.
1001.17 CABLES
1. The Contractor shall supply, install, wire, terminate, join, test and
commission all local and through signalling, power and telecommunications cables.
1001.18 COMMUNICATIONS
1. The Contractor shall provide sufficient telecommunications bearers to

allow for implementing the signalling functions contained in this specification including
telemetry, remote level crossing monitoring and remote alarms. Where new bearers are
required they shall be fibre optic cables with a suitable interface approved by the PTA.
1001.19 LIMITS OF WORK
1. The limits of work for the signalling are Signal No. 344 (20.014km) to
Signal No. 335 (19.211km) to Location case F177 (mainline) and via Points 874 to the
down end of the existing level crossing approach to existing Tydeman Road level
crossing including Leighton yard.
2. Outside of these limits the Contractor shall design, supply, install, test
and commission all the associated works to interface the new signalling system with the
adjoining systems in accordance with R-001-F001, R-001-F002 and R-001-F003 in
Appendix 1.

1001.20 INTERFACE WORKS
1. The Contractor shall design, supply, install, modify, test and commission
all interface equipment necessary to ensure the safe and correct operation of the
signalling system at and outside the contract boundaries defined by the Limit of Works.
2. This work includes, but is not limited to:
• Automatic signalling circuits for signal control;

• Signal approach locking and warning circuits;
• Level crossing controls;
• DC track circuits;
• Power distribution circuits;
• Communications circuits;
• Additional equipment accommodation;
• Signal and traction bonding.
1001.21 PRELIMINARY WORKS
1. The scope of works includes supply and installation of track work and
associated overhead works. Therefore, it may be necessary for the Contractor to stage
preliminary works to relocate, test and re-commission signalling and/ or
communications equipment obstructing implementation of new works.
2. This equipment may include, but is not limited to:
• Signals;
• Location cases;
• Cabling;
• Communication pillars;
• Trunking;
• Conduits;
• Pits.
1001.22 STAGE WORKS
1. In additional to the preliminary signalling works to allow construction of

the Tydeman St bridge, the formation and the track work, it is envisaged that the new
level crossing and rail loop works work will pre-tested, allowing the project to be
commissioned in a single stage. This stage will include installation of the new mixed
gauge turnout 880 and signalling works associated with ensuring standard gauge trains
cannot be signalled towards Points 880 / 880K from the down direction of the up /
down mainline.
2. The Contractor shall allow for any stage works associated with
decommissioning of turnouts and their associated signalling infrastructure, also
equipment at the existing Tydeman Road level crossing. This work includes the
intermediate stage works associated with decommissioning Leighton Yard as indicated
on plan R-001-F-003 (Appendix 1) and any clipping or scotching of turnouts as
required by PTA-WA.
1001.23 TESTING AND COMMISSIONING
1. The Contractor shall test and commission the complete system including
all preliminary and stage works in accordance with the PTA’s testing and
commissioning procedure 8190-600-002.

2. The Contractor shall in accordance with this specification provide
sufficient qualified resources to change over and test and commission the complete
system, including any preliminary and stage works.
1001.24 REDUNDANT EQUIPMENT, MATERIAL AND CLEAN UP
1. Redundant signalling shall be delivered to the PTA Signal maintenance

depot located at Claisebrook unless the Fremantle Ports Authority direct that it be
scrapped in which case the Contractor shall arrange for recovery and correct disposal.
2. All redundant components from the decommissioning of the existing

level crossing shall be recovered and returned to the PTA Signal maintenance depot
located at Claisebrook.
3. Clean up shall include removal of signalling and telecommunications

wiring made redundant by this project in existing equipment cases or in the relays
rooms at Fremantle or North Fremantle within the limit of works.
1001.25 MAINTENANCE AND OPERATIONS MANUALS AND

TRAINING
1. The contractor shall only supply equipment currently type approved by

the PTA. There is no requirement to prepare or supply maintenance documentation and
manuals or provide training to PTA’s design or maintenance staff.
2. The Contractor shall provide information to update PTA’s asset register

(in a format nominated by Fremantle Ports) and maintenance copies of plans at least
one week before the assets are commissioned.
1001.26 SPARES AND TEST EQUIPMENT
1. The contractor shall only supply equipment currently type approved by

the PTA. There is no requirement to supply test or diagnostic equipment or spare parts
under this contract.
1001.27 MATERIAL/EQUIPMENT TO BE SUPPLIED BY FREMANTLE

PORTS AUTHORITY
1. No material/equipment will be supplied by FPA.
1001.28 SIGNAL SIGHTING
1. The Contractor shall arrange confirmation of the positions and heights of

each new or amended signal and light unit types, prior to manufacture and installation
of any signals. This work must be completed via and with the approval of the FPA and
the PTA.

WORKS NOT INCLUDED
1001.29 GENERAL
1. The following details the work excluded from this design and
construction specification and work supplied and/or provided by Fremantle Ports
Authority.
• Preparation of the Signalling Arrangement plans, R-001-F001 and R-

001-F002.
MAINTENANCE
1001.30 WORKING LIFE & RELIABILITY
1. The entire Signalling System shall be so designed, manufactured and

commissioned as to require minimal maintenance throughout its expected working life,
whilst providing a high level of reliability and availability.
2. In particular the Contractor shall demonstrate by producing a design

report which shows that that the detailed trackwork design of the turnout from the
mainline to the North Quay rail loop, (see track work specification), the point machine
and the point machine rodding has been designed using an integrated systems approach
in order to maximise safety and reliability.

ANNEXURE 1001A
SIGNALLING OPERATIONAL SPECIFICATION
BACKGROUND
1001A.01 GENERAL
1. Fremantle Ports Authority wish to develop a new rail container handling

terminal in the general location of the current rail terminal on the North Quay. The
terminal will be connected to the Fremantle line via a single track, the North Quay rail
loop and which will replace the existing freight terminal access via Leighton Yard
North Fremantle.
3. The PTA of WA have advised that the down mainline will be resignalled
for bi-directional running as part of the Victoria Quay Freight Line Alterations project.
EXISTING SIGNALLING ARRANGEMENTS
1001A.02 GENERAL
1. Currently the signalling between Fremantle and Leighton Yard is

controlled from a VDU based signal control system located in the Public Transport
Centre.
2. The main line is double track fitted with unidirectional colour light route
signalling.
3. Bi-directional signalling is currently being installed on the current down

mainline from North Fremantle to Victoria Quay by Others, as part of the Victoria Quay
Freight Line Alterations project.
NEW SIGNALLING SYSTEM
1001A.03 OVERVIEW
1. The proposed signalling arrangements are R-001-F001 & R-001-F002 in

Appendix 1. The proposed alterations to signalling will permit signalled dual gauge
moves between the container terminal and Fremantle dual gauge mainline (or the
narrow gauge down main line) via the up/down DG mainline. All new or altered signals
and point motors will be remotely controlled from the Public Transport Centre.
2. Signal No. 335 (and associated ATP transponders) is to be relocated 69m

towards Fremantle just in advance of points No. 880 subject to PTA Signal Sighting
Committee approval. The resultant changes to the associated overlap track circuit and
the ATP beacon positions are shown in drawings R-001-F001 & R-001-F002. A shunt
aspect light unit and a position 1 “feather” type route indicator will be fitted to Signal
335 and new route 335(S) added.
3. Points 880 are provided to access the rail loop and catchpoints No. 884
provide runaway protection for the container terminal.

4. Signal No. 342 is provided as a yard exit signal which when held at stop
allows shunting on the signal approach without activating the Tydeman Road boom
barriers.
5. Semi-automatic shunt signal No. 344 is provided to ensure trains from the
terminal do not shunt towards the level crossing when a down train has been signalled
towards the terminal.
6. A new level crossing is to be constructed on Tydeman Road fitted with

Level 3 style level crossing protection (1/2 boom barriers and flashing lights). The level
crossing will be fitted with Level 3 automatic pedestrian gates on both sides of the
roadway.
7. Signal No. 342 is interlocked with the control of the boom barriers,
flashing lights and pedestrian gates. Operation of the level crossing will be automatic.
8. Otherwise there are no other changes to signal positions or maximum line

speeds on the main line, so existing braking distances and ATP overlap distances will
prevail.
9. There is no requirement to provide for ATP on the rail loop.
10. In conjunction with commissioning the new terminal and rail loop,
Leighton Yard and the existing Tydeman Road level crossing will be abolished and the
associated signalling equipment shall be removed.
11. Signal No. 331 will be converted to automatic operation.
1001A.04 ASSUMPTIONS
1. The following assumptions have been made in this specification:
a. There is adequate signal spacing to accommodate a freight train line

speed increase from 20kph to 30kph between 19.335km and
20.189km.
b. The line speed for freight trains will be Fremantle to Terminal entry
30kph, Terminal speed 20kph;
c. The signalling alterations defined in Appendix 1 diagrams ES-P-

2950 & ES-P-2951 will proceed and be undertaken in advance of the
North Quay Rail Terminal project and be funded by others;
d. Freight train braking = 0.3ms-2 plus 10 seconds brake activation time

(600m train);
e. Maximum freight train acceleration = 0.5ms-2 (light locomotive);
f. The in-house developed Westrail ICS will support the proposed

method of operation.
g. Existing dual gauge trackwork on the west mainline north of the new
Points 880 will be converted to narrow gauge as part of this project.
This will preclude standard gauge access to Leighton Yard;

h. Road train acceleration is 0.63ms-2. Maximum length of road train is
36.9m;
i. Access to Leighton yard is not required;
j. The new “phoenix” single train control system” will not control or
monitor the Fremantle Line before this project is commissioned.
1001A.05 NEW AND ALTERED SIGNALS AND POINTS
Signals Description Route Remarks

Indications
335 Fremantle DG Main LH ‘feather’ Signal relocated

to Signal No. 331 type route 69m towards
(Route 335A) and to indicator Fremantle. New
North Quay Position 1 location in advance
container terminal of Points No. 880.
(Route 335(S)) New position 1
‘feather’ type
indicator to be
installed.
Route 335A (to
mainline) requires
detection of NG
train.
New shunt aspect to
be added (335(S)).
355 Fremantle DG Main Overlap to extend

to Signal No. 335 100m on loop line
and 180m on
mainline. Mainline
overlap requires
detection of NG
train.
357 Fremantle NG Down Overlap to extend

Main to Signal No. 100m on loop line
335 and 180m on
mainline.
344 North Quay - New fixed red semi-

container terminal to automatic shunt
Signal No. 342 signal located at
+830m on 1st (up
end) hand points.
342 North Quay rail loop - New signal located

to Signal No. 350 50m on downside of
Tydeman St. level
crossing.
D186 Fremantle DG Up/ Signal 331

Down main to converted to
Signal No. D178 automatic signal.
Remove shunt
aspect light unit and

Signals Description Route Remarks
Indications
route indicator.
324, 322, Leighton Yard Signals to be

326, 325 signals removed.
1. Signalling shall be modified to remove bi-directional operations and

gauge detection between Leighton yard and the new 880 points. Bi-directional
operation and gauge detection must be provided between Points No. 880 and Fremantle.
Points No. Description
880 New motorised mixed gauge points Up/Down

Mainline to North Quay rail loop.
(Crank handle configuration A2 to be relocated from

Points No. 882)
884 New motorised catchpoints North Quay container

terminal to rail loop. Located 47m on downside of
Tydeman St. level crossing. Alarmed if reverse and
free.
(Crank handle configuration A3 to be relocated from

Points No. 883)
876A, 876B, Leighton Yard point machines to be abolished.

876BK, 874
2. Dual control facilities will be provided for all new motor points. (The
interlocking will detect that the points have been put in hand operation and prevent
operation of all routes affected by the points).
1001A.06 TRAIN OPERATIONS
1001A.06.01 DOWN TRAIN MOVEMENTS
1. For a down freight train at Fremantle bound for the North Quay container
terminal the train controller will contact the North Quay yard controller by telephone or
radio and obtain permission to dispatch the train.
2. The Yard Controller will check that the train can be accommodated
directly in the terminal without fouling the Tydeman Road level crossing before giving
the train controller permission to dispatch the train. The Yard Controller will then
arrange the yard hand points to accept the train.
3. Down freight trains will be signalled from Signal No. 355 (DG Main) or
Signal No. 357 (NG Down) to the North Quay container terminal via signal No. 335.
For these routes Signal Nos. 355 and 357 will clear to a yellow aspect when Points 880
are reversed, the overlap is clear and Signal No. 335 has cleared to a proceed (shunt)
aspect with illuminated left hand “feather” indicator. When points 880 are reverse
Signal No. 335 will not be able to clear unless Signals 342 and 344 are at stop, there are
no opposing routes set and the section is clear between Signal 335 and Signal 344.

4. The condition to not allow Signal Nos. 355 and 357 to clear with 880
reverse until there is a proceed aspect on Signal No. 335 is to minimise the likelihood of
holding trains at Signal 335 which may block the mainline.
5. The Westrail Signalling Control System has automatic route setting so

Points No. 880 and Catch No. 884 will run to the required lie when a route is called.
6. Points No. 880 will be released when a down train has cleared track
circuit FGH1T (880N) or FGH2T (880R) allowing Signals 355 and 357 to be cleared
for a mainline move towards Perth, regardless of the position of catchpoints 884
provided that there is a route in progress towards the terminal. Route 335(A) will prove
catchpoints 884 normal or 335(S) route in progress as an initial condition only.
7. Catchpoints 884 will self-normalise after passage of the train. Should

catchpoints 884 not restore to normal within 1 minute of the train passing clear of
Signal No 342 and track circuit FGMT is clear, an alarm will be raised in the Public
Transport Centre.
8. When there is a yellow or green aspect on Signal Nos. 355 and 357, it
will not be possible to move points No. 880.
1001A.06.02 UP TRAIN MOVEMENTS
1. Signal No. 344 will normally be at proceed unless the signaller has set the
signal to stop to allow a down train to be signalled from Signal No. 335 to the terminal
or there are vehicles on the track between Signal No. 344 and 342.
2. For an up freight train ready to depart the North Quay container terminal,
the train driver will contact the train controller to request that the train be dispatched.
3. When the mainline and yard are clear of trains, the train controller will
ensure Signal 344 is at proceed, then reverse signal lever no. 342 which will reverse
Points No. 880 and catchpoints No. 884 and allow Signal no. 342 to clear.
4. Catchpoints 884 will self-normalise after passage of the train. Should

catchpoints 884 not restore to normal within 1 minute of the train passing clear of
Signal No 342 and track circuit FGKT is clear, an alarm will be raised in the Public
Transport Centre.
1001A.06.03 SHUNTING MOVEMENTS
1. Hand signalled shunting moves can be undertaken at any time on the

down side of signal No. 342 at stop without affecting the level crossing or the mainline
signalling. The signalling will not allow for terminal shunting moves across the level
crossing, only for arrivals and departures.
2. The signalling will not allow a double headed train to detach a

locomotive between Signals 344 and 342, set back into the sidings and then shunt ahead
to recouple with the first locomotive.
1001A.06.04 OPERATIONS WHEN LEIGHTON YARD SIGNALLING IS

REMOVED
1. PTA require unsignalled access to Leighton Yard for narrow gauge trains
for a period following the commissioning of the North Quay Rail Loop. And interim
decommissioning stage shall be provided based on the configuration shown in R-001-F-
003.

