Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

SECTION 4 : TRACK WORKS

4.00 GENERAL FOR TRACK WORKS

(1) Description

This Specification sets forth basic requirements of the works to design, manufacture, furnish,
install and construct various track facilities, inclusive of modification, changing or removal of
the existing facilities described herein. Track works shall also include switch-over procedure
and operational testing and commissioning thereof.

Tender Drawings shall be referred to for detailed designing and the Contractor shall be
required to submit Shop Drawings for approval by the Engineer based on findings by site
surveys.

(2) Scope of Work

(a) Contract Limits

Unless otherwise specified in this Specification, installation, construction, modification
or removal of track facilities shall be carried out in accordance with the Drawings.

(b) Installation and Construction Limits

Under the Contract, installation and construction of track facilities shall consist of, but
not limited to:
Permanent Track Structure Construction
Railway Switches Facility
Buffer Stop Facility
Level Crossing Pavement
Track Sign and Post Installation
Temporary Track Structure Construction
Track Modification and Removal Works

(c) Works to be Coordinated

Through Contract Period, due consideration shall be taken into close coordination with
other section of works.

(3) Method of Work

(a) Contractor’s Responsibility

Types and numbers of track facilities shown on the Drawings shall be reviewed by the
Contractor through the period of site surveys and the requirements of the Contract. Any
incorrect information, if any, on the Drawings shall not relieve the Contractor from
responsibility of performing all the site work under the Contract. Prior to preparing
detailed work programmes and during execution of the work, the Contractor shall
coordinate with other related works.

(b) Work Coordination with PT. KAI

The Contractor shall be responsible to coordinate with PT. KAI for train operation and
safety procedure to be required by the site track work, switch-over or any other works
under train operation.

(4) Survey and Design

The Contractor shall be required to execute the track alignment survey and detailed design
of horizontal and vertical track alignment for approval of the Engineer in accordance with this

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

Specification and Indonesian Railway Standards, including the following major design
standards:

Track guage : 1,067 mm

Maximum train speed for main line : 120 km/hour
Maximum train speed for commuter line : 100 km/hour
Axle load : 18 ton

(5) Materials

Materials for track facilities shall be in accordance with this Specification and shall be
approved by the Engineer before procurement. Quantity of all the materials necessary and
required for track facilities shall be measured by the Contractor based on the results of
survey and design and shall be submitted to the Engineer for his approval. Any testing
requirements for materials shall be in accordance with this Specification and shall be
checked and approved by the Engineer before shipment to the site.

(6) Documentation

The Contractor shall submit three (3) copies of each of the following drawings and
documents to the Engineer according to the time schedule or as otherwise directed by the
Engineer.

(a) Manufacturing Drawings

The Contractor shall submit to the Engineer for approval prior to manufacturing the
drawings and documents of the equipment or materials to be delivered in accordance
with the applicable provision in each section of this Specification. Manufacturing
drawings and documents shall contain the general assembly and main parts of
equipment or materials.

(b) Shop Drawings

The Contractor shall submit Shop Drawings to the Engineer for his approval prior to
installation of equipment or materials as required by the Engineer.

(c) Material Test Reports

Material test reports performed at the time of completion of manufacturing, including the
description of test method, shall be submitted in booklet form. The test reports shall show
the test results performed to prove compliance with the specified test criteria.

(d) Final As-Built Drawings

The Contractor shall submit As-Built Drawings of the completed track facility according to
the final track alignment. Final As-Build Drawings shall be submitted to the Engineer
before Provisional Hand-Over under this Contract.

(7) Programme

Prior to commencement of the work, the Contractor shall be required to submit the track work
programme for approval of the Engineer regarding the location, track length, construction
schedule and work method, including work progrmme for window-time. Construction work
plan during window-time at the operating track shall only be permitted by the Engineer after
confirmation with PT. KAI.

(8) Construction

The Contractor shall be required to install and construct the track facilities under PT. KAI
train operation in accordance with this Specification. Before commencement of any track
works at site, the Contractor shall be required to coordinate with PT. KAI for work method,
switch-over procedure, safety arrangement, train operation schedule etc. which shall be

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

approved by the Engineer. The Contractor shall be required to ensure the safety of
completed track facility for PT. KAI train operation after finishing any section of track work.

(9) Operational Tests

The Contractor shall be responsible for carrying out operational tests by PT. KAI train on the
installed track facilities in accordance with this Specification. The Contractor shall be
required to coordinate with PT. KAI through the Employer and the Engineer for arrangement
and execution of operational tests.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.01 RAIL R54

(1) Description

This work shall consist of furnishing, delivering to site and arranging new R54 rails for
permanent track. Rail shall conform to UIC standards and this Specification. The Contractor
shall submit technical data and testing data from the manufacturer for approval of the
Engineer prior to placing any orders for new rail.

(2) Method of Manufacture

(a) New rail shall be manufactured from steel ingots or continuous casting blooms
(hereinafter referred to as C.C. blooms) made either by basic open hearth, electric, or
basic Bessemer process or basic oxygen converter.

Chemical composition shall be as follows:

Carbon : 0.70 – 0.80%

Manganese : 0.90 – 1.10%
Silicon : 0.15 – 0.35%
Phosphorus : Max. 0.035%
Sulphur : Max. 0.025%

(b) Ends of blooms and ingots shall be sufficiently cropped so as to ensure that rails are
free from internal defects and slag.

(c) Rails shall be uniform in shape throughout the entire length and be free from flaws,
twists and other defects.

(d) All rail shall have their ends sawn or machined and the sawn section of rail shall show
no pipes or other internal defects.

(e) Both ends of rail shall be rectangular to longitudinal axis, all burrs shall be removed
and rail ends shall be chamfered 1.5mm.

(f) Camber of rails after cooling shall not exceed 100mm per 10m length and shall be
straightened by applying gradual pressure. Chemical composition of rail shall be
analyzed by Quantvac analysis and the results shall conform to the requirements
specified in this Specification.

(g) Both ends of R54 rail in length of 25 meters shall not be drilled at ends, necessary
holes at end for rail joint shall be drilled at site in accordance with UIC or this
Specification.

(h) Mechanical properties shall be as follows:

Tensile strength : 80 Kgf / mm²

Elongation : Min. 10%
Hardness : Min. HB 270

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

(3) Marking

(a) Manufacturer's name, initials or other recognized mark, year of manufacture and initials
identifying DGR shall be rolled in embossed letters at least 20mm in size on one side of
web of each rail. Lettering shall read from end adjacent to top of ingot or C.C. bloom and
shall remain legible so long as rails are in service.

Following abbreviations are recommended for purpose of marking:

OA : Open hearth, Acid

OB : Open hearth, Basic
BA : Bessemer, Acid
BB : Bessemer, Basic
E : Electric
LD : Linz Danowits

An arrow shall indicate the top of ingot or the top of C.C. bloom.

(b) Cast Identification

In addition to the markings as specified, the following shall be hot-stamped at one end of
each rail. Figures and letters shall be 20 mm in size.

Number of batch as well as ingot or C.C. bloom number from which rail has been rolled,
as well as appropriate letter to indicate the order relative to the top of ingot or C.C.
bloom.

(4) Weight and Dimension Tolerances

A weight variation of minus 0.5% to plus 1% of the theoretical unit weight of short rails over
300 mm long shall be tolerated and provided this is met the following dimension variations
will be tolerated.

