EDILON Dex -K 2K - Contracts Finder

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