2. Entry to and departure from Leighton Yard during the interim
decommissioning stage will be by hand signalling in accordance with a special PTA
Safeworking Procedure yet to be developed.
3. The Contractor shall undertake the final design of the interim

decommissioning stage in conjunction with the PTA, who shall develop their
procedure. The Contractor shall undertake a risk assessment of the final configuration
(infrastructure and procedures) of the interim decommissioning stage in accordance
with AS4360 to show that the proposal is “Not less safe” than the existing method of
signalling trains in and out of Leighton yard.
4. The final stage of decommissioning the signalling in Leighton Yard is

shown in R-001-F-002 and shall include removing turnout No. 876 and ‘straight
railing’ the track.
1001A.07 LEVEL CROSSING
1001A.07.01 TYDEMAN ROAD
1. Where the new rail loop crosses Tydeman Road at grade a new level
crossing with Level 3 crossing protection (1/2 boom barriers, RX-5 flashing lights and
automatic pedestrian gates on both sides of the roadway) will be provided. The level
crossing layout plan is contained in drawing R-01-Z-001.
2. Signal No. 342 is interlocked with the control of the boom barriers,
flashing lights and pedestrian gates. Operation of the level crossing will be automatic.
3. The approach distances and times are:
Direction of Approach Approach Warning time

Train Approach Speed Distance (See below)
(Line speed +
3kph)
Down 33kph 340m 39 secs
Up 23kph 249m 39 secs
4. Operation of the level crossing protection will be indicated on the train

controller’s indication diagram.
5. Train Movements in Up Direction

a. Signal No. 342 is interlocked with the level crossing protection. With
Signal No. 342 at stop and catchpoints No. 884 normal trains can
shunt on the level crossing up approach without operating the boom
barriers;
b. When Signal No. 342 is set to proceed (and after catchpoints No. 884
have run reverse) and the train is not on the up approach track circuit
FGNT, the level crossing will operate automatically. The up warning
distance is fixed to allow a 39 second warning time at 23kph;
c. When Signal lever No. 342 is set to proceed (and after catchpoints
No. 884 have run reverse) and a train is on the up approach track
circuit FGNT, the level crossing protection will commence operating.
Signal 342 will clear after 25 seconds of warning time.
d. After the train passes the catchpoints they will self-normalise; and
e. Replacing signal lever 342 to stop with a train on the up approach

will cause the level crossing protection to reset (i.e. boom barriers to
rise) after 60 seconds unless the train is detected as being foul of the
roadway or pedestrian crossings.
6. Train Movements in Down Direction
a. The level crossing will operate automatically for a down train;
b. The down warning distance is fixed to allow a 39 second warning

time at 33kph (braking to 23kph at the level crossing);
c. After the train passes the catchpoints they will self-normalise.
1001A.07.01.1 Level Crossing Warning Tydeman Road

1. Tydeman Road carries road trains that access the port facility. The time
between the commencement of the flashing lights and the commencement of the boom
barrier descent has been increased from 7 seconds to 15 seconds to allow time for a
road train to clear the crossing.
2. Tydeman Road is 19m wide and under PTA standards an additional 3

seconds clearance time is to be allowed for.
3. The warning time is:
a. Minimum Warning time 25 seconds
b. Clearance time + 3 seconds (1 second for every 3 m over

10m)
c. Adjustment time + 0 seconds (use relays for control, 1 sec

already included in MWT)
d. Buffer time + 8 seconds (to allow for road trains)
e. Pre-emption time + 0 seconds (not traffic light co-ordinated)
f. Subtotal 36 seconds
g. Speedo error 6% +2.2 seconds
h. Total warning time = 39 seconds

4. Level crossing warning distances are based on the total warning time (39
seconds) and the line speed plus 3kph.
1001A.07.01.2 Focussing Diagrams

1. A focussing diagram for the new level crossing is contained in the
drawings R-001-Z001.
1001A.08 CONTROL CENTRE ALTERATIONS
1. The following controls are to be added to the Westrail VDU signal

control workstation:
a. Signal control 342, 344 and 343 (Exit Button);
b. Point controls 880 and 884.
2. The following indications are to be added to the Westrail VDU signal

control workstation:
a. Signals 342, 344 and relocated Signal 335;
b. Points 880 and catchpoints 884;
c. Track circuits FGJ1T/FGJ2T, FGKT, FGLT/FGMT and

FGNT/FGOT;
d. Level crossing operating – (New) Tydeman Road, and
e. Catchpoints 884 failure alarm.
3. Current controls and indications associated with 324, 322, 326, 325 and
331 Signals and 876A, 876B, 876BK and 874 Points will be removed from the signal
control workstation and the overview diagram. The limit of indications is shown on
drawings R-001-F001 & R-001-F002.
4. The works will include the following changes to allow the remote control
of the North Quay Rail Loop from the Public Transport Centre:
a. Changes to the signal control system at the Control Centre including

any changes to the train controllers VDU based control panel and the
train controllers indication overview diagram and maintainers
indication screens;
b. Changes to the telemetry system;
c. Changes to the local Interlocking Control System computer (ICS)

located in North Fremantle relay room;
d. Changes to the local relay interlockings at North Fremantle.
5. Communications between the Public Transport Centre and the North

Quay Yard Controllers Office will be undertaken to PSTN telephone or by train radio
portable. A direct telephone connection is not required.
1001A.09 TESTING AND COMMISSIONING
1. Where possible signalling equipment will be pre-tested and installed prior

to the onsite testing and commissioning. (e.g. point machines, shunt signals, etc…).

2. Testing and commissioning shall be undertaken in accordance with PTA
procedures.
3. The commissioning programme will be developed in conjunction with

FPA and WA PTA.
REFERENCES
MT 01 6407 R003 Proposed Intermodal Terminal at North Quay Train
Simulation HGM 5.09.02

APPENDIX 1
STAGING DIAGRAMS

Infrastructure Systems Branch
. .
FREMANTLE
Infrastructure Systems Branch
. .
FREMANTLE
S PECIFICATION 1002
TRACKWORK
CONTENTS
Clause Page
GENERAL................................................................................................................................................... 1
1002.01 SCOPE OF WORK .............................................................................................................. 1
1002.02 DESCRIPTION OF THE WORKS...................................................................................... 1
1002.03 CO-ORDINATION OF THE WORKS................................................................................ 3
1002.04 LIMITS OF THE WORK..................................................................................................... 3
1002.05 INTERFACES TO RELATED WORKS ............................................................................. 3
1002.06 REFERENCES ..................................................................................................................... 3
TECHNICAL REQUIREMENTS ............................................................................................................ 4
1002.07 GENERAL ........................................................................................................................... 4
1002.08 MAINTENANCE................................................................................................................. 4
1002.09 DETAILED REQUIREMENTS........................................................................................... 5
1002.10 INTERFACES...................................................................................................................... 5
MATERIAL SUPPLY ............................................................................................................................... 5
1002.11 GENERAL ........................................................................................................................... 5
1002.12 PACKING, TRANSPORT, HANDLING AND STORAGE ............................................... 6
1002.13 TRACK SYSTEM................................................................................................................ 7
1002.14 RAILWAY SIGNS AND MARKERS................................................................................. 7
1002.15 SPARES, SPECIAL TOOLS AND TEST EQUIPMENT ................................................... 7
1002.16 BUFFER STOPS .................................................................................................................. 8
CONSTRUCTION ................................................................................................................................... 10
1002.17 GENERAL ......................................................................................................................... 10
1002.18 TRACK ALIGNMENT...................................................................................................... 10
1002.19 SLAB TRACK TOLERANCES ........................................................................................ 13
1002.20 INSTALLATION OF RAILS ............................................................................................ 14
1002.21 RAIL WELDING ............................................................................................................... 15
1002.22 ALUMINOTHERMIC WELDING.................................................................................... 19
1002.23 RAIL JOINTS .................................................................................................................... 19
1002.24 FINAL FASTENING DOWN OF RAILS ......................................................................... 20
1002.25 ELECTRICAL REQUIREMENTS IN TRACK CIRCUITED TRACK............................ 20
1002.26 INSTALLATION OF TURNOUTS................................................................................... 22
1002.27 INSTALLATION OF BALLASTED TRACK .................................................................. 23
1002.28 INSTALLATION OF SLAB TRACK ............................................................................... 25
1002.29 INSTALLATION OF BUFFER STOPS............................................................................ 25
1002.30 INSTALLATION OF RAILWAY SIGNS AND MARKERS........................................... 25
TESTING AND COMMISSIONING ..................................................................................................... 26
1002.31 GENERAL ......................................................................................................................... 26
1002.32 PLANNING........................................................................................................................ 26
1002.33 FACTORY ACCEPTANCE TEST (FAT)......................................................................... 27
1002.34 INSPECTION..................................................................................................................... 28
1002.35 SITE ACCEPTANCE TEST (SAT)................................................................................... 28
1002.36 COMMISSIONING ........................................................................................................... 28
ANNEXURE 1002A ................................................................................................................................... 1
EXTENT OF EXISTING TRACK REMOVAL...................................................................................... 1

Associated Roadworks Trackwork
SPECIFICATION 1002
TRACKWORK
GENERAL
1002.01 SCOPE OF WORK
This specification applies to Trackwork as referred to in Series 100 – General

Management Requirements
1. The Contractor shall manufacture, procure, install, test and commission a Scope
complete, integrated permanent way system, comprising the rails and their support
structure above the top surface of the capping layer or structural slab, together with
other items generally associated with the permanent way (buffer stops, derailment
containment, signs & markers, etc.).
2. The scope of trackwork covers the track structure from the new See clause
connection on the Fremantle to Perth line to the end of the Stage 1 terminal layout. 1001.22 Clause
2.
3. The scope for removal of trackwork covers the existing rail, sleepers and
ballast from 20m north of the Tydeman Rd level crossing through Baguley’s site and
immediately south of Patrick new entrance to the new Rail Terminal as shown in
Annexure 1002A - SK022 “Existing Track Structure Removal”.
4. The connection to the Fremantle to Perth line and the chord to the
entrance to the terminal is to be in conventional ballasted track together with track 4 of
the freight terminal. The freight terminal lines are to be laid on a track slab.
1002.02 DESCRIPTION OF THE WORKS
1. The scope of works for civil works has been fully detailed with the
exception of:
a. The 1:16 turnout from the main line, 1:10 turnouts on the terminal
(types to be confirmed by PTA);
b. The design of the track slab in the terminal and associated transition
slab.
c. Buffer stop assemblies to suit performance requirements in the

Technical Requirements;
d. All temporary works required to support the Contractor’s method of

working.
2. Those works listed in 1002.02.1 and any other works not specifically
detailed in the Principal’s detailed design which are necessary to fulfil the requirements
of the Principal’s project requirements is deemed to be concept design.
3. The scope of supply shall include, but not be limited to the following.
Detailed specifications are given in the Technical Requirements.

a. The track structure - including all rails, preassembled, insulated track
joints fasteners, baseplates, sleepers, bearers and support structure
(ballast, track slab or other support).
b. Turnouts catchpoints and rail movement joints;
c. Rail end safety devices, including friction buffer stops, fixed buffer
stops, wheel stops, etc;
d. Track ducts in the slab track structure;
e. Signs and markers to meet operational requirements;
f. Flash butt and aluminothermic rail welding equipment including

consumables;
g. Spares to meet operational requirements, special tools and

equipment; and
h. All plant, tools and Temporary Works necessary for the installation.
4. The works shall include, but not be limited to the following. Detailed
specifications for the Principal’s detailed design are given in the Technical
Requirements.
a. Installation of complete permanent way systems for ballasted and

slab track structures, including turnout layouts and all necessary
temporary works;
b. Installation of associated works, including buffer stops, preassembled

insulated track joints, signs and markers, etc;
c. Establishment of site access, temporary accommodation and facilities

for the Contractor’s own use;
d. Testing, commissioning and setting to work, as specified in Clause

1002.32;
e. Maintenance of the trackwork including tamping, regulation, ballast

consolidation, rail head grinding and the like between installation
and final completion of the works; and
f. Interfacing with other contractors.
5. The following suppliers shall provide warranties:

a. Manufacture and supply of rail;
b. Manufacture and supply of turnouts and rail movement joints;
c. Manufacture and supply of rail fastening system;
d. Manufacture and supply of resilient baseplates (or other resilient

components used in the slab track system);
e. Manufacture and supply of friction buffer stops;
f. Manufacture and supply of concrete sleepers and bearers; and
g. Supply and/or installation of any portion of the works deemed by the

Superintendent to be a significant element of the Permanent Way
system.
h. Preassembled insulated rail joints
1002.03 CO-ORDINATION OF THE WORKS
1. The Contractor shall ensure the entire works are carried out with due
consideration to the work within and between these parts:
a. Earthworks, Series 300;
b. Bridges & Retaining Walls, Series 800;
c. Specification 1001
1002.04 LIMITS OF THE WORK
1. The limits of the WORKS for Trackwork are shown on the Site
Drawings.
1002.05 INTERFACES TO RELATED WORKS
1. Trackwork shall interface and coordinate with the Existing Suburban

Passenger Railway.
1002.06 REFERENCES
1. The trackwork shall conform to the requirements and parameters as

contained in this document and other referenced documents; in particular shall conform
to the requirements of the PTA Narrow Gauge Mainline Code of Practice – Track and
Civil Infrastructure (Draft Oct 1998) and the Australian Standards referenced therein.
All work shall satisfy the rail safety requirements of AS 4292.
Standards and Codes
Draft PTA Narrow Gauge Mainline Code of Practice – Track and Civil
Infrastructure (Draft Oct 1998)
AS 4292 all parts Railway Safety Management PTA Drawing for 1:10 turnout
PTA Drawing for a catchment
AS 1055 all parts Acoustics – Description and measurement of environmental noise
AS 1085 all parts Railway Permanent Way Material
AS 1141 all parts Methods for Sampling and Testing Aggregates
AS 1152 - 1993 Specification for Test Sieves
AS 1302 - 1991 Steel Reinforcing Bars for Concrete
AS 1303 - 1991 Steel Reinforcing Wire for Concrete
AS 1304 - 1991 Welded wire reinforcing fabric for Concrete
AS 1397 - 1997 Specification & Supply of Concrete
AS 2205 all parts Methods of destructive testing of welds in metal
AS 2734 - 1984 Asphalt (Hot Mixed) Paving – Guide to Good Practice
AS 2758.1 - 1998 Aggregates and rock for Engineering Purposes – Concrete
Aggregates
AS 2758.7 - 1996 Aggregates and rock for Engineering Purposes – Railway Ballast
AS 3972 - 1997 Portland & Blended Cements
AS 4100 - 1998 Steel Structures
AS 4680 - 1999 Hot Dipped Galvanised Coatings on Ferrous Articles
AS 4799 - 2000 Installation of underground utility services and pipelines within
railway boundaries.
ISO 9000 all parts Quality management and quality assurance standards
ISO 9001 - 2000 Quality management systems – requirements
2. The Contractor shall comply with the provisions of the following
documents as appropriate.
− ROA Draft Code for the installation of other parties’ electrical

power overhead lines adjacent or over railway land;
− The structural clearances for permanent structures adjacent to
and above the tracks shall conform to PTA’s minimum structural
clearance diagrams and specifications as shown on Drawing 82035/3
Rev 0.
TECHNICAL REQUIREMENTS
1002.07 GENERAL
1. The operation of the terminal relies on the fact that safety, robustness,
reliability and minimal maintenance requirements are the over riding issues in the
permanent way design and the primary determinants in the selection of track structure
and component type and quality. The Contractor shall carry out all work under this
contract in accordance with the criteria specified, keeping these aims in mind, in order
to contribute to the provision of a completed project which meets all objectives and
expectations of the Principal and prospective railway users.
1002.08 MAINTENANCE
1. All equipment and infrastructure supplied must be designed and

constructed for minimum maintenance. Maintenance activity required must be capable
of being performed with little or no impact on the train service. The Contractor shall
demonstrate that maintenance requirements have been considered in the selection of
components for the following maintenance regimes.
2. Maintenance is required in two main areas, routine/preventative and

corrective, both of which affect availability. Routine/preventative maintenance
increases reliability due to the fact that the ageing effect upon that function is
decreased, however, routine/preventative maintenance periods are limited to the time
during which a function is not required to be available (i.e. railway shutdown or off-
peak times). For routine/preventative maintenance programmes not to affect
availability, all works must be completed before the function is required to be available.
Maintenance must not introduce faults, which cause unavailability.