Length (25 m rail) : + 10.0 mm to – 10.0 mm

Height of Rail : + 0.8 mm to – 0.4 mm
Width of Rail Head : + 0.8 mm to – 0.4 mm
Thickness of Web : + 0.8 mm to – 0.4 mm
Width of Rail Foot : + 0.8 mm to – 0.8 mm
Deviation of Rail Head : + 0.8 mm to – 0.8 mm
Squareness of Ends : + 0.6 mm to – 0.6 mm

(5) Method of Measurement

The quantity to be measured for payment of new rail shall be the actual number of metric
tonnes of new rail in 25m lengths delivered to site and arranged for the track work.

(6) Basis of Payment

The quantity of new rail, as determined above, will be paid for at the Contract unit price for
the pay item listed below. Payment for new rail shall include manufacture, delivery to site
and arranged for the track work.

Pay Item No. and Name Unit of Measurement

401 Rail R54 metric tonne

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.02 RAIL WELDING

(1) Description

This work shall consist of arrangement and execution of thermit welding at site provided at all
main lines and station compounds laid with R54 rails. The Contractor shall furnish all labor,
materials, tools and equipment to complete the work as described in this Clause.

(2) Scope of Work

The Contractor shall submit to the Engineer for approval the welding process or other
processes to be used and data for effective term of material prior to commencement of any
welding. The Contractor shall submit full details of welding equipment to be used, testing
programme for the type of weld and the extent and relationship of laboratory and onsite
inspection. Testing shall be performed at an authorized laboratory.

Before welding work, the Contractor shall perform a hardness test, bending test and break
surface inspection for pieces of test specimens welded two rails of 0.75m length for approval
of the Engineer. Results on the tests shall be submitted with certification from the laboratory
performing the tests. The Contractor shall repeat the tests as required by the Engineer if the
results are unsatisfactory. Hardness test shall comply with Brinell Hardness test more than
HB 270 at the welded section and HB 210 at the base metal affected by the heat of welding
within 15cm of the welded section.

(3) Method of Work

Thermit welding or other welding methods approved by the Engineer shall be performed
under the direct supervision of a welding foreman or supervisor. Welding records shall be
kept to show the following:

Date and time

Km Location
Inspector name
Welder name
Welding foreman or supervisor name
Portion identification
Results of inspection
Weather condition
Batch number

A copy of these records shall be submitted daily to the Engineer.

(4) Construction

End 150mm of rails shall be cleaned to remove grease, oil, dirt, rust and moisture from all
surfaces. Welds shall not be closer than 5m from any joint or other weld. Alumino-thermic or
other welds shall be positioned in the center of the bed between two sleepers. Welding gap
shall be between 24 and 26mm or as required by the specification of the manufacturer and
both ends shall be square and vertical. Free hand cutting of the rail ends is prohibited and
only rail cutting by machine is acceptable. Vertical and horizontal alignment of the joint prior
to welding shall be checked with a I m long straight edge.

Four (4) pieces of 25m long rail shall be welded to form one rail of approximately 100m
length. Molds around welds must be removed so that the welds can be inspected to confirm
they are satisfactory before further work is undertaken. Main vent risers shall not be
removed until cold. Wedges shall be examined and replaced where necessary to maintain
the original level and shall not be removed for at least 30 minutes after stripping. When

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

trimming a welded part, a minimum of 2 mm of surplus metal shall be left for final grinding
after which alignment and level shall be checked.

Grinding must not commence until wedges have been removed, and in case of welds on site,
until fastenings, pads and insulators have been positioned. Main riser shall first be ground
down to rail profile and a suitable straight edge used to obtain the correct overall level. Care
must be taken when grinding that the weld area conforms to the rail head profile. Where
there is a difference in the wear of rail head profile, the less worn rail shall be taper-ground
to suit. Traffic shall not be allowed to pass over a new weld until 30 minutes after trimming
is complete but if this is not possible the speed of traffic over the weld shall be less than 5
kilometers per hour.

Tolerance of finished rail head top and inner side surface shall be as follows:

Individual Horizontal Camber  0.5 mm in 1m at weld

Individual Vertical Camber + 0.5, -0.1 mm in 1m, at weld

(5) Marking

Marking of welding section shall be made by paint at least 200mm from the welding part to
show the following:

Date and time

Km location
Weather condition

(6) Inspection

All welds shall be visually and physically inspected using a 1 meter long straight edge and a
tapered feeler gauge to confirm a tolerance of no more than 0.5mm per 1 meter straight
edge. Prior to commencement of train operation, ultrasonic test of welding parts shall be
carried out by the Contractor under supervisory engineer approved by the Engineer.
Defective welds shall be replaced with extra rail and all costs in making defective welds good
shall be borne by the Contractor. Minimum length of extra rail shall be not less than 10.0m.

(7) Method of Measurement

The quantity to be measured for payment shall be the actual number of each welded joint
completed. The work shall include collection from store, transport, handling, assembly and
laying of all necessary materials in position, all cutting of closures and joining to abutting
sections, all welding, grinding and all testing of welds. For purposes of measurement a weld
shall be considered as a single welding between two rail ends.

(8) Basis of Payment

The quantity of rail welding, as determined above, will be paid for at the Contract unit price
for the pay item listed below. This price and payment shall be full compensation for welding
and installation of rail completed at site.

Pay Item No. and Name Unit of Measurement

402 Rail Welding each

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.03 RAIL JOINTS

(1) Description

This work shall consist of furnishing, delivering and installing ordinary rail joints by various
fittings such as fishplates, fishbolts, nuts and spring washers for R54 rails and assembling
them at site, excluding railway switches.

This work shall also consist of furnishing, delivering and installing insulated rail joints at
locations as shown on the Drawings or as instructed by the Engineer, including railway
switches. Scope of work also includes furnishing and delivering spare materials for use in
maintenance of the insulated rail joints installed under this Contract equivalent to ten (10)
percent of the installed joints.

(2) Materials

Materials shall conform to standards acceptable to those specified in this Specification.

Shape and dimensions shall be as shown on the Drawings or approved by the Engineer. The
Contractor shall submit technical data and testing data from the manufacturer for approval of
the Engineer.

The Contractor shall be responsible for determining and providing the quantities of materials
needed to carry out the work required under this Contract based on the Drawings and in
accordance with this Specification.

(a) Ordinary Rail Joint

1) Chemical composition shall be as follows:

Component Fishplate Fishbolt Nut Spring Washer

Carbon 0.40% - 0.55% 0.38% - 0.43% 0.37% - 0.53% 0.59% - 0.86%
Silicon Max. 0.40% 0.15% - 0.35% 0.15% - 0.35% 0.15% - 0.35%
Manganese 0.55% - 1.00% 0.60% - 0.85% 0.60% - 0.90% 0.30% - 0.90%
Phosphorus Max. 0.04% Max. 0.03% Max. 0.03% Max. 0.04%
Sulphur Max. 0.045% Max. 0.03% Max. 0.035% Max. 0.04%

2) Mechanical properties shall be as follows:

Property Fishplate Fishbolt Nut

Tensile Strength Min. 70 Kgf/mm2 Min. 110 Kgf/mm2 Min. 85 Kgf/mm2
Elongation Min. 12% Min. 10% Min. 13%
Hardness HB 262 - 331 HB 262 - 341 HB 262 – 341

Manufacture of washers shall be in accordance with UIC Code 684 - 3/0. Spring steel
washers shall be hardened in oil at a temperature between 20 to 40oC and mechanical
properties after heat treatment shall conform to Rockwell Hardness HRC 40 to 46.
Preliminary loading shall be with a 1,500 kgf load.