3. Upon failure, it is necessary to provide corrective maintenance as
expeditiously as possible so that the unavailable function can be restored in the
minimum time. To optimise corrective maintenance, techniques employing automatic
diagnostics, test points, line replaceable units and rapid repair facilities will be used.
Condition and health monitoring techniques will aid both routine/preventative and
corrective maintenance and should be adopted wherever possible.
1002.09 DETAILED REQUIREMENTS
1. The Contractor shall be responsible for ensuring that all proprietary

components of the track including, inter alia, rail fastenings, rail joints, standard and
special components comply with the Technical Requirements. The Contractor shall be
responsible for ensuring compatibility between such components, for determining the
methods of production of all items and for supervising their manufacture.
2. Some track components have been nominated in these Technical

Requirements. In these cases, the required performance, functional and design
requirements may not have been included within the Technical Requirements. The
Superintendent, however, reserves the right to have a track component, or any of its sub
components, independently checked by the Contractor and tested to confirm the
manufacturers’ claim of suitability for use in the Works with the predicted traffic
loading. For standard clips and fast clips the actual clip should be confirmed by the
Contractor for approval.
1002.10 INTERFACES
1. At turnouts, the formation level will be lower due to increased depth of

rail and bearers. The formation will be stepped accordingly (this is dealt with in Civil
Works documentation).
MATERIAL SUPPLY
1002.11 GENERAL
1. All materials and components to be used for the installation of the track
and construction of the track structure shall be new and as defined in these Principal’s
project requirements. They shall be free of damage, dirt and loose rust immediately
prior to being taken to the point of installation and at the time of fixing in position. Mill
scale shall be removed from rails in the weld areas and the heads during grinding.
Materials which are not to the required standards shall be removed from Site and
replaced by the Contractor.
2. The Contractor shall identify all known hazards associated with materials
and components and specify recommended safe methods of storage, use and disposal to
ensure the safety of staff and that the condition of the component remains suitable for
installation into the track after the storage period which may be long term. The
Contractor shall abide by the manufacturer’s instructions on health and safety and use
of their product.
3. The Contractor shall undertake materials testing in accordance with the

requirements of the appropriate parts of this and the following section Testing and
Commissioning. Where a test identified is not covered by recognised standards or
codes, the testing authority is to issue a Certificate of Conformance. A copy shall be
submitted to the Superintendent.

1002.12 PACKING, TRANSPORT, HANDLING AND STORAGE
1. The packing, transport, handling and storage of the permanent way

components shall be appropriate to the material and in accordance with the suppliers’
instructions.
2. The Contractor shall ensure that the packing and transport of the
materials will not induce undue stress, vibration, extremes of heat, corrosion nor impact
their properties. The Contractor shall ensure that components of similar physical type
but differing properties are packed and labelled clearly. Small components shall be
crated or palletised suitable for mechanical handling and where practical, vertical
stacking.
3. All material purchased by the Contractor shall be suitably handled and

stored so that they will be fully protected from damage and corrosion, with particular
regard to the climatic conditions prevailing. All packaging shall be robust and such as
will not deteriorate during long periods of storage. Site storage shall be in cool, dry
conditions away from direct sunlight or the manufacturer’s recommendations. Any
product past its shelf life shall be removed from site.
4. All normal and regulatory precautions against fire shall be taken during
both storage and use. Dangerous goods shall be handled and stored in accordance with
the relevant regulations and in accordance with the requirements of the relevant
Authorities. Aluminothermic weld portions shall be stored in a dry ventilated container
to the requirements of the FESA. Weld igniters are classified as dangerous goods. The
Contractor shall comply with all relevant regulations.
5. The Contractor shall take all necessary precautions to prevent crippling or

permanent damage to the rails during transit, handling and storage. The rails shall not
be subjected to direct blows. Rails shall be lifted by magnets, tongs or rail clamps by
the head with spreader beams to ensure vertical lifts with horizontal rails. Rails shall be
stacked with the foot resting on a flat surface with head uppermost and vertical in
regular parallel layers with suitable separators between layers. The separators shall
support the rails at their ends and at 3 metres maximum centres. The rails shall be
aligned in the stack so that the rails do not touch or overlap. Rails within the same stack
should be of similar length. The rails shall not rest directly on the ground during
storage. The moveable length of a switch rail shall be strapped to the stock rails until
installed on the track.
6. Suitable measures shall be taken to prevent corrosion while fishplates and

fishbolts are in transit and in storage. All threaded components, bolts, nuts and similar
items shall be in covered waterproof and ventilated storage.
7. Stacks of sleepers shall consist of sleepers laid side by side but not
touching each other, in layers separated by two timbers laid along the length of the
stack in the rail seats. The timbers shall be of sufficient thickness to support the upper
layer of sleepers clear of the fastenings and components of the lower layer of sleepers.
8. Components shall be lifted only at points described in the preliminary

design or as directed by the Superintendent and shall be handled and placed without
impact.
9. Prepared ballast shall be handled in such a manner that is kept clean and
free from segregation and the accumulation of fines. Vehicles used for transportation of
ballast shall be clean and free from rubbish and substances, which may contaminate or
damage the ballast and must be in good condition to prevent leakage of waste material
during transportation.

1002.13 TRACK SYSTEM
1. All track system components shall be constructed in accordance with

PTA construction standards.
2. The railway track shall be Dual Gauge, consisting of three rails forming
Narrow Gauge 1067mm (NG) and Standard gauge 1435mm (SG), with the geometric
design to conform with the plans, profiles and typical cross sections produced during
the concept design.
3. The subgrade shall be compacted to a minimum of 99% maximum dry

density. The formation shall consist of a minimum of 6.0m wide formation capping of
230mm compacted thickness of crushed limestone, with a minimum of 175mm crush
rock ballast, under a Dual Gauge monoblock, prestressed concrete sleeper, with rubber
pads under continuously welded 50kg/m rail, held down by resilient “PR or Fastclip”
fastenings on insulated railpad.
4. Bearers are to be prestressed monoblock concrete type and fasteners are

to be a modern resilient type, with a positive fixing load appropriate for the application.
The contractor’s proposal for fastening supplier and type are to be submitted for
approval.
5. Turnouts are to incorporate the concrete bearers and be of a modern

tangential design commonly used by PTA, with swing nose crossings at the mainline
turnout for reduced vibration.
6. The rail terminal shall consist of three DG 50kg/m continuously welded

rail tracks embedded into the concrete track slab via a resilient, removable elastomeric
grout Sika Icosit KC 340/45 or similar approved.
The Contractor may propose alternatives with prices identified separately

for each alternative proposed.
7. For details of track foundations over the bridge and at transition slabs,
refer to the contract drawings.
1002.14 RAILWAY SIGNS AND MARKERS
1. Track speed restriction signs shall be in accordance with Appendix 7 of

the PTA Narrow Gauge Mainline Code of Practice - Track and Civil Infrastructure
(Draft Oct 1998).
1002.15 SPARES, SPECIAL TOOLS AND TEST EQUIPMENT
1. The Contractor shall obtain and store and prior to the issue of the
Practical Completion Certificate for the Works hand over to the Principal the spare
components. The components shall be identical to those provided in the Works.
2. The Contractor shall submit for Review by the Superintendent the storage
requirements and storage protection for the spare parts 6 weeks prior to the delivery.
The spare parts shall be manufactured, factory tested, suitably packed and identified for
prolonged storage, and delivered to Site within 30 days of the first Key Date for the
completion of trackwork. The Contractor shall deliver the spare parts to a location to
be identified by the Superintendent.
3. The Superintendent reserves the right to order spare parts to be inspected

or tested on receipt and then re-packed if approved after such inspection or testing.

4. The information supplied in respect of each spare part or special tool shall
include, but not be limited to, the following:
a. The manufacturer and his part number;
b. Space for PTA’s part number;
c. Description - a full description of the spare part, including a note as

to whether it is a sealed unit or whether it is an assembly or sub-
assembly which can be broken down into component parts;
d. Overall dimensions and weight including packing (if any) for shelf
space purposes;
e. The source - the manufacturer’s name and address; and
f. The normal manufacturing and shipment lead times for additional

quantities.
5. The form of presentation of the above information shall be subject to the

Review of the Superintendent.
6. A preliminary list of spare components is identified below. During the

procurement phase of the contract, the Superintendent will rationalise the spares list to
reflect the actual materials being supplied by the Contractor in the Permanent Works,
and instruct the Contractor as necessary.
1002.16 BUFFER STOPS
1. The contractor shall undertake the procurement of the buffer stops

through internationally recognised specialist suppliers of railway buffer stops. The
Contractor shall propose the suppliers to the Superintendent for review. The buffer
stops shall be based on existing products which have been accepted and installed on a
major railway.

Permanent Way Spares & Special Tools
Ref Item Unit

Rails
1.1 AS 50 kg/m Rail, plain un-drilled as-rolled grade Tonne
1.2 AS 50 kg/m Rail, plain un-drilled head hardened grade Tonne
1.3 AS 60 kg/m / AS 50 kg/m junction rail 6.0m long (matched pair) Pr
Rail Fastenings
2.1 Pandrol rail clip Nr
2.2 Pandrol AS 50 kg/m Insulator Nr
2.3 Pandrol AS 60 kg/m Insulator Nr
2.4 Pandrol AS 50 kg/m rail pad Nr
2.5 Pandrol AS 60 kg/m rail pad Nr
Rail Joints
3.1 AS 50 kg/m factory assembled bonded insulated joint Set
3.2 AS 60 kg/m factory assembled bonded insulated joint Set
3.3 AS 50 kg/m four hole joggle fishplate set with 4 G clamps per set for Set
emergency repair of broken welds
3.4 AS 60 kg/m four hole joggle fishplate set with 4 G clamps per set for Set
emergency repair of broken welds
3.5 AS 60 kg/m Fishplates and Fishbolts Set
Rail Supports
Concrete Sleepers
4.1 Concrete sleeper Nr
Turnouts
Switch assemblies, complete with all baseplates and rail fastenings
5.1 - 1:16 turnout left hand curved Set
5.2 - 1:10 turnout left hand Set
5.3 - 1:10 turnout right hand Set
Crossing assemblies, complete with baseplates and rail fastenings
5.4 - 1:16 swing nose crossing curved Set
5.5 - 1:10 fixed common crossing Set
Check rail assemblies, complete with supports, bolts and nuts
5.6 - 1:16 turnout left hand curved Set
5.8 - 1:10 turnout left hand Set
Sundry
6.1 Buffer stop spare parts as recommended by the manufacturer Set

CONSTRUCTION
1002.17 GENERAL
1. The Contractor shall not commence any installation of the Permanent

Works for a Section until the following have been carried out:
a. Method statements for the installation of the track for the Section
inspection and test plans have been Reviewed without objection by
the Superintendent;
b. The results of the track base survey, together with proposals for
correcting out of tolerance aspects have been Reviewed without
objection by the Superintendent.
2. Installation shall be carried out in accordance with the Contractor’s

method statements and manufacturer’s instructions.
3. The Contractor shall not operate any rail mounted equipment over any
track until the track has been properly assembled and is safe for the passage of the rail
vehicles. Before any such operations take place, details of the proposed vehicles to be
used, dimensions and maximum axle load shall be submitted to the Superintendent for
Review. See clause 1002.19 for exceptions to this, associated with the installation of
the track slab.
4. After installation of the trackwork, all components, including the rails,

track bed, ducts, troughs and drains, shall be made clean, using vacuum cleaners where
necessary. The Contractor shall conduct a rail to rail resistance test to determine that
the degree of cleanliness is compatible with the required level of electrical insulation.
Should this level not be achieved, such further cleaning as the Superintendent considers
necessary shall be carried out. The rail to rail resistance test shall be carried out in
accordance with the procedures laid down in Clause 1002.25.
1002.18 TRACK ALIGNMENT
1. The overall installation tolerances at the running rails wheel/rail interface

are to be checked at trackwork completion and again at Substantial Completion for each
Section of the Works. The general procedure for the tolerance checks shall be proposed
by the Contractor and Reviewed by the Superintendent.
2. The track gauge shall be measured 16 mm below the rail head and shall
conform to:
Track Gauge
TRACK HORIZONTAL TOLERANCE AT CONSTRUCTION TOLERANCE AT CONSTRUCTION
GEOMETRY (NARROW GAUGE) (STANDARDS GAUGE)
Tangent (horizontally straight) 1067.5mm (+1, -1) 1435mm (+2, -2)
track
Curved Track 1073.5 (+1, -1) 1441mm (+2, -2)
0 – 310 m radius [Note 1]
Curved Track 1070.5mm (+1, -1) 1435mm (+2, -2)
311 – 610 m radius [Note 2]
Curved Track 1067.5mm (+1, -1) 1435mm (+2, -2)
611 m radius or greater

Note 1 - On concrete sleepered track where the gauge requires to be increased between tangent track and
curves of radii less than 311 meters the gauge dimension shall be increased in two steps by the installation
of 1070.5mm gauge sleepers from the tangent point to a point halfway along the transition. On slab track
the gauge shall be increased uniformly along the length of the transition.
Note 2 - On concrete sleepered track for curves between 311 and 610 m in radius the gauge dimension
shall be increased in one step from 1067.5 to 1070.5mm at a point halfway along the transition. On slab
track the gauge shall be increased uniformly along the length of the transition.
Gauge widening where required (in curves) shall be achieved by increasing the distance from the track
design centreline to the gauge face of the inside (low) rail. The distance from the design track centreline to
the gauge face of the outer (high) narrow gauge rail shall remain at 533.75 mm.
3. The horizontal track alignment shall be constructed to tolerances of:
Horizontal Alignment
CRITERIA AT CONSTRUCTION
CONCRETE SLEEPERS CONCRETE SLAB
General Tolerance Design (+5 mm, -5 mm) Design (+3 mm, -3 mm)
Maximum Deviation in any +2 mm, -2 mm +2 mm, -2 mm
10 metres of track
DEFECTS LIABILITY TOLERANCES
General Tolerance Design (+5 mm, -5 mm) Design (+3 mm, -3 mm)
Maximum Deviation in any +5 mm, -5 mm +3 mm, -3 mm
10 metres of track
4. The vertical profile of the track shall be constructed to the tolerances

shown in the following table. The vertical profile of the track shall be designed and
constructed to the inner (low) rail on curves having superelevation.

Vertical Profile
Rail level – maximum deviation from Design Design
design rail level-open track (+3 mm, -3 mm) (+2 mm, -2 mm)
design rail level – at platforms, under (+2 mm, -2 mm) (+2 mm, -2 mm)
overhead structures etc See also Clause See also Clause
1002.11 1002.11
Surface – maximum deviation within +2 mm, -2 mm +2 mm, -2 mm
any 10 metres of track
design rail level-open track (+5 mm, -5 mm) (+2 mm, -3 mm)
design rail level – at platforms, under (+5 mm, -5 mm) (+2 mm, -3 mm)
overhead structures etc See also Clause See also Clause
1002.11 1002.11
Surface – maximum deviation within +5 mm, -5 mm +3 mm, -3 mm
any 10 metres of track
5. The superelevation shall be applied by raising the outer rail by the

specified amount above the inner (grade) rail. The minimum of 10 mm of
superelevation shall be applied to all curves up to and including 15,000 metres in
radius.
6. The superelevation shall increase uniformly from zero at the

commencement of the transition (starting at the junction with the tangent track) to the
full design value for the circular curve at the termination of the transition (at the
junction of the transition with the circular curve).
7. Superelevation shall be constructed to the tolerances shown in the

following table.
Superelevation
Maximum variation from design. +2 mm, -2 mm +2 mm, -2 mm
Maximum rate of change of variation +2 mm, -2 mm +2 mm, -2 mm
over any 10 metres of track
Maximum variation from design. +5 mm, -5 mm +3 mm, -3 mm
Maximum rate of change of variation +5 mm, -5 mm +3 mm, -3 mm
over any 10 metres of track

8. The track shall be constructed to the tolerances of cross level as shown in
the following table.
Cross Level
Tangent Track 0 mm (+2 mm, -2 0 mm (+1 mm, -1
mm) mm)
Maximum rate of change over any 10 +2 mm, -2 mm +2 mm, -2 mm
metres of track
Tangent Track 0 mm (+3 mm, -3 0 mm (+2 mm, -2
mm) mm)
Maximum rate of change over any 10 +5 mm, -5 mm +3 mm, -3 mm
metres of track
9. There are additional tolerances on the installation of some track features,

such as welds, insulated joints, fastenings, sleepers, derailment upstands etc., and these
are given in the paragraphs of this Technical Requirement, which describe those items
in detail and their installation.
1002.19 SLAB TRACK TOLERANCES
1. At the final rail alignment check of the slab track sections prior to
pouring the infill concrete, the rail alignment shall be checked using a self-propelled
track recording trolley, such as the Geismar ECG7 or similar testing procedure. Rails
are to be restrained to very tight tolerances to allow the passage of rail vehicle without
any movement, then be removed without movement and have restraints removed..
Final track testing should take place under track load in accordance with the following
section Testing and Commissioning.
2. The following parameters shall be measured by the track recording

trolley:

a. Distance along the track from the start of recording. This shall have
the option of being achieved either by a manual event marker or
automatically by a trigger device attached to the rail by a simple
means. The automatic system shall mark the continuous chart at 1
metre and 10 metre intervals to an accuracy of +/- 50mm;
b. Alignment of both rails to an accuracy of +/- 1.0mm;
c. Alignment of both rails to an accuracy of +/- 1.0mm;
d. Rail crown level of both rails to an accuracy of +/- 1.0mm;
e. Versine of both rails to an accuracy of +/- 1.5mm;
f. Gauge to an accuracy of +/- 1.0mm; and
g. Superelevation to an accuracy of +/- 1.0mm.
3. The data measured shall be presented on Site in the form of a clearly

visible continuous scaled trace and in a tabular spreadsheet format. The recorded data
shall also be stored in digital form suitable for on-Site computer analysis and down
loading to a standard PC for future analysis. The vital equipment such as the chart
recorder, computer etc shall be housed in an accessible waterproof cabinet which shall
be lockable. The data shall be recorded such that noise, electrical interference and data
at unreliable wavelengths shall be filtered out prior to data storage or data presentation.
4. The recorded data shall be used to produce for consecutive 200 metre
sections of track:
a. Track top filtered at 35 metre and 70 metre wavelengths;
b. Track quality standard deviations of the filtered track top data; and
c. A table of exceedances of preset critical values for rail top of both

rails, alignment of both rails, cant, gauge and twist.
1002.20 INSTALLATION OF RAILS
1. On main line tangent track and track of 400 metres radius and greater, the
running rail steel shall be as-rolled grade. On main line track with radius less than 400
metres, the running rail steel should be head hardened grade. Grades are as specified in
AS 1085.1.
2. Rails shall be moved from their storage location around the Site in a
manner that will not damage the rails. The Contractor shall submit to the
Superintendent full details of his proposed methods of handling, stacking, installing and
subsequent cleaning of the rails. Rails shall be moved longitudinally by a suitable
means that shall not cause damage to any part of the Works. The rails may be pulled by
winch or tractor provided they are on rollers.
3. Rails shall be unloaded without dropping and placed onto the concrete or
ballasted track with rollers, ramps or other devices, which shall prevent damage of any
kind to the rail, other components and the track structure.
4. Rail cutting shall be strictly controlled in order to achieve the economic

use of the rolled lengths as supplied. Rails which are to be cut by the Contractor shall
be cold sawn square across the rail and vertical. The maximum gap between two rails
when butted up will be 2mm. All burrs shall be removed from the rail and ends made
smooth. The cutting speed, coolant and rate of feed shall be controlled to prevent
overheating. The cutting of the rail by means of a flame torch is prohibited except for
the initial cut of a CWR de-stressing operation, which will be cut out after stressing.

5. No rail less than 9 metres long, except junction rails, shall be installed in
the track. The production of continuous rail lengths incorporating several short rails is
prohibited. No more than one short rail in any 180m length will be allowed.
6. Details of the proposed fixing and drilling to the rail shall be submitted to
the Superintendent for Review prior to procurement. All drilling of the rail shall be
centred on the rail neutral axis (except for fishplate and insulated joints). Holes 24 mm
diameter or less shall be drilled 1 mm smaller diameter than specified and reamed with
chamfer edges to the correct size or milled by rotary cutter. Holes larger than 24 mm
diameter shall be drilled 1mm smaller diameter than specified and cold expanded to the
correct diameter. The maximum diameter of hole shall not exceed 32 mm. The drilling
speed, coolant and rate of feed shall be controlled to prevent overheating.
7. The forming of holes in the rails by means of a flame torch or an

explosive punch is prohibited.
1002.21 RAIL WELDING
1. All main line tracks, yards and turnouts shall be continuously welded
except at insulated rail joints and other specific locations indicated in the Principal’s
detailed design or at the instruction of the Superintendent. Wherever possible, all rails
shall be welded by the flash-butt welding process. Where geometric constraints within
turnouts prevent the use of flash-butt welding plant, the aluminothermic welding
process shall be used.
2. The Contractor shall draw up a detailed schedule of locations at which

aluminothermic welding of main line rails is required and submit it for Review by the
Superintendent. No aluminothermic welding of main line rails shall be undertaken until
the schedule submitted has been Reviewed without objection by the Superintendent.
3. The Contractor shall submit a method statement and procedure manual

for the welding of rails by both the flash-butt and aluminothermic process to the
Superintendent for Review.
4. All welds shall be marked by such means that they can be identified for a
minimum of 5 years. The marking shall be a structured numbering system enabling
traceability to testing and weld parameters. The means of weld identification shall
permit traceability to the records and the information obtained at the time of production
of each and every weld. The means of weld identification shall be Reviewed by the
Superintendent.
5. Rail ends, which are to be joined by welding, shall not be holed. There
shall not be less than 9m between welds.
6. The straightness along the end 1.5m of the rail prior to welding shall be
measured as a chordal ordinate of a 1m straight edge and shall be;
Head; Sideways 0.5mm
Upwards 0.5mm
Downwards nil
Foot; Sideways 1.0mm
7. The rail ends shall be cut in accordance with Clause 1002.21 if necessary
to remove any dipped or hogged rail ends.
8. Any step between the rails across the weld in the ‘as welded’ condition
shall not exceed the following:

a. 0.5mm vertically on the running surface;
b. 0.5mm horizontally on the aligned gauge faces;
c. 2.0mm horizontally on the rail foot; and
d. 1.0mm horizontally on the rail foot where the weld falls on the rail
seat.
9. It is not acceptable to attempt to correct steps by pressing. If steps cannot

be corrected by profile grinding, the weld, including the heat affected zone, shall be
removed and the joint re-welded.
10. Machining or grinding to profile shall be carried out using equipment

Reviewed by the Superintendent. Profiling may be used to remove localised steps
across a weld joint. The profiling operation shall not cause any thermal or mechanical
damage to the rail. Profiling shall only take place on welded rails that have been
clipped down.
11. Profile finishing operations for vertical and lateral alignment shall be
carried out over the minimum length possible. The maximum length profiled shall not
exceed 450mm either side of a weld.
12. Any deviation from straight after any pressing and profiling operation has
been completed, measured relative to a 1.0 metre straight edge central to the weld, shall
not exceed the following, as shown below, regardless of cause:
a. 0.0mm to 0.3mm high vertically at the centre line of the rail head, no
dips allowed; and
b. +/-0.4mm maximum horizontally on both side faces of the rail head.
Tolerance for Rail Alignment at Finished Welds

13. The flatness of the weld shall also be checked relative to a 200mm
straight edge. The maximum gap in any position around the weld area between the
straight edge and the finished rail surface shall be 0.2mm on the rail head running
surface and gauge face. The correction of errors of this wavelength shall not be
corrected by profile grinding.
14. The Contractor shall submit for Review the details of the flash-butt
welding machine The machine shall comply with the following:
a. Be manufactured and supplied by a specialist rail welding

manufacturer and of a type and model certified for use on a Major
Railway;
b. Be capable of achieving the weld alignment specified above;
c. Shall incorporate an automatic programmed welding sequence for the

rail section and steel grade; and
d. Shall incorporate integral rail alignment and weld collar shearing.
15. Prototype tests shall be carried out on four welds manufactured

consecutively for 50 and 60 kg/m rail sections in each steel grade. Of these welds, two
shall be in the finished condition (welded, aligned and profile finished) and two welds
shall be in the "as welded" condition.
16. All of the welds shall be visually inspected for welding, trimming, profile
finishing defects, which could affect the subsequent service performance.
17. All the welds submitted in the "as welded" condition shall be measured to
determine the step across the joint, which shall not exceed the limits specified above.
The weld upset on all the welds in the "as welded" condition shall be measured and
shall not exceed:
a. 1 mm on aligned faces of the head, on the foot tips and on the upper
and under sides of the foot; and
b. 2 mm on all other surfaces.
18. In addition, there shall be no evidence in the upset of tearing, notches

from the extrusion or cracks or undercut or damage to the adjacent rail. Particular
attention shall be given to the quality of trimming on the underside of the rail.
19. All of the welds submitted in the "as-welded" condition shall be subject
to Slow Bend Tests using the procedure described in Appendix D of AS 1085.15, using
test equipment Reviewed by the Superintendent. All welds shall withstand the
minimum load given in the table below. The test shall continue until each weld has
fractured or the recommended load limit is achieved, at which point the test shall be
terminated and the load and mid-span deflection recorded. If failure occurs down the
weld line, the fracture surfaces shall be inspected. The size and location of weld
features shall be recorded. If failure occurs remotely from the weld, the fracture
surfaces shall be inspected to ensure the absence of "die burn" defects.
Slow Bend Test Loads for Flash-butt Welds
Rail Type as Minimum Load Recommended Load

Limit
50 kg/m KN
KN
As-rolled grade 1020 1130

Head hardened grade 1100 1210
20. The finished welds shall be measured to determine their alignment, which
shall not exceed the limits specified above. The finished welds shall be inspected using
full X-Ray inspection methods around the profiled finished area of the head, as well as
the web and foot. All welds in rails to be laid inside the slab are to be fully tested
before placement within the grooves. If any surface cracks, tears, inclusions, die burns
or other production defects are found, then the procedure shall be deemed unsuitable.
21. The variation in hardness shall be measured across the heat affected zone
of each of the two finished welds not more than 5.0mm below the running surface. The
Brinell Hardness test, carried out generally in accordance with AS 2205.6.1, shall be
used. The hardness variation across the samples shall comply with the following
requirements:
1. Minimum HBW hardness = P - 20 HBW
2. Maximum HBW hardness = P + 60 HBW
Where P = average parent material hardness.
22. One of the finished welds shall be subjected to a fatigue test using the
procedure described in Appendix C of AS 1085.15, using test equipment Reviewed by
the Superintendent. On completion the weld shall be subject to a Slow Bend Test in
accordance with the requirements given above.
23. The welding parameters shall be determined during procedural trials and
prototype test welds and submitted for Review by the Superintendent. Once the
welding parameters have been ‘Reviewed without objection’ by the Superintendent, the
procedure shall not be changed without re-submission for Review by the
Superintendent. Welding shall be carried out, and parameters monitored and recorded,
in accordance with the list below. Records shall be referenced to the appropriate weld
and submitted to the Superintendent. The parameters to be recorded are:
a. Welding current;
b. Upset force or pressure;
c. Displacement;
d. Welding time;
e. Welder plant programme identification and setting details; and
f. Weld location and identification.
24. The flash-butt weld operator shall be trained and certified by the flash-
butt welding machine supplier or other suitably qualified instructor. The Contractor
shall submit for review for Review to the Superintendent the course syllabus and
examination proforma. Prior to undertaking any welding on site, the operator shall
perform two welds inclusive of final profile grinding, in the presence of the
Superintendent, which shall meet the following tests and criteria:
a. Visual examination;
b. Weld alignment, including profiling, in accordance with Paragraphs

above; and
c. Slow Bend Test in accordance with the requirements given above.