(b) Insulated Rail Joint

Insulated materials shall be epoxy fiberglass as shown on the Drawings or equivalent as

approved by the Engineer. The Contractor shall submit technical data from the
manufacturers for approval of the Engineer. Physical properties of joint bar materials
shall be as follows:

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

Tensile Strength : 103 kgf/mm²

Flexural Strength : 99 kgf/mm²
Compressive Strength : 67 kgf/mm²
Hardness : 73.3 Rockwell (5 mm/100kg)
Water absorption : Max.0.3 % (8 weeks 600C immersion)

Insulated materials must be cast to the exact dimensions shown on the Drawings and no
grinding or cutting of epoxy fiberglass will be permitted.

Mechanical properties for joint bolts and nuts shall conform to the requirement in (2)
Materials, (a), 2) Ordinary Rail Joint in this Specification. Material for back-up plate shall
conform to the mechanical properties specified in JIS G 3101 or equivalent.

(3) Marking for Ordinary Rail Joint

Following shall be marked by the manufacturer on web of fishplates in legible characters and
manufacturer's name of abbreviation and DGR shall be clearly marked on heads of fishbolt.

Manufacturer's name
Last two figures of year of manufacture

(4) Construction

(a) Ordinary Rail Joint

Prior to commencement of this work, fishbolt holes shall be drilled to the web of rail by
drilling machine according to the Drawings. All joints shall have six (6) bolts per joint and
shall be fully bolted and fitted with spring washers. Before fastening rail joints, grease
coating shall be applied to the web of rails where fishplates contact and bolt holes of
fishplates shall be coated with lubricating oil. All joints shall be tightened to provide a flat
and smooth rail surface. Joints in parallel rails shall be squared or within 100mm
tolerance and in curves care shall be taken to insert shorter rails in the inner curve to
maintain square joints.

(b) Insulated Rail Joint

All parts shall conform to the required dimensions as shown on the Drawings and shall
be free from defects that will prevent proper functioning of the insulated joints.
Construction details shall be as specified for ordinary rail joints. Materials for insulated
rail joint assemblies equivalent to 10% of those installed at site shall be delivered to the
warehouse in Manggarai as spare parts.

(5) Method of Measurement

The quantities to be measured for payment shall be the actual number of sets of ordinary rail
joints or insulated rail joints installed in the R54 rails and completed at site. Ordinary rail
joints within railway switches will be measured separately for payment under Clause 4.06
“RAILWAY SWITCHES” and insulated rail joints within railway switches will be measured for
payment under this Clause. No measurement will be made of the additional 10% of insulated
rail joint assemblies to be furnished as spare parts. For purposes of measurement a joint
shall be considered as a single joint between two rail ends.

(6) Basis of Payment

The quantities of ordinary rail joints and insulated rail joints, as determined above, will be
paid for at the Contract unit price for the pay items listed below. This price and payment
shall be full compensation for manufacturing and furnishing all materials necessary for
ordinary rail joints and insulated rail joints and assembling at site, including rail cutting, rail
drilling and spacing adjustment works if necessary. The cost of spare parts for insulated rail

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

joints delivered under this Clause shall be considered to be included in the cost of insulated
rail joint parts installed at site.

Pay Item No. and Name Unit of Measurement

403(1) Ordinary Rail Joint set

403(2) Insulated Rail Joint set

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.04 SLEEPER AND FASTENING

(1) Description

This work shall consist of furnishing, delivering and installing sleepers of various types with
all fittings and fastenings in permanent tracks. The Contractor shall furnish all labor,
materials, tools and equipment to complete the work as described in this Clause. Types of
sleepers are classified as follows:

(a) Concrete Sleeper

Prestressed Concrete Sleeper for R54 rail as shown on the Drawings.

(b) Wooden Sleeper

Wooden Sleeper for R54 rail excluding those for use of (c) below.

(c) Bridge Sleeper

Wooden Sleeper for use on bridge section.

Prior to furnishing sleepers, the Contractor shall submit to the Engineer all technical data and
Shop Drawings and required test results.

(2) Materials

(a) Concrete Sleepers

Concrete sleepers shall conform to Indonesian Railway Standards and from local
factories approved by DGR with specified marking of month and year of manufacturing
as instructed by the Engineer. The Contractor shall test the quality of concrete sleepers
and submit test results as instructed by the Engineer for his approval.

(b) Wooden Sleepers (all types)

Wooden sleepers shall be hard, tough and resistant to splitting, abrasion, decay and be
sawn to regular shape and form, free from shakes, splits, hollows, knots, pith, heart
wood, compression failure or any other defects.

Dimensions of wooden sleepers shall be as follows:

Length Width Thickness

Wooden Sleeper 200 cm 22 cm 13 cm
Bridge Sleeper 200 cm 22 cm 18 cm

Tolerance shall be as follows: + 4 cm to – 2 cm + 2 cm to – 1 cm + 1 cm to – 0 cm

Where required, wooden sleepers shall be creosote treated to a depth of approximately

30 mm measured vertically from each side.

(c) Fastenings
Fastenings shall be double elastic type and conform to Indonesian Railway Standards
and shall include all parts and fittings for the various types of sleepers as shown on the
Drawings and instructed by the Engineer. The Contractor shall submit technical data
from the manufacturer for approval of the Engineer.

(3) Construction

(a) Standard track gauge shall be 1067 mm in straight section and standard sleeper
spacing 600mm. Sleepers shall be installed in accordance with the Drawings and this
Specification and shall be laid at right angles to the rails with the ends lined uniformly

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

as indicated on the Drawings. Rail joints shall be suspended joints with wooden
sleeper and sleeper spacing at the rail joint in accordance with Indonesian Railway
Standards.

(b) Rails shall be end-unloaded at appropriate locations adjacent to the designed track
laying and then laid in position and fixed to the sleepers. Joint gap shall be
established according to the rail temperature at the work site and fishplates then
attached.

(c) Upon completion of the work, all excess materials shall be hauled away and the site
shall be left clean and tidy to satisfaction of the Engineer.

(d) Wooden sleepers shall be marked in carving of month and year of completion after
installation at site, which shall be in conformity with Indonesian Railway Standards.

(4) Method of Measurement

The quantities of sleepers to be measured for payment shall be the actual number of pieces
for respective types of sleepers supplied and installed to site and the actual number of
fastening sets for the various types supplied and installed.

Fastenings used for each type of sleeper will be considered as one set for one sleeper.
Fastenings for concrete and wooden sleeper will be considered to include tie plates, screw
spikes, spacers, pads, double elastic type fastenings and all other accessories necessary for
fixing the sleeper to the rail. Sleepers for simple turnout and scissors crossing shall be
measured under other sections of this Specification.

(5) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price per
unit of measurement for the pay items listed below. The payment for sleepers and fastenings
shall be full compensation for furnishing, delivery of various types of sleepers to site,
installing in track, fixing various components of fastening to sleepers, setting rails on sleeper,
attaching fastenings to assemble rail and sleeper and positioning the assembled track panel
at preliminary alignment, including incidental works necessary for completion of the work
described in this Clause.

Pay Item No. and Name Unit of Measurement

404(1) Concrete Sleeper R 54 piece

404(2) Wooden Sleeper R 54 piece
404(3) Bridge Sleeper R54 piece
404(4) Fastening for Concrete Sleeper set
404(5) Fastening for Wooden Sleeper set

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.05 TRACK PANEL ASSEMBLY

(1) Description

This work shall consist of staking out the new track center, spreading and compacting
ballast, setting the track panel, making up and tamping the upper ballast cross section and
related work for setting the track panel assembly. The work shall include all field surveys
and measurements necessary to lay out the work, set the track panel and tamp the ballast at
the assembled location in conformity with the lines and grades shown on the Drawings or
established by the Engineer. The Contractor shall furnish all labor, materials, tools and
equipment to complete the work. After this work, horizontal and vertical track alignment
shall be in accordance with the final design alignment and the track condition shall be
suitable for train operation.