25. The flash-butt weld operator shall be re-certified by the supplier or
suitably qualified instructor on an annual basis.
26. All of the finished flash butt welds shall be inspected using the magnetic
particle inspection method around the profiled finished area of the head, as well as the
web and foot. If any surface cracks, tears, inclusions, die burns or other production
defects are found, then the procedure shall be deemed unsuitable.
27. No flash-butt weld shall be produced as part of the Permanent Works

until the Welding Prototype test welds and the weld operator certification welds have
been Reviewed without Objection by the Superintendent.
28. When using long welded rail, where internal string flash butt welds fall
on a rail seat, the sheared weld collar on the rail foot shall be dressed by hand grinding.
29. Rails to be installed in the slab section shall be welded into full length
strings before being positioned in the grooves. All welds must be flash-butt, no
aluminothermic welds are to be used in these sections.
1002.22 ALUMINOTHERMIC WELDING
1. Technical requirements and testing for aluminothermic welding shall be

in accordance with Table 4.2 and using the desirable construction standards of Table
4.5 of the PTA Narrow Gauge Mainline Code of Practice - Track and Civil
Infrastructure (Draft Oct 1998) and AS 1085.15 - 1995, “Railway permanent way
material, Part 15: Aluminothermic rail welding.
2. The aluminothermic welders shall be trained and certified, the Contractor

shall submit for review for Review to the Superintendent the course syllabus and
examination proforma. Prior to undertaking any welding on site, the operator shall
perform two welds inclusive of final profile grinding, in the presence of the
Superintendent. Aluminothermic welders shall not be permitted to weld without direct
supervision from a qualified welding supervisor until they have a minimum of three
months continuous welding experience.
3. No aluminothermic weld shall be produced as part of the Permanent

Works until the Prototype welds and the weld operator certification welds have been
Reviewed without Objection by the Superintendent.
4. Aluminothermic welded joints shall be in pairs and within the same

sleeper bed however this shall not constitute a requirement to add a weld to make a pair.
1002.23 RAIL JOINTS
1. All rail joints shall be installed in accordance with Paragraphs 3.12.7 and
3.12.9 of PTA Narrow Gauge Mainline Code of Practice - Track and Civil
Infrastructure.
2. Insulated joints shall be installed where determined by the Contractor’s

design to meet signalling and level crossing protection needs. The assembly and
installation of insulated rail joints shall be strictly in accordance with AS 1085 - part 12
together with the joint assembly manufacturer’s recommendations. All joints showing
faults shall be replaced by cleaning the rail and joint bars back to bright metal and
installing a new joint kit. Any factory assembled joint that fails during the defects
liability period shall be replaced by cutting out both plug welds.

1002.24 FINAL FASTENING DOWN OF RAILS
1. The Contractor shall keep a complete record of the mean rail temperature
and air shade temperature at the time of finally fastening down all rails and provide a
copy to the Superintendent within seven days of fastening down. In the case of rails
which have been fastened down prior to welding, the time of final fastening shall be
taken to be the time the connecting weld is made.
2. Rail temperature shall be measured with thermometers designed to

measure rail temperature and they shall be used in accordance with the manufacturers’
instructions. The thermometers shall be checked at regular intervals, as required by the
Superintendent, to ensure accuracy of the temperature recorded to +/-2oC.
3. The rails shall be finally fastened down at a neutral or stress free rail
temperature of 40oC ± 2 oC. Achieving the neutral temperature for final fastening
down of the rail shall be either by natural means or artificially by the use of hydraulic
rail tensors.
4. The final fastening down shall not be undertaken until the track is in the
design horizontal and vertical location, the full ballast profile has been formed and
consolidated and the method of working for final fastening down has been Reviewed
without objection by the Superintendent.
5. The minimum anchor length should be at least 90m if tensors are used to
obtain the stress free temperature. This should be increased to at least 135m at rail
movement joints. If this minimum anchor length cannot be achieved, then the absolute
minimum anchor length shall be calculated using a maximum creep resistance of 5
kN/fastener or as directed by the Superintendent.
6. Maximum length of destress in one operation is 400m on straight track,

300m on curves radius 800m or greater and 200m on curves sharper than 800m radius.
7. “Tell Tale” markers to monitor free rail movement shall be set up at

maximum 100 metre intervals throughout the length being finally fastened down.
8. Rails shall be finally fastened down in pairs forming a section of track.
9. The final welding of joints within turnouts items shall be undertaken in a

sequence Reviewed by the Superintendent and within the stress free temperature range.
10. When finally fastening down track running through a turnout by artificial
means, the length of turnout from the stock rail joint to the first switch heel block shall
be laid at the stress free temperature.
11. Rails may be laid outside the stress free range but shall be released and
refastened before the track is offered for final acceptance.
12. After final fastening down of the rails in accordance with the above
Paragraphs, no further adjustments of the rails shall be made, without prior Review by
the Superintendent.
1002.25 ELECTRICAL REQUIREMENTS IN TRACK CIRCUITED

TRACK
1. The electrical insulation of the running rails is provided in stages.

a. The rail shall be electrically separated from the rail clip and shoulder
by an insulator and from its immediate support surface by a pad,
except for switch rails on slide baseplates;
b. Within the concrete, the shoulder shall be electrically separated from

the reinforcement by physical separation;
c. Cast baseplates shall have plastic ferrule lined holes and LDPE
bedding shims; and
d. Bonded baseplates provide insulation between the top plate and

baseplate frame.
2. As a result of these measures, the unbonded rail to reinforcement

resistance shall not be less than 10 ohm-km and the minimum unbonded rail to rail
resistance shall be 20 ohm-km.
3. Tests to check these values shall be carried out after track assembly but
before bonding of the track.
4. The following equipment shall be used to measure rail to rail resistance,

and rail to reinforcement resistance for slab track:
a. Electronic multi scale voltmeter and ammeter which have negligible

effect on current passed;
b. Battery (30Amp-hr) of sufficient voltage to register a voltage at the

far end of the rail to rail test; and
c. Test leads and on/off switch.
5. The rail resistance (Rr) is calculated on the basis of:
Rr = VxL/A
Electrical Resistance Test Circuit for Slab Track

6. A rail to rail test (support media resistance) shall be undertaken on all
track lengths over 50 meters as a check of the leakage of current through the trackbase
and rail fastening system from one rail to another. This shall be undertaken after the
track has been completed and cleaned but before it is finally formed into a continuous
length and all the bonds are attached.
7. The test shall be undertaken as shown below and the minimum resistance
shall be 20 ohms km of single track.
8. The maximum length of a section of track under test shall be 1000 m or

as dictated by the voltage used and the requirement to practically read the voltage drop
over the test length.
9. The following procedures shall be followed for the rail to rail resistance
test:
a. The equipment shall be connected as shown below;
b. Rust and dirt shall be removed from all contact points; and
c. The following shall be recorded in an approved format:
− ammeter reading (A) amperes;
− voltmeter reading (Vf and Vr) volts; and
− length of track under test (L) Metres.
10. The rail to rail resistance shall be calculated as follows:
R = (Vf+Vr) x L ohm km
2A x 1000
Rail to Rail Electrical Resistance Test
1002.26 INSTALLATION OF TURNOUTS
1. The Contractor shall assemble and install the turnouts and layouts strictly
in accordance with the detailed working drawings, alignment and tolerances supplied
by the turnout supplier.

2. Installation shall be generally in accordance with Clause 1002.26 of these
Technical Requirements. Rails in turnouts shall be laid in accordance with Clause
1002.20 of these Technical Requirements.
3. The switch toes shall be square across the through track. The switch rail
shall fit properly against the stock rail and bear evenly against the distance blocks.
When the switch blade or swing nose is in the open position, the minimum flangeway
clearance between the stock rail and the switch rail at the commencement of the rail
head planing shall be 50mm. The minimum movement of the switch rail at the switch
toe shall be 150mm.
4. All Point Operating Mechanisms shall be supplied and fixed by the

Contractor, with details to be co-ordinated with the signalling design.
5. Subsequent to installation, all sliding surfaces of the slide baseplates shall

be free of all loose rust and foreign matter.
6. The flangeway gap for common crossing check rails shall be set to the
design value.
7. Rail joints shall be of the type and at the locations indicated on the
supplier’s drawings and in accordance with Clause 1002.15.
8. When a pair of switches has been completely assembled and installed,

they shall be firmly clamped and locked. The equipment to clamp and lock the
switches shall be provided by the Contractor and submitted for Review by the
Superintendent. No train shall operate over switches until they have been clamped and
locked. Switch clamps shall be retained until the points operating mechanism is fully
installed and commissioned for manual operation.
9. As part of the trackwork completion works, the turnouts shall include all
the necessary operating mechanism to allow the manual operation of the switches by
Works Trains operators. Point motors shall be fitted and locked in motor operation
mode with a master key padlock. The key and lever for manual operation shall be
issued to the Principal.
10. After installation of a turnout layout, the Contractor shall thoroughly

clean the layout including the removal of all debris in flangeway gaps, and at all gaps
between rail fastenings and pads.
11. The bolts and metal washers fastening switch and crossing units together
shall be removed, wire brushed, coated with a suitable oil based compound, replaced
and re-tightened to the correct torque. Only one bolt shall be removed at any one time
in the unit.
1002.27 INSTALLATION OF BALLASTED TRACK
1. The Contractor shall install the ballasted track as indicated on the

Principal’s Drawings on the formation constructed in accordance with the Technical
Requirements for Civil Works and Structures.
2. Sleeper and bearer spacing shall be as follows:
Location Description Spacing (Centres) No. per km

mm
Mainline - tangent 700+/-20 1410-1450
Curves 300m radius and above
Curves less than 300m radius 600+/-20 1650-1690
3. Additional spacing requirements are as follows:
a. Turnouts to plain line 5m @ 600mm; and
4. The Contractor's methods for installing and assembling the main ballasted
track shall be such as not to foul, disturb or cause any damage to manholes, catch-pits,
buried pipes and ducts, drains, safety fences, cables, or cable troughs etc. The
Contractor shall make allowance for the presence of partially constructed items such as
lighting posts, draw pits, concrete support structures, acoustic barriers, safety fences
etc. as indicated in the Principal’s detailed design.
5. Sleepers shall be laid normal to the centre line of the track and shall not
be more than 10mm out of square across the gauge lines. Sleeper spacing tolerance is
+20, - 20 with no less than 1410 and no more than 1450 sleepers in any one kilometre.
The seating on the sleepers and the underside of the rail foot shall be free of loose dirt
and foreign matter when the rail is fastened down. The sleepers shall be handled and
laid with appropriate equipment. They shall not be subjected to blows from a hammer
or any other tool or appliance whilst being handled, laid or aligned. Sleepers shall not
be dropped.
6. The track laying method ie tracklaying machine or other plant shall be

selected by the Tenderer and submitted to the Superintendent for approval. The track
laying method selected shall achieve the specified track structure.
7. Rails shall be laid in accordance with Clause 1002.20 of these Technical

Requirements.
8. Further ballast shall be distributed following the completed track

assembly. It shall then be spread, roughly trimmed and consolidated to give the correct
track level, cant and alignment within the specified tolerances. The final track ballast
shall be consolidated beneath the sleepers with heavy duty track mounted tamping
equipment capable of meeting the specified track tolerances and suitable for the
specified ballast.
9. The Contractor shall determine the tamping variables, including rate of

advance, number of passes, number of insertions per sleeper or bearer, length and
number of tines, and frequency of vibration for the tamping equipment to thoroughly
consolidate the ballast during preliminary and final levelling and aligning work.
10. Each lift of ballast on plain track shall be thoroughly consolidated for a
length of 450mm each side of the rail. Both ends of the sleeper, inside and outside of
the rails, shall be tamped simultaneously. The ballast under the centre of the sleeper
shall not be consolidated.
11. When jacks are used to lift the track, they shall be placed close enough
together to prevent undue bending of the rail or strain on rail joints or distortion of
switch and crossing units. All rails shall be raised at one time and as uniformly as
possible.
12. Sleepers which have been moved out of position during lifting operations
shall be corrected. Rail and rail fastenings which become loose during lifting
operations shall be corrected.
13. When the track has been brought to the correct alignment and level and
the ballast under the sleepers is fully consolidated, the ballast between the sleepers and
within the ballast shoulders shall be consolidated and trimmed to profile.
14. Ballast shoulders shall be formed in accordance with the Principal’s

Drawings.

1002.28 INSTALLATION OF SLAB TRACK
1. Rails are to be fully welded and weld testing completed before placement
in prepared grooves.
2. Rails shall be chocked and shimmed as required to achieve level and

alignment tolerances given in 1002.18.
3. As rails are to be fully restrained and will be affected by heat of hydration

of the grout, rail temperature at installation may be in the range 30-40 deg C.
4. Before placement of grout the rails shall be surveyed to sufficient

accuracy to ensure adherence to the required tolerances. These shall apply to each
gauge and shall record.
a. Guage
b. Cant
c. Twist in 5m track section
d. Level
e. Versine on 5m chord.
5. Survey records shall be approved by the Superintendent before placement

of grout.
6. The common rail shall be grouted first.
7. Before initial set of the grout, alignment is to be checked in case of

disturbance of the rail.
8. The Contractor shall submit his proposals for the correction of any aspect
exceeding the permitted tolerances.
9. The Contractor shall submit his proposals for the correction of any aspect
exceeding the permitted tolerances.
1002.29 INSTALLATION OF BUFFER STOPS
1. The buffer stops shall be installed to meet the performance requirements

specified in Clause 1002.17 and Principal’s Drawing R-02-G-002, in accordance with
the manufacturers’ recommendations and subject to the Superintendent’s Review.
2. The friction buffer stops shall be assembled on the track in strict

compliance with the manufacturer’s instructions and to PTA acceptability. The rails
over which the sliding friction buffer stops will operate shall have welded joints which
have been ground to the full head and web profile.
1002.30 INSTALLATION OF RAILWAY SIGNS AND MARKERS
1. Permanent way signs and markers are to be installed as follows.

a. Survey Bench Mark Plates, at each kilometre and half kilometre
marker on the line;
b. Track Speed Restriction Signs, at each change of design speed along

the main line and loop, including turnout leg speeds, in accordance
with the standards set down in Appendix 7 of the PTA Narrow
Gauge Mainline Code of Practice – Track and Civil Infrastructure;
2. The markers shall be fixed to the trackbed or adjacent structure on slab

track. On ballasted track they shall be fixed to an adjacent structure or mounted on a
general purpose steel post where there is no suitable structure.
TESTING AND COMMISSIONING
1002.31 GENERAL
1. Testing and Commissioning shall be carried out generally in compliance

with this section.
2. Additional testing requested by the Superintendent shall be at the expense

of the Principal except where there is a failure by the Contractor to meet specified
requirements, in which case the cost of testing and replacement shall be borne by the
Contractor.
3. The Contractor shall be responsible for all materials, consumables, test

equipment, labour and facilities for the testing, unless otherwise specified.
4. Unless specifically stated otherwise, all testing required shall be carried

out at independent commercial testing laboratories. Laboratories shall be certified to
ISO 9001 or equivalent and hold appropriate accreditation. The Contractor shall submit
details of the proposed testing facilities for Review by the Superintendent 60 days prior
to undertaking any testing.
5. Copies of all Design Documents shall be provided. Design Documents

shall be sufficient to enable the Superintendent to review design, manufacture,
construction, assembly, installation, workmanship, clearance, tolerance, and functioning
of the item.
1002.32 PLANNING
1. The Contractor shall submit for Review by the Superintendent the Testing
and Commissioning Plan, one month before undertaking any tests. The plan shall
detail:
a. All tests to be carried out;
b. Scheduled test dates;
c. Location of the tests;
d. Functions to be tested and requirements to be demonstrated; and
e. Parties responsible for the testing.