(2) Materials

(a) Rail R54

Rail R54 shall be furnished by the Contractor under Clause 4.01 “RAIL R54” of this
Specification.

(b) Rail Joint

Rail Joint shall be furnished by the Contractor under Clause 4.03 “RAIL JOINT” of this
Specification.

(c) Sleeper and Fastening

Sleeper and Fastening shall be furnished by the Contractor under Clause 4.04
“SLEEPER AND FASTENING” of this Specification.

(d) Ballast
Ballast shall be furnished by the Contractor under Clause 4.08 “BALLAST SUPPLY” of
this Specification.

(3) Construction

(a) Preparation
Necessary field surveys and measurements shall be carried out carefully by the
Contractor as required to accurately lay out the work, which shall be checked and
approved by the Engineer. Prior to commencement of the work, the Contractor shall
prepare a proposed work schedule for approval of the Engineer.

(b) Execution
Prior to commencement of the work, the Contractor shall prepare a well-planned work
schedule for approval of the Engineer. The work schedule shall include outline of the
work, preparatory arrangement for the work, required temporary facilities or structures,
proper assignment of workers, communication method and other means necessary for
proper performance of the work.

The work shall be executed by staking out the new track center, spreading the lower
ballast over the prepared sub-ballast layer, which is previously completed under
SECTION 2 “CIVIL WORKS” of this Specification and compacting the ballast from the
required depth as shown on the Drawings below the bottom level of the sleepers. The
track panel, including sleepers, rail and fastenings, is assembled on the above prepared
lower ballast in accordance with Clause 4.04 “SLEEPER AND FASTENING” of this
Specification.

The work shall be further executed by making up the upper ballast cross section,
tamping and setting the track panel such that the track horizontal and vertical alignment
is in accordance with the final design alignment and the track condition suitable for train

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operation. The work in this Clause also includes for all field surveys and measurements
as necessary, including furnishing all labor, materials, tools and equipment to complete
the work.

(c) Initial Tamping

After setting the track panel assembly on the designated track alignment, the Contractor
shall execute the initial tamping for compaction of ballast structure by using the tamping
equipment arranged by the Contractor or newly procured ones under Clause 4.16
“TRACK WORK EQUIPMENT” of this Specification. Initial tamping shall be completed in
accordance with the lines and grades of the approved track alignment with the
permissible tolerances by this Specification. After completion of initial tamping, the
Contractor shall execute the operational test of PT. KAI train by locomotive running etc.
and any defects of track facility and initial tamping work shall be rectified and be suitable
for regular train operation by PT. KAI.

Upon completion of the work, all excess materials shall be hauled away and the site shall
be left clean and tidy to satisfaction of the Engineer.

(4) Method of Measurement

The quantity to be measured for payment shall be the actual number of linear meters of track
assembled and laid on the site where all the work is completed, adjusted and accepted by
the Engineer for PT. KAI train operation, including track alignment setting and adjustment by
initial tamping works.

Track section assembled by railway switches will be measured separately for payment under
Clause 4.06 “RAILWAY SWITCHES” of this Specification.

Final tamping works shall be executed by the Contractor under Clause 4.09 “TRACK
TAMPING, RAISING AND SHIFTING” of this Specification after regular train operation by
PT. KAI.

(5) Basis of Payment

The quantity determined, as provided above, will be paid for at the Contract unit price for the
pay item listed below. The price and payment shall be full compensation for carrying out all
activities, materials, cutting rails, disassembly, removal, placing, assembling track panel,
connecting rails, initial tamping and compaction of ballast, track alignment adjustment and
operational test by PT. KAI train etc. necessary to satisfactorily complete the work prescribed
in this Clause.

Pay Item No. and Name Unit of Measurement

405 Track Panel Assembly linear meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.06 RAILWAY SWITCHES

(1) Description

This work shall consist of furnishing and installing new railway switches of types and
quantities necessary to complete the required track construction as shown on the Drawings.
The work shall include switch assemblies, wooden sleepers, ordinary fastening devices and
related work for assembling and installing the railway switches at site. The Contractor shall
furnish all labor, materials, tools and equipment required to complete the work. General plan
of switches shall be as shown on the Drawings and the Contractor shall submit Shop
Drawings in accordance with Indonesian Railway Standards for approval of the Engineer
prior to commencement of manufacture and should be coordinated with and suitable for
signalling system.

(a) Types of switches are as follows:

Simple Turnout R54 # 8
Simple Turnout R54 # 10
Scissors Crossing R54# 8
Scissors Crossing R54#10

(b) Switches comprise the following components:

Switch assembly (including switch rail, stock rail, slide plate and rigid brace)
Frogs (including nose and wing rails)
Main rails (including guard rail)
Closure rails (lead rails)
Wooden sleeper
Accessories (including bolts, nuts, spring washers, joint bars, tie plates and fillers)
Materials for switching device (insulated base plate and rod bracket)
Tongue clamp for necessary temporary lock (set for right and left sides per switch)

(2) Materials

(a) Except for frogs as described below, all materials to be used for railway switches shall
be in accordance with requirements given in Clause 4.01 "RAIL R 54", Clause 4.03
"RAIL JOINTS" and Clause 4.04 "SLEEPER AND FASTENING" of this Specification.

(b) Materials to be used for frogs, including nose and wing rails, shall be high manganese
cast steel conforming to the requirements specified below.

1) Mechanical Requirement
Tensile Strength : Min. 80 Kg/mm2
Elongation : Min. 40%
Bending Property : 180 degrees (inside radius 25 mm)
Brinell Hardness : 170 – 223 HB (after casting)

2) Chemical Composition
Carbon : 0.90 – 1.20%
Manganese : 11.0 – 14.0%
Silicon : 0.3 – 1.8 %
Phosphorus : Max. 0.05%
Sulphur : Max. 0.035%

(c) Other accessories and materials shall be of manufacturer’s standard type.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

(3) Marking for Frog

Following shall be marked by casting in relief on web of frog in legible characters.

Manufacturer’s name
Last two figures of year of manufacture
Rail profile

(4) Construction

(a) Fabrication
All parts shall conform to the required dimensions and be free from defects. Tongue rails
for switches shall be made from special section rails of Section A, UIC 861-2-0 or
equivalent standards and be elastic type. Heel ends of tongue rails shall be shaped so as
to ensure smooth connection with lead rails. Full consideration shall be made to ensure
that the part where special machining for elasticity is required shall have sufficient
strength. Frogs shall be made by monoblock casting. Railway switches shall be of a type
easily fitted with throwing mechanism, detector rods and all other accessories and
materials necessary for the smooth operation of point machines to be installed under
SECTION 8 “SIGNALLING SYSTEM WORKS” of this Specification.

(b) Finishing
All castings shall be carefully cleaned of sand, fins, detachable oxide and shall be free
from casting holes, gates and shrinkage heads. They shall also be free of such defects
as pipes, scales, blisters and shrinkage cracks.
Running surfaces and their connecting fillets, fishplates and all surfaces which make
contact on assembly shall be to correct profile and gauge. Fishbolt holes shall be drilled
and chamfered to 1 mm at the ends. Holes for sleeper screws and for electrical
connections shall be cast under size and then opened out to correct size.