2. The Superintendent will indicate which tests he intends to witness and
which test specifications and reports shall be submitted for Review. Without prejudice
to any other provisions of the Contract, the Superintendent reserves the right to witness
any or all tests, and to require submission of any or all test specifications and reports.
The Superintendent reserves the right to reasonably call for additional tests if
considered necessary.
3. The Contractor shall re-issue the Testing and Commissioning Plan

monthly thereafter, until completion of all tests, updating all information as test
scheduling is confirmed and tests are carried out, annotating which tests the
Superintendent will witness and which test reports shall be submitted. No test date shall
be changed without the Superintendent having a minimum of 15 days notice.
1002.33 FACTORY ACCEPTANCE TEST (FAT)
1. For any tests required on a major product; such as the rail, sleepers,
bearers, turnouts, baseplates, etc, no testing shall be carried out until the test
specification has been Reviewed without objection by the Superintendent. Test
specifications shall include sample test certificates which shall clearly indicate the
required values and tolerances adopted.
2. Where material or details used in this Contract are not covered by

separate specifications, samples of such materials shall be tested, if required by the
Superintendent. All material or details represented by samples, which are found to be
non-compliant, will be rejected.
3. The Contractor shall replace any material or detail destroyed in the

process of testing if it forms part of the Permanent Works.
4. As part of the verification process, Prototype Tests shall be carried out to

demonstrate that the products are fully in compliance with the requirements specified in
the Technical Requirements.
5. Pre-production samples of track components manufactured using the

facilities proposed for the production manufacturing shall be tested in accordance with
the appropriate Technical Requirements or the relevant technical standard.
6. First Article Inspection (FAI) shall be performed on, at a minimum, the

following components, but others will be advised by the Superintendent following the
Review of the Contractor’s Testing Plan:
a. Resilient baseplates;
b. Concrete sleepers and bearers;
c. Turnouts;
d. Rail; and
e. Components interfacing with the rail (rail fastening systems).
7. Type tests shall be carried out on subassemblies of components to prove

that the subassembly has been assembled in accordance with the Principal’s or
Supplier’s Drawings and that the component parts are compatible and will function
collectively as required by the Technical Requirements. The Contractor shall submit to
the Superintendent for Review details of the tests to be undertaken.
8. Type tests shall be carried out on the following subassemblies:

a. All rail fastening assembly types on sleepers, bearers and baseplates;
b. Slab track components where applicable (e.g. LVT blocks, boots and
pads); and
c. All turnouts.
10. During the product manufacturing phase routine testing shall be

undertaken as defined for specific components in Clause 1002.12 – 1002.17 or
appropriate technical standard.
1002.34 INSPECTION
1. Without prejudice to any other provisions of the Contract, the

Superintendent shall have free access to the Contractor's and his manufacturers’
premises throughout the Contract, for the purpose of reviewing and inspecting the
design and manufacture processes.
2. The Contractor shall propose a structured set of inspection hold points

with the tender for Review by the Superintendent. The hold points shall be structured so
that a formal hold point is allowed for each significant item of procurement and
installation. At each hold point, the Superintendent shall hold a formal inspection, or
advise that the inspection has been waived. The First Article Inspection of all
manufactured Permanent Materials shall be a hold point unless advised otherwise by the
Superintendent.
1002.35 SITE ACCEPTANCE TEST (SAT)
1. During the installation process, tests shall be undertaken to prove that the
Technical Requirements are being met. In addition to the standard quality control test
on the materials, a check on assembly and tolerances shall include:
a. Alignment test;
b. Weld tests; and
c. Electrical resistance tests.
2. Partial Acceptance Tests shall be undertaken for each Separable Portion

of the Works or sub-section of the Works, subject to Review by the Superintendent and
shall consist of the submittal of all Product Manufacturing Tests, defined in Clause
1002.12 – 1002.17 and Installation Tests, defined in Clause 1002.31 and a formal
inspection by the Superintendent.
3. The System Acceptance tests shall be deemed to have been performed

upon successful completion of the Partial Acceptance Tests on all Sections of the
Works and a visual inspection.
1002.36 COMMISSIONING
1002.36.01 TESTS ON COMPLETION
1. The following tests and inspections shall be undertaken to confirm the

full compatibility of the Works with other disciplines within this Contract, to
demonstrate the completion of the Works and that it is ready for train trials etc.
2. Commissioning shall also be in accordance with Series 100 General

Management Requirements.

3. The trackwork shall be subject to a full inspection by the Contractor in
the presence of the Superintendent and representatives of the Principal inclusive of the
Structural Gauge test identified in Clause 1002.36.02. The Contractor shall carry out
such remedial work as is found to be necessary.
4. All switches shall be tested following the installation of the point motor
and detection equipment. The test shall include the following:
a. All switches shall be subject to a test for the force required to throw
the switch;
b. The switch shall be thrown in both directions a minimum of ten times

and the peak force required to throw the switch recorded. The peak
force recorded for each direction shall not exceed the maximum
specified by the manufacturer; and
c. Should the force exceed the maximum permitted, the Contractor shall
identify and rectify the fault prior to repeating the test.
d. A Track Recording Car shall be used to confirm compliance with

tolerances prior to Commissioning or Practical Completion,
whichever occurs first and at the end of the defects liability period.
5. Following each pass of the test train, the Contractor shall check that the
trackwork has not deviated from its position as fixed, and that all fastenings and fittings
are tight and in their correct position.
6. On completion of testing up to the line speed, the Contractor shall submit

details for Review by the Superintendent demonstrating:
a. That the level and alignment of all parts of the track when unladen
remain within the installation tolerances given in Clause 1002.18;
b. That the track has not moved laterally or vertically under the passage
of the test train by more than the normal elastic deflection of the
components. The extent of any vertical movement under traffic shall
be checked by the Contractor, and
c. That the trackwork is free from defects or damage and is in all

respects in accordance with the Specification and safe for full railway
operations.
7. Prior to the issue of the Certificate of Practical Completion for the Works
or a separable portion, the Contractor shall undertake a final adjustment and tightening
of all fixings of the Permanent Works. This shall include but not limited to:
a. Adjustment of rail movement joints;
b. Adjustment of switches;
c. Check and tighten all bolts; and
d. Carry out any other tests or remedial or repair work as may be

necessary or as directed by the Superintendent.
8. The Contractor shall assist in the train trials and undertake the
Operational Maintenance Support as defined by the Principal.
9. The Contractor shall at least 14 days prior to the Practical Completion of

the Works submit for Review a Commissioning Plan Compendium, recording all testing
carried out, functions and performance demonstrated, reports produced and Reviewed
by the Superintendent. This shall include all System Performance Demonstrations.

1002.36.02 STRUCTURE GAUGE CHECK
1. All fences, masts, posts, structures and the like within 3m of the track
centreline shall be surveyed and clearance supplied to PTA-WA.
1002.36.03 OPERATION AND MAINTENANCE MANUALS
1. The Contractor shall provide an Operation and Maintenance Manual

including all Works-as-Executed Drawings in accordance with the requirements of
Series 100 for the following:
a. Turnouts;
b. Rail fastening system; and
c. Sliding friction buffer stops.
2. The Operation and Maintenance Manuals shall include but not be limited
to, detailed description, procedures and materials for the following as appropriate:
a. Assembly and dismantling;
b. Insitu and workshop repair;
c. Routine inspection and maintenance;
d. Detailed inspection and maintenance;
e. Replacement;
f. Welding technique;
g. Specialist tools required;
h. Safety; and
i. Spares inventory.
3. The manual shall include a full parts list, detailed down to nut and bolt
size, manufacturer, part number and the design torque for bolts.
4. The Operation and Maintenance Manuals shall reference all relevant

specifications and drawings.
5. A draft copy of the Operation and Maintenance documentation for the

track relevant to each separable portion shall be submitted before Practical Completion
of each separable portion.
6. The final copy shall be submitted 1 month after the Key Date for first
Practical Completion of a Separable Portion. The final document shall incorporate all
comments identified by the Superintendent and information gained during the Tests on
Completion.
7. In developing the O & M Manual, the Contractor shall consult with the
PTA permanent way maintenance manager and ensure compatibility of maintenance
methods, techniques, available and required plant and equipment. The Contractor shall
incorporate details and maintenance of all proprietary permanent way components.

1002.36.04 NOT USED
1002.36.05 PATROLLING AND INSPECTION
1. Regular patrols shall be undertaken along the full length of the Works,
with a minimum visual inspection twice weekly for ballasted plain track and all turnouts
and weekly for non-ballasted plain track. Routine visual track inspections shall identify
defects which, if uncorrected, could affect the safety or reliable operation of the
railway. Particular attention must be paid to new defects and to developments of
existing defects.
2. When, in carrying out visual track inspections, defects in the works of

others are observed, such defects shall be reported.
3. Items to be monitored during routine inspections shall include:
a. Obstructions of the line;
b. Gauge, cross level and twist in plain line, in turnouts at tips of

switches, at all switch drives, at the fixed heel blocks on both routes,
at the flangeways at the wing and check rails of crossings. In
addition, in turnouts, the distance between the check rail rubbing face
and opposite running edge (including crossing nose) shall be
measured;
c. Level and alignment;
d. Wheel/rail contact marks (for evidence of wheel slip);
e. Obstructions in switches and flangeways;
f. Visible rail defects, including cracks and breaks;
g. Defective or damaged components, including broken sleepers,

fishplates, detached signalling or electrical bonds, defective switch
rails, damaged stretcher bars, rail movement joints, crossings;
h. Loose or missing bolts (including fishbolts and baseplate fixings) and

fastenings;
i. Emergency clamped fishplates (including number of clamps present);
j. Insulated rail joints, including lipping of rail ends, damaged end-

posts and defective insulation;
k. Expansion gaps, including rail creep and rail movement joint

settings;
l. Longitudinal position of check rails, to ensure that crossing noses are

covered;
m. Gauge widening;
n. Misalignments and dips in the rail surface;
o. Deficiencies in ballast provision (especially the profile in cribs and

shoulders);
p. Signs of ballast voiding, slurrying or effects of inadequate drainage

on ballast conditions;

q. Track drainage (signs of flooding, damaged manhole covers etc.);
r. Permanent way materials interfering with signalling or other track-

mounted equipment;
s. Rail-carrying structures (e.g. track slabs) and associated components;
t. Refuges and walkways (particularly for obstructions); and
Lineside signs, including temporary speed restriction equipment.
4. Where practicable, adjustments shall be made and basic maintenance

shall be performed and minor defects, such as flangeway or switch toe obstructions and
loose or missing fastenings, shall be rectified during the inspection.
5. Where defects are discovered or maintenance requirements identified

which cannot be rectified during the inspection, the Contractor shall submit for Review
by the Superintendent a plan for appropriate remedial action at the earliest available
opportunity.
6. The visual inspection regime shall include auditable arrangements to

record defects found and work programmed and carried out. Records shall be retained
and passed to the Superintendent on Practical Completion of the separable portion.
1002.36.06 DETAILED INSPECTIONS
1. In addition to the routine visual inspection of all switches, detailed

inspection of switches for wear on the switch and/or stock rails shall be carried out at
intervals not exceeding three months. Detailed inspection of crossings shall be carried
out at intervals not exceeding 6 months. All switches shall be inspected to ensure that
the clearance at the switch toe between the switch and stock rail when in the open
position is maintained within the specified tolerances. The correctness of the check and
wing rail flangeways, track and check rail gauge shall be monitored to enable corrective
action to be taken to prevent damage to the crossing nose.
2. Switches, in running lines, when secured out of use shall have their
scotches, locks etc specially inspected at intervals not exceeding two months. A record
shall be kept of each inspection.
3. Plain rails shall be inspected for sidewear at maximum intervals of six

months on curves where permanent speed restriction is enforced due to curvature.
Sidewear shall be measured at a minimum of one location per 100m along the curve on
each track. These locations must be where, on visual examination, the sidewear appears
worst. They shall be marked and their position recorded so that subsequent
measurements are taken in the same place to enable accurate assessment of the wear
rate. Written records of sidewear locations, together with details of the severity of the
sidewear and the date of measurement, shall be forwarded to the Superintendent.
4. An inspection shall be carried out after any flooding, when the water has
subsided, to check for collection of debris in flangeways, point openings, between
floating slab units and at track-mounted equipment, undermining due to ballast washout
and increased slurrying of formation.
5. Buffer stops shall be inspected every six months. The inspection shall
include general condition, any evidence of collision damage, warning lights and, in the
case of a sliding buffer, any need for it to be returned to its normal position, condition
of holding-down bolts, and cleanliness of the running rails behind the buffer. The
details of the inspection shall be recorded together with any repairs carried out.

6. Where practicable, adjustments shall be made, maintenance shall be
performed and defects shall be rectified during the detailed inspections. Where defects
are discovered or maintenance requirements identified which cannot be rectified during
the inspections, the Contractor shall submit for Review by the Superintendent a plan for
appropriate remedial action at the earliest available opportunity.
7. The inspection regime shall include auditable arrangements to record

defects found and work programmed and carried out. Records shall be retained and
passed to the Superintendent on substantial completion.
8. Where additional ballast is required to restore the track alignment and

stability due to the effects of sub-ballast settlement, the Contractor shall submit full
details of the proposed remedial works to the Superintendent for Review before
undertaking the work.
9. Where the Contractor in his inspections advises the Superintendent of a

defect requiring remedial works that cannot be reasonably undertaken during the
inspection, the Superintendent shall determine if these are a defect in the Contractor’s
work or wear and tear from railway traffic. The Contractor shall be responsible for
remedial work on any defects, and is to implement the work with due regard to
operational safety of the track.
10. Where the remedial work is determined as wear and tear due to rail traffic
or the movement or settlement of the track base, the Superintendent shall instruct the
necessary remedial works and the Contractor shall implement with due regard to
operational safety.
1002.36.07 RAIL GRINDING
1. The Contractor shall carry out an initial rail grind prior to the start of
Timetable Operations. The timing of the operation shall be identified based on the
Works Program, following coordination with the Railway Systems works and subject to
Review by the Superintendent.
2. The Contractor shall make all arrangements for a rail grinding vehicle and
operators to be made available and delivered to the Works by road or using the existing
rail connections, subject to availability. The Contractor shall provide all resources in
the form of labour, plant and consumables to prepare the vehicle for operation.
3. The Contractor shall submit for review the details of the rail grinding vehicle. The
machine shall be manufactured and supplied by a specialist rail grinder manufacturer,
of a type and model certified for use on a Major Railway and suitable for all rail
sections and grades used in the Contract.
4. The rail grinding vehicle operator shall be trained and certified by the
supplier or other suitably qualified instructor. The Contractor shall submit for review to
the Superintendent the course syllabus and examination proforma. Prior to undertaking
any grinding on site, the operator shall perform a trial grind, in the presence of the
Superintendent.
5. The operation and maintenance of the vehicle, fuel, oil, lubricants and
grind stone replacement will be undertaken by the Contractor, including the provision
of all resources necessary for:

a. Gaining access to the track;
b. Coordination with Railway Systems works;
c. Pre & post grind inspection;
d. Flag men, train protection and fire suppression, management and

control;
e. Post grind cleaning and waste disposal; and
f. Coordination and protection to track side equipment.
6. All main line trackwork shall have a nominal 0.1 mm surface grind. The
profile shall meet the standard rail head from 50 degrees gauge side to minus 10
degrees field side. The Contractor shall carry out a pre-grind inspection and submit his
grinding proposals for review by the Superintendent.

ANNEXURE 1002A
EXTENT OF EXISTING TRACK REMOVAL

S PECIFICATION 1003
OVERHEAD LINE WORKS

CONTENTS
Clause Page
GENERAL .................................................................................................................................................. 1
1003.01 DESCRIPTION OF THE WORKS...................................................................................... 1
1003.02 WORK INCLUDED ............................................................................................................ 1
1003.03 TECHNICAL SPECIFICATIONS....................................................................................... 1
1003.04 RELEVANT PTA STANDARDS AND DRAWINGS. ...................................................... 2
1003.05 AUSTRALIAN STANDARDS ........................................................................................... 2
1003.06 PUBLIC TRANSPORT AUTHORITY STANDARDS AND CODES OF PRACTICE ... 2
1003.07 DEFINITIONS & TERMS.................................................................................................. 2
1003.08 PERFORMANCE ................................................................................................................ 3
1003.09 DOCUMENTATION........................................................................................................... 3
1003.10 EXISTING SYSTEMS......................................................................................................... 3
1003.11 INTERFACES...................................................................................................................... 4
CONSTRUCTION ..................................................................................................................................... 4
1003.12 DESCRIPTION OF OVERHEAD WIRING SYSTEM WORKS ....................................... 4
1003.13 ASSOCIATED WORKS...................................................................................................... 4
1003.14 CONSTRUCTION ............................................................................................................... 5
1003.15 CLEARANCES.................................................................................................................... 6
1003.16 EARTHING AND BONDING ............................................................................................ 6
1003.17 MAST FOOTINGS .............................................................................................................. 6
SUPPLY OF EQUIPMENT AND MATERIALS ................................................................................... 7
1003.18 GENERAL ........................................................................................................................... 7
1003.19 PACKING, TRANSPORT, HANDLING AND STORAGE............................................... 7
1003.20 PROTECTION FROM CORROSION................................................................................. 8
1003.21 STAGE WORKS.................................................................................................................. 8
1003.22 TRACK POSSESSIONS AND ISOLATIONS.................................................................... 8
1003.23 INSPECTION AND TEST PLANS..................................................................................... 9
1003.24 OCCUPATIONAL SAFETY REQUIREMENTS ............................................................... 9
TESTING AND COMMISSIONING....................................................................................................... 9
1003.25 TESING AND COMMISSIONING..................................................................................... 9
1003.26 TESTING AND COMMISSIONING DOCUMENTATION .............................................. 9
1003.27 HAND-OVER AND HAND-BACK.................................................................................. 10
ANNEXURE 1003A ................................................................................................................................. 11
OHLE DRAWINGS............................................................................................................................... 11
APNNEXURE 1003B ............................................................................................................................... 12
DOCUMENTS & STANDARDS .......................................................................................................... 12
ANNEXURE 1003C ................................................................................................................................. 13
PTA REFERENCE DRAWINGS .......................................................................................................... 13
ANNEXURE 1003D ................................................................................................................................. 15
OVERHEAD DATA SHEETS AND TENSION LAYOUT ................................................................. 15

Associated Roadworks OHLE
SPECIFICATION 1003
OHLE
GENERAL
1003.01 DESCRIPTION OF THE WORKS
1. The North Quay Rail Loop project will require the installation of a
turnout from and a track slew of the existing Down Fremantle Line for approximately
245 metres.. The track alterations are described on drawing R-01-G-004. In addition
the new North Quay Loop track will foul 3 overhead masts adjacent the Down
Fremantle.
2. This document defines the scope of the OHW activities and relevant PTA
specifications for these modifications.
3. All work must be in accordance with standard procedures and PTA

Network and Corridor Standard Safety Instructions for the Electrified Area.
4. The work includes planning and management of the interface issues to

ensure all alterations are carried out without unplanned disruption to the rail operations.
1003.02 WORK INCLUDED
1. The contractor shall produce an OHLE design based on the drawings as

listed in Annexure 1003A and contained in the contract. This design must comply with
the relevant PTA standards. Any non-compliance must be notified to the
Superintendant and submitted for review.
2. Based on concept design the installation of the North Quay Rail Loop
will typically require the following overhead wiring modifications:
a. 1 new push off cantilever mast at F19.142D
b. 4 new pull off masts – note if the embankment is too steep to install
a heavily laden pull off on the outside of the curve, then push off
mast on inside of curve to be considered..
c. Install new Balance Weight assembly for wire run No. 150.
d. Adjust height and staggers as required.
3. It is the contractor’s responsibility to co ordinate design and installation

activities with other disciplines involved in the project works.
1003.03 TECHNICAL SPECIFICATIONS
1. All work that is to be completed by the Contractor shall comply fully with the
requirements of the most recent versions of the Standards, Specifications and Codes of
Practice listed below in the following precedence:

a. Public Transport Authority (PTA) and New Metro Rail (NMR)
Technical
b. Specifications and Guidelines;
c. Australian Standards.
d. International Standards
1003.04 RELEVANT PTA STANDARDS AND DRAWINGS.
1. All 25kV OHE design and installation must comply with the PTA (PTA)
Specifications and Procedures described in Annexure 1003B.
2. Refer to Annexure 1003C for list of relevant PTA standard drawings.
1003.05 AUSTRALIAN STANDARDS
Railway Safety Management AS4292
1003.06 PUBLIC TRANSPORT AUTHORITY STANDARDS AND CODES

OF PRACTICE
• PTA Safety Instructions for the Electrified Area (SIFEA)
• PTA Track Access Permits, Information Circular, PTA
• 8190-800-001 The Design, Supply, Construction and Commissioning of 25kV
• AC Traction Overhead Catenary System, PTA- Parts A and B.
• Specification 228E Guidelines for Earthing and Bonding in 25kV a.c. Electrified
Areas
• 005/001 Guidelines to 25kV AC Overhead System requirements for Passenger

Stations, PURD
• Specification 512M/A Supply and Delivery of Overhead Line Isolators for

25kVRailway Electrification
• Specification 231E Guidelines for Clearance Requirements in 25kV a.c. Electrified

Areas – Provisional Draft Copy For Information Only.
• 4020-300-002 Traction Distribution System - Working Guidelines
1003.07 DEFINITIONS & TERMS
• A.C =. Alternating current
• OHWS = 25kV Traction Overhead Wiring System as described in PTA document

No. 8190-800-001 and other documents

1003.08 PERFORMANCE
1003.08.01 OPERATIONAL REQUIREMENTS
1. The operational performance parameters are as follows.
a. Track gauge: 1067 mm
b. Design train speed: NSTS 110 km/h
c. Structural design wind load based on 34 m/s factored to AS 1170.2
d. Coefficient of drag for all conductors: 1.2
e. Shade air temperature: max 47 oC, min -3 oC
f. Conductor temperature: 0 oC to +80 oC
g. Daily average max temperature 31 deg
1003.08.02 DETAILED REQUIREMENTS
1. Wherever possible the masts, assemblies and fittings installed during the
alterations shall be identical to existing equipment. Where this is not possible the
Contractor shall inform the Superintendent for direction to proceed.
2. The Contractor shall be responsible for ensuring that all proprietary

components of the OHW comply with the Technical Requirements. The Contractor
shall be responsible for ensuring compatibility between such components, for
determining the methods of production of all items and for supervising their
manufacture.
1003.09 DOCUMENTATION
1. The design must be independently verified, then submitted to the PTA for
approval. Following this the documentation must be submitted to the Superintendent at
least 30 days prior to work commencing.
2. As built documentation and field notes will be required to be submitted

by the installer.
1003.10 EXISTING SYSTEMS
1003.10.01 RECOVERIES/SYSTEMS TO BE DECOMMISSIONED
1. The Contractor shall recover the following equipment:
a. Existing overhead wiring components replaced or removed as part of these

works.
b. Where redundant, the Contractor shall decommission and remove the existing
equipment.
c. All recovered reusable equipment shall be removed from site and stored in a
secure area. The equipment shall be cleaned and inspected for damage. The
satisfactory equipment shall be returned to the PTA.

1003.11 INTERFACES
1. The Contractor shall be responsible for the management of all interfaces

that exist for the work under the contract refer to clause 100.03. This shall include all
the planning and coordination required to interface with other aspects of the North
Quay Rail Loop installation during the work stages and track closures to execute the
works.
CONSTRUCTION
1003.12 DESCRIPTION OF OVERHEAD WIRING SYSTEM WORKS
1. The following masts will require removal to allow installation of the

North Quay Rail
a. Loop track.
− Down Fremantle Line – F19.162D;
2. Drawing No: ES-RHL-1065 details the existing layout arrangement for

this area.
3. To facilitate the North Quay track installation, new mast structures are to
be placed at the following locations:
a. Down Fremantle Line – F19.160D;
b. Down Fremantle Line – F19.160U;
c. Down Fremantle Line – F19.142D;
d. Down Fremantle Line – F19.122D;
e. Down Fremantle Line –; F19.122U
4 P.O. structure F19.122U is required at to avoid the installation of non-

standard push off at F19.122D.
5. Installation and design of foundation for mast F19.160D will require

special attention as it will be on an embankment.
1003.13 ASSOCIATED WORKS
1. Associated works include the earthing and bonding, removal of redundant

equipment, track registration plates and structure numbering and other such fittings for
the traction system.

1003.14 CONSTRUCTION
1. The Contractor shall supply, install, test and commission all equipment
and materials necessary for construction / alterations of the overhead wiring system as
detailed in the detailed design contract documentation including, but not limited to all
masts, foundations and system components. The proposed works are depicted in
drawings listed in Annexure 1003A.
2. Works to the overhead wiring system shall be constructed in accordance

with PTA specification 8190-800-001 “The Design, Supply, Construction and
Commissioning of 25kV AC Traction Overhead Catenary System, PTA”.
3. Specific attention is required to the following requirements:
a. The type of mast specified in the detailed design is in accordance with

masts currently in use. Barclay Mowlem Australia are sole suppliers
of these masts. It is Contractor’s responsibility to carry out a visually
inspection, prior to receipt and transportation of the masts, to
establish that the structures are free of any cracks or deterioration and
the uni-struts and ferrules are clean and clear;
b. Foundations shall not be left open;
c. Support assemblies and any temporary work shall be constrained

during construction to prevent movement under wind loads and to
prevent damage to railway equipment or other parts of the erected
overhead equipment;
d. Installation procedures shall be such as to prevent the overloading of

components during erection or damage to any components during
adjustment;
e. All wedge clamps shall be internally greased prior to wire insertion;
f. All swivel pins, swivel clips etc. shall be greased;
g. Any threads which may require future adjustment such as

turnbuckles, or adjusters shall be greased with a suitable water
resistant grease and set mid-way of their adjustment;
h. Any preformed wrap on wire fittings, dead ends or splices shall not
be reused in permanent installations after removal. Any such devices
provided or used by the Contractor shall be identified by indelibly
bright green paint;
i. All insulators installed in the system shall be cleaned and free from
any defects at the date of handover;
j. Insulators shall be suitably protected to prevent any deposits from

abrasive cutting wheels or similar deposits from touching an insulator
when working in the vicinity of insulators. Any insulators so damaged
shall be removed from the equipment and subjected to a routine
insulation test and discarded on failure of test;
k. All fasteners and fixings shall be tightened securely and correctly and
the equipment erected using good engineering techniques. Torque
wrenches shall be used where necessary;

l. All ends of tubes shall be neat and free from burrs and sharp edges
both internally and externally;
m. Cut stranded wire shall be tied off in a manner to prevent stranding of

the wire and corrosion;
n. Attention is drawn to the specification for paint treatment of any bare

metal including cut ends of tubes and steel wire; and
o. Contact wire splices shall not be installed in “in-running” sections of

the contact wire for the final works;
p. Attention is drawn to adequate planning of work. Sufficient time shall

be allocated to allow for replacement of temporary OHW (installed
for the purpose of staging work) by permanent installation within
PTA scheduled shutdowns;
q. Interfacing with other contractors and parts of work.
1003.15 CLEARANCES
1003.15.01 CLEARANCE FROM 25KV OVERHEAD EQUIPMENT
1. At no time shall any part of any new structure, materials, fittings, plant
and equipment be positioned permanently or temporarily within the minimum electrical
clearances from live 25kV traction overhead equipment, as nominated in the PTAC’s
“Safety Instructions for the Electrified Area”, unless otherwise approved in writing by
the Superintendent.
1003.15.02 CLEARANCES FROM TRACK
1. At no time shall any part of any plant and equipment be positioned

permanently or temporarily within the PTA structural clearance envelope detailed in
PTA specification 8190-800-001 “The Design, Supply, Construction and
Commissioning of 25kV AC Traction Overhead Catenary System, PTA”.
2. The structural clearances for permanent structures adjacent to and above

the tracks shall conform to PTA’s minimum structural clearance diagrams and
specifications as shown on Drawing 82035/3 Rev 0.
1003.16 EARTHING AND BONDING
1. The E&B design shall be compatible with the track signalling system
installed. E&B cable sizes shall be in accordance with PTA standards. This must be
PTA approved prior to submission to the Superintendent.
1003.17 MAST FOOTINGS
1. The Contractor shall be responsible for the design of mast footings. The
Contractor must provide to the Superintendent independently verified design of the
footings at least 14 days prior to masts installation.
2. Mast Foundation Construction Manual shall be submitted to the

Superintendent’s review prior to the commencement of work.