(c) Assembly and Inspection

All switches shall be pre-assembled in the mill and checked to confirm that the
permissible variations specified below are met after which they shall be knocked down
and packed. Permissible variations shall be as follows:

Item Main Track Depot Track Remarks

Gauge + 2 mm to – 2 mm + 3 mm to – 3 mm
Alignment + 2 mm to – 2 mm + 3 mm to – 3 mm Per 10 m length
Cross Level + 3 mm to – 3 mm + 3 mm to – 3 mm
Longitudinal Level + 3 mm to – 3 mm + 3 mm to – 3 mm Per 10 m length

(d) Installation
The Contractor shall inspect switches prior to installation to verify that materials are in
conformity with this Specification. The Contractor shall check and correct all defects
before proceeding with installation of switches. Switches shall be assembled at the site
near the final installed position. An assembly platform shall be prepared level and solid
to prevent deformation or any damage to the switches. All sleepers shall be arranged
accurately as shown on the Drawings. After installing all parts and materials of switches,
the Contractor shall execute initial tamping work and measure each dimension and
elevation of switches and check for conformity with matching the final design alignment
and the track condition suitable for regular train operation by PT. KAI. Tolerances of
matching and acceptability shall be approved by the Engineer.

Simple Turnouts R54#8 in Cipinang Depot Yard as shown on the Drawings shall be
assembled with and operated by manual point lever which will be the salvaged
materials from the site. The Contractor shall be required to obtain the necessary point

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

levers from PT. KAI through coordination with the Employer and to assemble them with
the newly installed switches, including necessary repairing works and installation works
of accessories and indicator etc. according to Indonesian Railway Standards.

(5) Method of Measurement

The quantity to be measured for payment shall be the actual number of sets of new railway
switches, furnished, installed and accepted by the Engineer, including delivery of tongue
clamp set for each switch. Insulated rail joints installed in railway switches will be measured
separately for payment under Clause 4.03 “RAIL JOINTS" of this Specification. Ballast for
railway switches will be measured separately for payment under Clause 4.08 “BALLAST
SUPPLY”. Initial tamping work for final alignment at the newly installed switches area shall
be included in this Clause and final tamping work will be measured separately for payment
under Clause 4.09 "TRACK TAMPING, RAISING AND SHIFTING" of this Specification.
Railway switches installed on the temporary track will be measured separately for payment
under Clause 4.14 “TRACK FACILITY TEMPORARY WORK” of this Specification.

(6) Basis of Payment

The quantities of railway switches, as determined above, will be paid for at the Contract unit
price for the pay items listed below. This price and payment shall be full compensation for
furnishing the switches and wooden sleepers for switches and will include all assemblies,
compaction and initial tamping of ballast, labor, tools and incidental works, including manual
point lever assembly, necessary for the proper completion of the work prescribed in this
Clause.

Pay Item No. and Name Unit of Measurement

406(1) Simple Turnout R 54 # 10 set

406(2) Simple Turnout R 54 # 8 set
406(3) Scissors Crossing R 54 # 10 set
406(4) Scissors Crossing R 54 # 8 set

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.07 TRACKBED REFORMATION

(1) Description

This work shall consist of furnishing all materials, improving the existing embankment and
constructing drainage for trackbed formation, where the existing trackbed and ballast
structure are deteriorated by mud-pumping or drain water etc. Trackbed reformation work
shall include the detail survey at the required location and work method programme by the
Contractor. The work shall also include the construction of trackbed drainage facility and
connection to the nearest existing one, conforming to the requirements of this Specification.

(2) Materials

Materials to be applied for trackbed reformation shall be geotextile, cobble stone, coarse
sand, gravel and sand in accordance with SECTION 2 “CIVIL WORKS” of this Specification.
Quantity necessary and required for trackbed reformation works shall be the responsibility of
the Contractor.

(3) Preparation

Prior to commencement of the trackbed work, the Contractor shall be required to submit the
track work programme for approval of the Engineer regarding the location, length of
improving track, construction schedule and temporary work method, including work
programme for window-time. Construction work plan during window-time at the operating
track shall only be permitted by the Engineer after confirmation with PT. KAI.

(4) Construction

After work arrangement is ready to commence trackbed improvement, the existing ballast will
be temporarily removed and trackbed embankment shall be constructed for reformation. The
Contractor shall perform excavation of every type of material encountered within the limits of
work to the lines, grades and elevations indicated on the Drawings. After completion of all
the earth reformation and compaction works and the trackbed drainage facility installation,
the temporarily removed ballast will be cleaned, backfilled and treated by initial tamping as
required in Clause 4.05 “TRACK PANEL ASSEMBLY”, including operational test of PT. KAI
train. The track position shall be in accordance with the final design track alignment.
Construction of ballast protection by gabion will be executed separately in SECTION 2 “CIVIL
WORKS”.

(5) Method of Measurement

The quantity to be measured for payment shall be the actual number of cubic meters for
trackbed reformation constructed and accepted by the Engineer, including delivery of all
materials, backfilling and tamping of ballast and the completed works measurement etc. The
quantity of trackbed reformation constructed shall be measured in accordance with lines,
grades and section lengths from Shop Drawings approved by the Engineer. The quantity to
be measured for payment shall be the actual number of linear meters for trackbed drainage
constructed and accepted by the Engineer.

(6) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for all costs
necessary for the proper completion of the work prescribed in this Clause.

Pay Item No. and Name Unit of Measurement

407(1) Trackbed Reformation cubic meter

407(2) Trackbed Drainage linear meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.08 BALLAST SUPPLY

(1) Description

This work shall consist of furnishing and providing ballast at site for track construction,
conforming to the requirements in this Specification. Ballast supply work shall be classified
by the following work purposes and will be measured by separate quantity and payment as
required for the respective Clauses in this Specification.

(a) Ballast for New Track Installation

Ballast supply shall be required under Clause 4.05 “TRACK PANEL ASSEMBLY” and
Clause 4.06 “RAILWAY SWITCHES” and this ballast shall be provided and measured
under Clause 4.08 “BALLAST SUPPLY”.

(b) Ballast for Track Raising and Shifting

Ballast supply shall be required and provided under Clause 4.09 “TRACK TAMPING,
RAISING AND SHIFTING”.

(c) Ballast for Track Facility

Ballast supply shall be required and provided under Clause 4.10 “RAIL AND SLEEPER
REPLACEMENT”, Clause 4.11 “BUFFER STOPS” and Clause 4.12 “TRACK SIGN AND
POST”.

(d) Ballast for Temporary Track Installation

Ballast supply shall be required and provided under Clause 4.14 “TRACK FACILITY
TEMPORARY WORK”.

(2) Materials

Ballast shall be obtained from quarries approved by the Engineer. Material shall be crushed
basalt, granite or andesite that is durable, angular and hard and does not contain any
organic materials, soils and debris and shall conform to the following grading requirements.

Sieve (mm) Size (inch) Percentage passing by weight

63.5 2½“ 100
50.8 2” 80-100
38.1 1½“ 35-75
25.4 1” 0-40
19.1 3/4 “ 0-5
Ballast shall be tested at the authorized laboratory approved by the Engineer whenever
directed by the Engineer to examine grading requirements, resistance to abrasion, gravity
and soundness etc. Coefficient of abrasion of the sampled ballast shall not exceed 30% in
accordance with AA SHTO-T-96.

(3) Construction

Ballast haulage method and temporary stockpile near the site shall be approved by the
Engineer. The Contractor shall be responsible for ballast supply from quarries to site of the
designated track facility construction in quality and quantity requirements, including
temporary stockpile arrangement, haulage transport system, quantity measuring methods
and actual supply record control etc.

Ballast shall be unloaded by means approved by the Engineer and unloaded ballast shall be
levelled with ballast plough or spreader to form the new track structure in accordance with
Clause 4.05 “TRACK PANEL ASSEMBLY” and Clause 4.06 “RAILWAY SWITCHES” of this
Specification.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

Up to the time of Provisional Hand-Over, the Contractor shall be responsible for ensuring
that the ballast remains clean and free from contamination with soil or other materials. Any
ballast which becomes contaminated shall be removed and replaced by the Contractor.