SUPPLY OF EQUIPMENT AND MATERIALS
1003.18 GENERAL
1. The Contractor shall supply materials and equipment required to

complete the project.
2. All materials and components to be used for the alterations, shall be new
and as defined in the Contract Drawings and within these Technical Requirements.
They shall be free of damage immediately prior to being taken to the point of
installation and at the time of fixing in position. Materials which are not to the required
standards shall be removed from Site and replaced by the Contractor.
3. The Contractor shall abide by the manufacturer’s instructions on health

and safety and use of their product.
4. The Contractor shall undertake materials testing in accordance with the

requirements of the PTA standards and these Technical Requirements. Where a test
identified is not covered by recognised standards or codes, the testing authority is to
issue a Certificate of Conformance.
5. A copy shall be submitted to the Superintendent.
6. The following suppliers shall provide warranties:
a. Manufacture and supply of masts;
b. Manufacture and supply of Porcelain Insulators;
c. Manufacture and supply of Synthetic Insulators and Sectioning

devices; and
d. Supply and/or installation of any portion of the works deemed by the

Superintendent to be a significant element of the OHW.
1003.19 PACKING, TRANSPORT, HANDLING AND STORAGE
1. The packing, transport, handling and storage of the OHW components

shall be appropriate to the material and in accordance with the suppliers’ instructions.
2. The Contractor shall ensure that the packing and transport of the
materials will not induce undue stress, vibration, corrosion or impact their properties.
The Contractor shall ensure that components of similar physical type but differing
properties are packed and labelled clearly.
3. Small components shall be crated or palletised suitable for mechanical

handling and where practical, vertical stacking.
4. All material purchased by the Contractor shall be suitably handled and

stored so that they will be fully protected from damage and corrosion, with particular
regard to the climatic conditions prevailing. All packaging shall be robust and such as
will not deteriorate during long periods of storage. Site storage shall be in cool, dry
conditions away from direct sunlight or to the manufacturer’s recommendations. Any
product past its shelf life shall be removed from the Site.
5. All normal and regulatory precautions against fire shall be taken during
both storage and use.

6. Dangerous goods shall be handled and stored in accordance with the
relevant Enactments and in accordance with the requirements of the relevant
Authorities.
1003.20 PROTECTION FROM CORROSION
1003.20.01 GENERAL
1. Where dissimilar metals abut, they shall be protected against electrolytic

corrosion in accordance with structures codes relevant to the materials concerned.
2. Equipment supplied shall be designed to operate without degradation of

its electrical characteristics and the life of components due to corrosion.
1003.20.02 SALT SPRAY
1. All materials and equipment supplied shall be designed to withstand

exposure to coastal and salt spray conditions for a minimum period of 20 years.
2. Materials and equipment shall be selected to suit the environment and to

minimise any corrosion potential.
1003.21 STAGE WORKS
1. The Contractor is responsible for the stage works for the OHW
installation of the North Quay Rail Loop Project.
2. The Contractor shall ensure that in addition to the staging for the OHW
alterations attention and co-ordination shall be carried out for all associated civil,
signalling and communication works required.
3. For the installation of overhead wiring system components that require

isolations and possession, works shall be carried out in accordance with clause 102.03
of Specification 102.
4. To determine what preparation work can be carried out by the Contractor

outside these times a method statement dictating their proposed method of works is to
be produced and submitted.
5. The Contractor shall submit a proposed staging plan with his tender
submission for approval. The plan shall indicate the proposed number of close downs
required and any other required isolation/possession requirements to complete the
alterations, testing and commissioning.
6. The Contractor shall endeavour to keep the total number of track closures
to a minimum.
1003.22 TRACK POSSESSIONS AND ISOLATIONS
1. The Contractor shall propose a schedule of work proposed for each

possession and isolation for submission to the superintendant.
2. The Contractor shall prepare method statements for the work proposed in
each possession.

3. The method statements shall ensure that a safe system of work is
established for each possession period.
4. The Contractor shall be responsible for arranging isolation of the

overhead traction wiring equipment to allow for the disconnection of cables and
conductors to the overhead wiring equipment.
5. The Contractor shall provide sufficient area lighting to enable night

works to be undertaken safely.
6. the Contractor will be charged for each required isolation in accordance

with Clause 102.03.4.
1003.23 INSPECTION AND TEST PLANS
1. Prior to mobilisation, the Contractor shall prepare full Inspection and Test
Plans, including Factory Acceptance Testing documentation for items listed in clause
1003.18.
1003.24 OCCUPATIONAL SAFETY REQUIREMENTS
1. The Contractor shall be aware that there are other gas and electricity
services located within the railway reserve.
2. The Contractor shall be responsible for ensuring that no additional

services are contained within the route that may present a hazard.
3. The Contractor shall inspect the proposed foundation locations and carry
out all works in accordance with Specification 105.
TESTING AND COMMISSIONING
1003.25 TESING AND COMMISSIONING.
1. The contractor shall produce an approved PTA Inspection and Test Plan
and submit to the Superintendant for approval for all works to be undertaken at least 30
days prior to work commencing.
2. The Contractor shall perform all testing and commissioning activities in

accordance with this and standard PTA specifications.
3. The Contractor shall be responsible for all materials, consumables, test

equipment, labour and facilities for the testing, pre-commissioning, commissioning and
setting to work of the Works, unless otherwise specified.
1003.26 TESTING AND COMMISSIONING DOCUMENTATION
1003.26.01 FACTORY ACCEPTANCE TEST PLAN
1. The Contractor shall prepare a factory acceptance test plan for all
equipment that is required to be factory tested prior to site installation.
2. First Article Inspection (FAI) shall be performed on, at a minimum, the

following components, but others will be advised by the Superintendent following the
Review of the Contractor’s Testing Plan:

a. Prestressed concrete tapered masts;
b. Insulators and sectioning devices and
c. The Factory Test Acceptance Plan shall be submitted to the

Superintendent for approval prior to any factory testing.
1003.26.02 INSPECTION
1. Without prejudice to any other provisions of the Contract, the

Superintendent shall have free access to the Contractor's and its manufacturers’
premises throughout the Contract, for the purpose of reviewing and inspecting the
design and manufacture processes.
2. Inspection of the alterations carried out during each closedown shall be

planned and recorded.
3. The inspections shall be carried out on completion of all work and will
signify the works have been completed in accordance with the technical requirements
and the OHW system is safe and suitable for operation. The Contractor’s nominated on
site representative shall be familiar with the PTA permit to work procedure.
1003.26.03 COMMISSIONING PLAN
1. The Contractor shall prepare a testing and commission plan.
2. The Testing and Commissioning Plan shall be submitted to the

Superintendent for approval.
3. All testing and commissioning shall be conducted in the presence of a

witness.
4. All testing records and certificates shall be issued to the Superintendant

on completion of the commissioning activities.
1003.27 HAND-OVER AND HAND-BACK
1. After commissioning of the system, the Contractor shall escort the

maintainer around the new installation and remedy any defects noticed and noted by the
maintainer.
2. The maintainer shall be liable for the maintenance of the new installation
once all significant defects are remedied.
3. All warranties for new equipment supplied shall be transferred to the

PTA.

ANNEXURE 1003A
OHLE DRAWINGS
Drawing No Description
R-01-G-001 Rail Loop Alignment
R-01-G-004 Main Line Realignment
R-01-X-001 Rail Loop Cross Sections Sheet 1
R-01-X-002 Rail Loop Cross Sections Sheet 2
R-01-E-001 Proposed OHW Layout drawing
F18950d Perth Urban Rail Overhead Data Sheet
F18994u Perth Urban Rail Overhead Data Sheet
ES-RHL-1065 Rev D Perth Urban Rail Overhead Line Equipment Layout

APNNEXURE 1003B
DOCUMENTS & STANDARDS
1003B.01 RELEVANT PTA DOCUMENTS STANDARDS
Document Title Description
8190-800-001 The Design, Supply, Construction and Commissioning of 25kV

Traction Overhead Catenary Equipment
8184-800-231 Guidelines for Clearances Requirements in 25kV ac Electrified

Areas.
1003B.02 AVAILABLE DOCUMENTS
The following documentation is available for inspection in NMR office on request:
1. 8190-800-001. The Design, Supply, Construction and Commissioning of 25kV AC

Traction Overhead Catenary System, PTA.
2. Applicable System Design Drawings.
3. 005/01 Guidelines to 25kV AC Overhead System requirements for Passenger

Stations, PURD.
4. PTA Safety Instructions for the Electrified Area (SIFEA)
5. 8140-800-001 TC228E/1-4 Technical Circulars Earthing & Bonding guidelines,

PTA
6. PTA Track Access Permits, Information Circular, PTA
7. Link to PTA Application to Access Railway Urban Reserve Electrified Area
8. DE02300-REP-5058 Interim Specification for Earthing and Bonding at Passenger

Stations
9. DE02300-REP-5058 Configuration of Double Rail Track Circuits (DRTC) to satisfy

Earthing and bonding in a 25kV Traction Power Application
10. 8100-800-047 Boundary Fences in the Electrified Area
11. 5620-200-001 Interfaces between Infrastructure and Station Works Packages

Guidelines for Station Designers
12. 10--H-25-0136 Suburban Electrification Overhead Line Equipment Return Conductor and Rail to
Return Current Busbar Connection

ANNEXURE 1003C
PTA REFERENCE DRAWINGS
Drawing No Description
ES-CG-77 Overhead Line Equipment Electrical Clearances
ES-CG-78 Boomgate Structure Electrical Clearances
ES-CG-79 Flashlight and Pedestrian Structures Electrical Clearances
ES-CG-80 Signal Structure Electrical Clearances
ES-CG-81 Lighting Structure Electrical Clearances
ES-CG-82 Platforms Electrical Clearances
ES-CG-83 Buildings Electrical Clearances
ES-FE-1506 Auto Boomgate Right Angle Crossing General Arrangement
ES-FE-1507 Auto Boomgate Obtuse Angle Crossing General Arrangement
ES-FE-1508 Auto Boomgate Acute Angle Crossing General Arrangement
ES-HG-1001 Overhead Line Equipment Concrete Mast Cantilever Arrangement
ES-HG-1002 Overhead Line Equipment Standard Spans for Sagged Contact Wire
ES-HG-1003 Overhead Line Equipment Cantilever Construction
ES-HG-1004 Overhead Line Equipment Portal Construction
ES-HG-1005 Overhead Line Equipment Insulated and Uninsulated Overlap for
Tangent and Curved tracks
ES-HG-1007 Overhead Line Equipment Anchor Tie Assemblies
ES-HG-1017 Overhead Line Equipment Conductor Particulars Contact and
Catenary Wires
ES-HG-101 Overhead Line Equipment Conductor Particulars Ancillary Wires
ES-HG-1019 Overhead Line Equipment Maximum Span Length for Curvature
ES-HG-102 Overhead Line Equipment Blow Off Offset & Stagger
ES-HG-1026 Overhead Line Equipment Electrical Clearances to be provided at

Overbridges
ES-HG-1027 Overhead Line Equipment Safety Sign for Electrification
ES-HG-1028 Overhead Line Equipment Structure Numbers
ES-HG-1032 Overhead Line Equipment Tramway Cantilevers Construction

Arrangement

ES-HG-1036 Overhead Line Equipment Arrangement of Booster transformer Structures
ES-HG-1037 Overhead Line Equipment Return Conductor Sag Chart
ES-HG-1038 Overhead Line Equipment Return Conductor Blow Off Chart
ES-HG-94 Overhead Line Equipment Track Registration Plate
ES-HG-1130 Overhead Line Equipment Concrete Portal Mast and Heavy Load
Cantilever mast
ES-HG-1131 Overhead Line Equipment Concrete Self-Supporting Anchor Mast
ES-HG-1132 Overhead Line Equipment 40kN Nominal Capacity Concrete Mast
ES-HG-1135 Overhead Line Equipment 50kN Nominal Capacity Concrete Feeder Mast
ES-HG-1185 Overhead Line Equipment Mast Guard Rail
ES-HG-1301 Overhead Line Equipment Disc Insulator
ES-HG-1302 Overhead Line Equipment Glass Fibre Rod Insulator
ES-HG-1305 Overhead Line Equipment Solid Core Post Insulator
ES-HN-19 Claisebrook traction Power Supply – Typical Arrangement
PE-3001 Electric Multiple Unit 1750 Pantograph Proposed Profile
1090H-10 Secondary Survey Field Data Sheet

ANNEXURE 1003D
OVERHEAD DATA SHEETS AND TENSION LAYOUT


FNQ

Cargado por

Información del documento

Descripción original:

Título original

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

FNQ

Cargado por

Copyright:

Formatos disponibles

TENDER DOCUMENTS FOR MAJOR WORKS PROJECT

using AS 4000 - 1997 General conditions of contract

TITLE JOB FILE NO.

NORTH QUAY: CONSTRUCTION OF A

DETAILED SCOPE OF WORK

OFFICE OF ORIGIN: FREMANTLE PORTS

BRIDGES, NOISE WALLS AND

EXCAVATION AND BACKFILL

North Quay: Construction of a Rail Series 800

EXCAVATION AND BACKFILL FOR STRUCTURES

1. This Specification covers general earthworks not associated with Scope

1. Australian Standards and MRWA Test Methods are referred to in

AS 2868 Classification of machinery for earthmoving, construction, surface

MRWA Specifications - Cross References

Specification 100 GENERAL MANAGEMENT REQUIREMENTS

1. Clearing shall be undertaken in accordance with Specification 301, Clearing

North Quay: Construction of a Rail 1 Series 800

1. Excavation in general shall include:- Scope

a) bulk excavation at bridge site

b) local excavation for installation of substructures, retaining walls and

c) excavation for protection works

all as shown on the drawings.

2. Excavation in rock shall comprise excavation of material in place whether Definition of

3. Excavation in all other classes of material shall be termed common

4. Bore Information drawings included give indications of materials to be Bore

5. The drawings show approximate locations of Services in the vicinity of Services

8. The Contractor shall give the Superintendent 24 hours notice on

801.06 NOT USED

801.07 FOOTINGS ON SOIL

1. Unless otherwise shown on the drawings, soil shall be finished

North Quay: Construction of a Rail 2 Series 800

2. The Contractor shall avoid damage to existing structures including water

3. Temporary drainage systems may be required to be installed to carry

4. Where a wellpoint system is used, care shall be exercised during

7. Prior to the commencement of any dewatering operations, the HOLD POINT

9. Any consequence of either ground water or surface water against any

North Quay: Construction of a Rail 3 Series 800

1. Prior to concrete blinding of the foundation surface the Contractor

801.10 BLINDING CONCRETE

1. The exposed bearing surface at the bottom of each excavation shall be

2. Immediately after the foundation bearing surface has been trimmed, it

3. Blinding concrete shall be as specified in Specification 820,

Sieve Size % Passing

North Quay: Construction of a Rail 4 Series 800

The material shall be free from boulders having any dimension

4. The contractor shall backfill around footings, abutment walls, piers,

North Quay: Construction of a Rail 5 Series 800

North Quay: Construction of a Rail Series 800

MECHANICALLY STABLISED EARTH WALLS

1. The work to be executed under this Specification includes design, Scope

1. Australian Standards and MRWA Test Methods are referred to in

AS 1289.F3.3 (Part F) - Soil Strength and Consolidation Tests, “Determination

MRWA Specifications - Cross References

Specification 801 EXCAVATION AND BACKFILL FOR STRUCTURES

Australian Bridge Design Code

a) anticipated design life (100 years minimum required)

b) anticipated movements over the life of the structure (vertical and

c) safety factors adopted for the design

d) requirements for fill material

e) proposed shape and surface finish of facing panels;

f) proposed reinforcing elements

with independent supporting evidence as appropriate.