(4) Method of Measurement

The quantity to be measured for payment shall be the actual number of cubic meters of new
ballast supplied and haulaged to site for new track construction. Ballast supply for new track
construction in accordance with Clause 4.05 “TRACK PANEL ASSEMBLY” and Clause 4.06
“RAILWAY SWITCHES” shall be measured by the quantity calculated in accordance with
lines and grades from Shop Drawings approved by the Engineer without consideration of
quantity to be shrunk by tamping works and without deduction of quantity to be occupied by
sleepers. Ballast supply necessary and required for other works by Clause 4.09 “TRACK
TAMPING, RAISING AND SHIFTING”, Clause 4.10 “RAIL AND SLEEPER REPLACEMENT”,
Clause 4.11 “BUFFER STOPS”, Clause 4.12 “TRACK SIGN AND POST” and Clause 4.14
“TRACK FACILITY TEMPORARY WORK” etc. will not be measured by this Clause but shall
be included and measured by the respective Clauses of this Specification.

(5) Basis of Payment

The quantity determined, as provided above, will be paid for at the Contract unit price for the
pay item listed below. This price and payment shall be full compensation for all costs
necessary for the proper completion of the work prescribed in this Clause. The work of
cleaning, replacing or adding the ballast before Provisional Hand-Over will not be measured
for payment and will be considered a subsidiary obligation under the work described in this
Clause.

Pay Item No. and Name Unit of Measurement

408 Ballast Supply cubic meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.09 TRACK TAMPING, RAISING AND SHIFTING

(1) Description

This work shall consist of track tamping, raising and shifting of ballast in accordance with this
Specification and in close conformity with the lines and grades shown on the Drawings or
established by the Engineer.

Track raising or shifting work shall consist of making the vertical or horizontal movement of
the existing track to form a new junction or a new alignment with an adjacent new track,
where changing of the existing alignment is necessary to be performed by tamping or any
other work method under no train movement thereon. Track section, completed by raising or
shifting works, shall be executed by initial tamping works and operational test by PT. KAI
train same as required by Clause 4.05 “TRACK PANEL ASSEMBLY” of this Specification for
regular train operation by PT. KAI. Final tamping works shall be executed under this Clause
4.09 “TRACK TAMPING, RAISING AND SHIFTING” after regular train operation by PT. KAI.

(2) Materials

Ballast, as required for changing of track alignment, shall be supplied and furnished by the
Contractor in accordance with Clause 4.08 “BALLAST SUPPLY” of this Specification.
Quantity of ballast supply shall be calculated by the Contractor in accordance with the lines
and grades from Shop Drawings approved by the Engineer and shall be the responsibility of
the Contractor for satisfactory completion of work as required by this Clause.

(3) Construction

Horizontal and vertical alignment of track shall be as shown on the Contractor's track layout
drawings as approved by the Engineer. All tamping work and track realignment by raising
and shifting works shall be based on the staking marks established by this Specification.

Ballast shall be well packed with Multiple Tie Tamper (MTT) or equipment approved by the
Engineer as final tamping works after regular train operation by PT. KAI under Clause 4.05
“TRACK PANEL ASSEMBLY”, Clause 4.06 “Railway Switches” and this Clause 4.09 “TRACK
TAMPING, RAISING AND SHIFTING”. The Contractor shall be responsible for arrangement
of MTT either by rent, lease or hire method for tamping work efficiency. The Contractor shall
trim the ballast to conform to the standard ballast section shown on the Drawings or
instructed by the Engineer. Any track irregularities at unloaded conditions shall be within the
following tolerances:

Gauge Difference : + 5 mm to – 2 mm (on straight)

Alignment Deviation : + 5 mm to – 5 mm (for 10 m span)
Longitudinal Level Deviation : + 7 mm to – 7 mm (for 10 m span)
Cross Level Deviation : + 6 mm to – 6 mm (at spot)

(4) Method of Measurement

The quantity of track tamping to be measured for payment shall be the actual number of
linear meters of track length for which final tamping works have been carried out under
Clause 4.05 “TRACK PANEL ASSSEMBLY”, Clause 4.06 “RAILWAY SWITCHES” and this
Clause 4.09 “TRACK TAMPING, RAISING AND SHIFTING”, completed in place and
accepted by the Engineer. The quantites of track raising and shifting shall be the actual
number of square meter of track line movement by final raising or shifting work, including
initial tamping works as required by this Specification and completed in place and accepted
by the Engineer. Ballast supply for track raising and shifting works will not be measured
separately under this Clause and shall be deemed inclusive to these works.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

(5) Basis of Payment

The quantities of track tamping, raising and shifting, as determined above, will be paid for at
the Contract unit price for the pay items listed below. This price and payment shall be full
compensation for all costs necessary for the proper completion of the work prescribed in this
Clause, including machine charges and costs of MTT arrangement and any other equipment
operation for track tamping and material and transport costs of ballast for track raising and
shifting.

Pay Item No. and Name Unit of Measurement

409(1) Track Tamping linear meter

409(2) Track Raising square meter
409(3) Track Shifting square meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.10 RAIL AND SLEEPER REPLACEMENT

(1) Description

This work shall consist of replacing the existing rail and sleepers damaged on the track by
new materials. The work shall include replacing ballast under the rail or sleeper, removing
the existing rail or sleeper, supplying and placing of new rail or sleeper and fastening,
furnishing of new ballast, adjustment of track irregularities, tamping and related work for
replacement of the rail and sleeper.

(2) Materials

Materials to be applied for rail and sleeper replacement shall be in accordance with this
Specification as listed below. Quantity necessary and required for rail and sleeper
replacement works shall be the responsibility of the Contractor.

Rail R54
Concrete Sleeper R54
Wooden Sleeper R54
Bridge Sleeper R54
Fastening for Concrete and Wooden Sleeper R54
Ballast

(3) Construction

Prior to commencement of rail and sleeper replacement works, rail and sleeper shall be
marked to fix the position. Rail and sleeper replacement shall be implemented during
window time after approval by the Engineer so as not to hinder train operation and
passenger service by PT. KAI. After tight fastening of rail and sleeper, ballast shall be
thoroughly compacted and adjustment work shall be implemented to maintain correct track
tolerances as required by this Specification. Removed rail and sleeper under this Clause,
including all accessories, shall be returned to the warehouse in Manggarai or as instructed
by the Engineer.

(4) Method of Measurement

The quantity of rail replacement to be measured for payment shall be the actual number of
linear meters of rail replaced in the track and tamped, completed and accepted by the
Engineer. The quantity of sleeper replacement to be measured for payment shall be the
actual number of pieces of various sleepers replaced in the track and tamped, completed and
accepted by the Engineer.

Rail welding work, if required, shall be measured under Clause 4.02 “RAIL WELDING” of this
Specification.

(5) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for supply of
various rail, sleeper and fastening, ballast, tools and labor for rail and sleeper replacement,
tamping compaction of ballast, track alignment adjustment, transportation and clearing of
removed rail and sleeper from the site.

Pay Item No. and Name Unit of Measurement

410(1) Rail Replacement linear meter

410(2) Concrete Sleeper Replacement piece

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

410(3) Wooden Sleeper Replacement piece

410(4) Bridge Sleeper Replacement piece

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.11 BUFFER STOPS

(1) Description

This work shall consist of furnishing all materials, assembling, installing and constructing the
various types of buffer stops, conforming to the requirements in this Specification and as
shown on the Drawings. Type of buffer stops shall be as follows:

Buffer Stop Type A by concrete and ballast stopper

Buffer Stop Type B by rail and ballast stopper
Buffer Stop Type C by rail stopper

(2) Materials

Rail shall be used rails salvaged from the site and arranged by the Contractor. Concrete and
wooden sleepers, together with fastening and rail joints, shall be used sleepers salvaged
from the site and arranged by the Contractor. Quantity necessary and required for buffer
stock works shall be the responsibility of the Contractor. Assembling parts shall be
fabricated from locally available materials. Ballast shall be in accordance with Clause 4.08
“BALLAST SUPPLY” of this Specification.

(3) Fabrication

Fabrication of rail stopper shall be commenced after approval by the Engineer. All steel work
shall be in accordance with Shop Drawings approved by the Engineer. Paint work shall be
completed after fabrication by the Contractor.

(4) Construction

Area for buffer stop installation shall be cleared, grubbed and compacted. Ballast shall be
provided as shown on the Drawings with tamping work. Buffer stops shall be assembled and
installed in accordance with Shop Drawings approved by the Engineer. Any related works
shall be executed in accordance with SECTION 2 “CIVIL WORKS”.

(5) Method of Measurement

The quantity to be measured for payment shall be the actual number of sets of buffer stops
constructed and accepted by the Engineer.

(6) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for furnishing
the used rail, fabrication materials, ballast, tools and labor for assembling, installing and
constructing buffer stops and related civil works and all costs necessary for the proper
completion of the work prescribed in this Clause.

Pay Item No. and Name Unit of Measurement

411(1) Buffer Stop Type A set

411(2) Buffer Stop Type B set
411(3) Buffer Stop Type C set

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.12 TRACK SIGN AND POST

(1) Description

This work shall consist of furnishing all materials, installing and constructing the various
types of track signs and posts, conforming to the requirements in this Specification and as
shown on the Drawings. Track signs and posts shall include as follows:

Gradient Sign
Curve Sign
Andrews Cross Sign
Kilometer Post
Meter Post
Clearance Post
Curve Datum Post

(2) Materials

Rail shall be used rail salvaged from the site and arranged by the Contractor. Assembling
parts shall be fabricated from locally available materials.

(3) Fabrication

Fabrication of signs and posts shall be commenced after approval by the Engineer. All steel
work shall be in accordance with Shop Drawings approved by the Engineer. Paint work shall
be completed after fabrication by the Contractor.

(4) Construction

All track signs and posts shall be anchored in place as indicated on the Drawings. Anchoring
of sign post shall be done by a method suitable for each site. The Contractor shall perform
excavation of installation ground to the lines, grades and elevations indicated on the
Drawings. Backfill of signs and posts shall be accomplished by using excavated soil and
shall be compacted. Installation of signs and posts shall not interfere with the existing train
operation. Locations of signs and posts shall be approved by the Engineer before
installation.

(5) Method of Measurement

The quantities to be measured for payment shall be the actual number of each track sign and
post constructed and accepted by the Engineer.

(6) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for furnishing
used rail, fabrication materials, tools and labor for assembling, installing and constructing
track signs and posts and all costs necessary for the proper completion of the work
prescribed in this Clause.

Pay Item No. and Name Unit of Measurement

412(1) Track Sign each

412(2) Track Post each

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.13 LEVEL CROSSING PAVEMENT

(1) Description

This work shall consist of furnishing all materials and constructing level crossing pavement
and drainage facility works, conforming to the requirements in this Specification and as
shown on the Drawings. Level crossing pavement work shall include the maintenance of
road traffic arrangement on the existing crossing locations under all the works including
interfacing works with public road until completion of final pavement works by the Contractor.
Any related works for ballast supporter and cross drainage facility shall be included in this
work in accordance with SECTION 2 “CIVIL WORKS”.

(2) Materials

Materials to be applied for level crossing pavement shall be as listed below and in
accordance with SECTION 2 “CIVIL WORKS” of this Specification. Quantity necessary and
required for level crossing pavement works shall be the responsibility of the Contractor.

Asphalt Concrete Surface Course

Asphalt Concrete Binder Course
Asphalt Treated Base Course
Sub Base Course
PVC Pipe for Fastening Cover
Rubble Stone Foundation
Concrete
Reinforcing Bar
Steel Structure Works for U-Ditch Cover

(3) Preparation

Prior to preparing detailed work programme and during execution of the work, the Contractor
shall coordinate and interface with other works such as civil, building, overhead contact,
power distribution, signalling and telecommunication works. Any coordination requirements
during installation of level crossing pavement shall be the responsibility of the Contractor.

(4) Construction

During execution of the various track works the Contractor shall be required to maintain road
traffic arrangement of any temporary facility works for all the level crossing locations,
including arrangement for temporary road or detouring road and coordination with local road
traffic authorities or police etc. After completion of final tamping works and confirmation of
final track alignment by the Contractor, level crossing pavement work shall be executed by
the Contractor to cover the track ballast and to interface with the existing public road surface
as shown on the Drawings. Any related structure works such as ballast supporter and cross
drainage facility under the level crossing area shall be constructed by the Contractor in
accordance with SECTION 2 “CIVIL WORKS”.

Existing asphalted and concrete roads shall be interfaced by an overlay of asphalt concrete
on the existing surface. Existing surface will be left intact but cleaned and trimed to accept
the new surface for asphalt overlay works.

(5) Method of Measurement

The quantity to be measured for payment shall be the actual number of square meters of
level crossing pavement constructed and accepted by the Engineer. The quantities to be
measured for payment shall be the actual number of linear meters of u-ditch and french drain
and the actual number of each of catch basin constructed and accepted by the Engineer.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

The quantity to be measured for payment shall be the actual number of linear meters of
ballast supporter constructed and accepted by the Engineer.

(6) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for furnishing
all the materials, tools and labor for constructing level crossing pavement and all costs
necessary for the proper completion of the work prescribed in this Clause.

Pay Item No. and Name Unit of Measurement

413(1) Level Crossing Pavement square meter

413(2) Level Crossing U-Ditch Drain linear meter
413(3) Level Crossing French Drain linear meter
413(4) Level Crossing Catch Basin each
413(5) Level Crossing Ballast Supporter linear meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.14 TRACK FACILITY TEMPORARY WORK

(1) Description

This work shall consist of furnishing all materials, installing and constructing track facility for
temporary use and maintaining temporary track facility, conforming to the requirements in
this Specification and as necessary or required by the track changing plan prepared and
construction method programme by the Contractor.

(2) Materials

Materials to be used for the temporary track work shall be as listed below and conform to the
requirements of this Specification. Materials to be applied for the temporary work will be
utilized from the procured or salvaged ones under execution of this Project and the
Contractor shall be responsible for arrangement of the necessary quantity of all materials.
Rail R54
Compromised Rail R54/42
Rail Joint
Sleepers and Fastening R54
Railway Switches R54 and R42
Ballast

(3) Preparation

Prior to commencement of the temporary track work, the Contractor shall be required to
submit the track work programme for approval of the Engineer regarding the location, length
of temporary track, construction schedule and work method, including work programme for
window-time. Construction work plan during window-time at the operating track shall only be
permitted by the Engineer after confirmation with PT. KAI.

(4) Construction

Temporary track facility shall be installed with ballast on trackbed to the lines, levels and
grades approved by the Engineer. Salvaged materials derived from other works, which shall
be arranged by the Contractor under the permission of PT. KAI, shall be returned to PT. KAI
when removed from the temporary track. Track laying and initial tamping works shall be in
accordance with Clauses 4.05 “TRACK PANEL ASSEMBLY” and 4.06 “RAILWAY
SWITCHES” of this Specification for regular train operation by PT. KAI.

(5) Method of Measurement

The quantity to be measured for payment of track panel section shall be the actual number of
linear meters of track panel assembly temporary use constructed and accepted by the
Engineer. The quantities to be measured for payment of railway switches section shall be
the actual number of sets of simple turnout and scissor crossing assembly temporary use
constructed and accepted by the Engineer

(6) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for furnishing
all the materials, tools and labor for constructing temporary track facility, including initial
tamping works, operational test by PT. KAI train, maintenance of temporary track facility for
regular operation by PT. KAI and removal works after no further use of temporary track
facility and all costs necessary for the proper completion of the work prescribed in this
Clause.

Pay Item No. and Name Unit of Measurement

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

414(1) Track Panel Assembly Temporary Use linear meter

414(2) Simple Turnout Assembly Temporary Use set
414(3) Scissors Crossing Assembly Temporary Use set

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.15 TRACK FACILITY REMOVAL WORK

(1) Description

This work shall consist of executing track facility removal work and transporting the salvaged
materials, conforming to the requirements in this Specification and as shown on the
Drawings.

Track removal work shall include removal of existing track panel, railway switches, buffer
stops, ballast and transportation of all removed materials, i.e. rail, rail accessories,
fastenings, switches, sleepers and any parts thereof etc. Those materials to be reused as
directed by the Engineer shall be prepared for reuse and transported to the location where
they shall be reused. All excess materials shall be transported to the warehouse in
Manggarai or other designated storage areas as instructed by the Engineer. The Contractor
shall furnish all labor, materials, tools and equipment to complete the work.

(2) Construction

Prior to commencement of the work, the Contractor shall prepare a proposed work schedule
for approval of the Engineer. Removal work of the existing track facility shall be executed at
the same time of track or switch installation according to the work schedule approved by the
Engineer. Cutting of rails, when necessary, shall be carried out by sawing and the end
surfaces of rails shall be right-angled to the longitudinal axis of rail. The Contractor shall
make an inventory of designated track materials to be removed and submit to the Engineer.
All removed rails shall be disassembled and transported to the location instructed by the
Engineer.

(3) Method of Measurement

The quantity to be measured for payment for “Track Panel Removal” shall be the actual
number of linear meters of track removed and accepted in accordance with this Specification,
including any miscellaneous work items on the existing track sides. The quantities for
“Simple Turnout”, “Scissor Crossing”, “Double Slip Switch” and “Buffer Stop Removal” shall
be the actual number of sets and “Ballast Removal” shall be the actual number of cubic
meters as removed and accepted in accordance with this Specification.

(4) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract unit price for
the pay items listed below. This price and payment shall be full compensation for all work of
removal and stockpiling all materials, including labor, transportation, equipment, tools and all
incidentals necessary to complete the work prescribed in this Clause.

Pay Item No. and Name Unit of Measurement

415(1) Track Panel Removal linear meter

415(2) Simple Turnout Removal set
415(3) Scissor Crossing Removal set
415(4) Double Slip Switch Removal set
415(5) Buffer Stop Removal set
415(6) Ballast Removal cubic meter

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.16 TRACK WORK EQUIPMENT

(1) Description

This work shall consist of supply and delivery of various equipment, machinery and tools for
use of track works under the Contract and in accordance with this Specification. The
Contractor shall procure all equipment after approval of the Engineer and maintain the
procured equipment in normal use for the site track works during Contract Period. After
Completion of the site track works the Contractor shall hand-over all equipment to the
Employer in an operable condition with acceptable wear and tear.

(2) Scope of Work

All equipment, machinery and tools shall be of a manufacturer’s standard type and durable
for the site works of track construction and maintenance. All equipment shall be brand new
and conform to this Specification. The Contractor shall be required to submit the
procurement programme for approval of the Engineer and shall provide the operation and
maintenance manuals of the following equipment:

(a) Track Work Car

Engine Power: 50 ~ 60 PS with ballast tamper and sleeper gripper attachments

(b) Track Motor Car

Engine Power: 230 ~ 250 PS, Hydraulic Crane: 5 ton

(c) Hand Tie Tamper

Tamper Motor: 450 W, Vibration Frequency: Not less than 2800 rpm

(d) Portable Engine Generator

Output: 4 kVA, 220 V

(e) Rail Handling Stand

Lifting Capacity: 1000 kg

(f) Track Panel Jack

Head: 10 ton, Toe: 8 ton

(g) Rail Jack

Head: 5 ton, Toe: 3 ton

(h) Rail Welding Machine

Method: Thermit Welding

(i) Rail Cutting Machine

Type: Reciprocating/Rotating

(j) Rail Drilling Machine

Drilling Diameter: Max. 32 mm

(k) Track Work Tools

Type: Standard

(3) Method of Measurement

The quantity to be measured for payment shall be the actual number of each individual type
of equipment measured as one set, conforming to the required performance indicated above,
delivered in satisfactory condition and accepted by the Engineer. Track work tools shall be
measured by a lot for all the required tools and devices.

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

(4) Basis of Payment

The quantities determined, as provided above, will be paid for at the Contract prices per unit
of measurement for the pay items listed below. This price and payment shall be full
compensation for supplying and delivering all equipment as described in this Clause,
including all accessories required and shall be reimbursed as follows:

- 70% on arrangement and supply of all equipment

- 30% on Provisional Hand-Over of all equipment

Pay Item No. and Name Unit of Measurement

416 (1) Track Work Car set

416 (2) Track Motor Car set
416 (3) Hand Tie Tamper set
416 (4) Portable Engine Generator set
416 (5) Rail Handling Stand set
416 (6) Track Panel Jack set
416 (7) Rail Jack set
416 (8) Rail Welding Machine set
416 (9) Rail Cutting Machine set
416 (10)Rail Drilling Machine set
416 (11)Track Work Tools lot

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 Railway Electrification and Double-Double Tracking of Java Main Line Project(I), Package A – Technical Specifications

4.17 TRACK MATERIAL OVERSEAS INSPECTION

(1) Description

This work shall consist of arrangement and execution of overseas inspection performance
with supply of all necessary arrangement for international and local transportation, testing
tools, materials and equipment necessary for inspecting activity by the representatives of the
Employer and the Engineer at the place of manufacture or factory of track material to be
provided by the Contract.

(2) Scope of Work

The Contractor shall carry out the inspection test for track material to be provided by the
Contract in the presence and supervision by the representatives of the Employer and the
Engineer. The Contractor shall provide all transportation and traveling arrangement to the
locations and furnish all labor and facility for carrying out the test.

(3) Method of Work

(a) The Contractor shall make a schedule for overseas inspection for track material to be
procured from overseas manufacturer or factory in accordance with this Specification.
(b) The factory inspection test shall be in accordance with this Specification and the
Contractor shall prepare test procedure and technical requirements complying with this
Specification before commencement of the inspection.
(c) Factory test report shall be documented including the test results and acceptance by the
inspection representatives of the Employer and the Engineer.

(4) Inspection Programme

An overseas inspection programme shall be established for one (1) week period for five (5)
inspectors from the representatives of the Employer and the Engineer. Inspection shall be
executed at the original manufacturer or factory of track material after production and before
shipment. The Contractor shall complete all the necessary arrangement for international
traveling, domestic transportation, accommodation and lodging, inspection activities and
reporting documentation of inspection results etc.

(5) Submittals

The Contractor shall submit in writing one (1) month advance notice to the Engineer of the
overseas inspection schedule when Contractor is ready to make the inspection test.

(6) Cost and Payment

Cost of complying with this Clause shall be included and reimbursable under pay item 401
“Rail R54”.

Section 4 – Track Works Page 34 of 34