IRCON International Limited has invited an online e-Tender for Design of broad gauge ballast less track BLT including supply, installation, testing and commissioning between Sivok and Rangpo approx. 39.05 km in connection with Sivok Rangpo New BG single line railway project.
- Tender Reference Number: IRCON/2046/SRRP/BLT-01
- Name of Work: Design of broad gauge ballast less track BLT including supply, installation, testing and commissioning between Sivok and Rangpo approx. 39.05 km in connection with Sivok Rangpo New BG single line railway project.
- Estimated Cost of Work: INR 277.71 Crore
- EMD: INR 1.45 Crore
- Period Of Work: 14 Months
- Document Download / Sale Start Date: 11th January, 2023
- Document Download / Sale End Date: 30th January, 2023
- Pre-Bid Meeting Date: 19th January, 2023
- Bid Submission Start Date: 24th January, 2023
- Bid Submission End Date: 30th January, 2023
- Bid Opening Date: 31st January, 2023
Scope of Work:
- Design of ballast less track with appropriate fastening system for 60Kg 1080 grade Head Hardened Class A Rails including arrangement for provision of derailment like slab/block, preparation of associated drawings & specifications, submission of construction methodology including QAP and maintenance manual for the ballast less track on freight/mixed (passenger and freight) traffic route for straight & curved track in tunnels, on Formation, on bridges, Yards and in transition portion from ballast less track to ballasted track with design criteria based on latest international standards/codes/proven practices and construction as per approved design of Ballast less track on the Section from Sivok to Rangpo (approx. 39.05 km) including additional approaches at tunnel faces in connection with Sivok – Rangpo New BG Single Line Railway Project (approx. 39.05 km).
- The work shall also include design & laying of Ballast less track in Yards, Turnouts, SEJ, etc. Including the RSI (Rail Structure Interaction) Analysis and Design on the Bridges if required.
- List of drawings of GAD of Tunnels having L-Section, X- Section are annexed as per Section-9 (Drawings). List of structures are annexed as per Section-10, where BLT is to be done.
- Submission of d e t a i l e d drawings, material specifications, technical parameters and characteristics, manufacturing tolerances, etc. of all the components of BLT (Ballast Less Track).
- Construction of Ballast less Track including provision of derailment arrangement and transitions portion including cost of labour, tools & plants, consumables, fuels, all materials, taxes etc complete as per approved drawings including linking of track as per specifications., more particularly, and without in any way limiting the generality of the foregoing, the work in this Contract shall include the following:
- Survey including traverse & levelling, fixing of intermediate control points, picking up the as build co-ordinates of the tunnel, adjusting alignment if required, Setting-out final alignment, etc.
- Construction of side drains wherever required and laying of Track slab.
- BLT shall be of re-inforced cement concrete structure. Derailment slab/block inside the running track. Typical X-Section of BLT structure is shown in the Tender Document under Section -9: Drawings for BLT at Page No 1,1A, 1B, 1C of 100.
- Complete track work such as linking, greasing, painting etc.
- Welding of UIC 60 IRS-T-12-2009, 880 grade rails and UIC 60, 1080 grade head hardened rails using the specified welding techniques.
- Provision of shear connector, wherever required, between 1st pour and 2nd pour reinforced concrete for ballast less track and also between Tunnel Invert Concrete and Track Slab.
- All other works incidental thereto for completion of the work.
- Testing of components and installation methods.
- Transportation of Rails & other fastenings from sivok stockyard to work site.
- Laying, Testing & commissioning of Turnouts, SEJs, etc.
- Welding of Track (Flash Butt Welding & AT welding) in stock yard & on track. The Contractor shall arrange his own mobile flash butt welding plant. QAP approval and standardization of Welding parameters for individual machines to be used for welding by RDSO will be mandatory as per para 5.6 of RDSO flush butt welding manual – 2012 or latest.
- Provision of ducts for electrical, signal & telecommunication etc. cables in longitudinal and transverse direction as required.
- Five sets of special gadgets / inspection equipment for measuring the toe load in service shall be provided.
- Design and drawings of BLT will have to be approved from a committee of officers nominated by the Railway Board. It shall not absolve the contractor from producing the Ballast less track of proper functional utility for which it is designed.
- All necessary software / specification and other documents required for evaluation of design and drawings will have to be arranged by the tenderer. A competent engineer shall be available for regular interaction with the Railways committee in this regard for approval of design/drawings.
- All enabling works for safe and satisfactory execution of the work.
- The BLT system proposed by the agency should fulfil the technical requirements specified hereunder & elsewhere in the tender document.
- The design & working methodology submitted by the agency will be proof checked and the agency will be responsible for providing the details and drawing to the proof check consultant and providing all assistance for the design will be in the scope of the agency.
- The work front will be provided in stages and not in one go. The work may have to be carried out in parallel to other works going on in the same area/ tunnel by different agencies. For construction works Contractor has to submit the Sequence of Works considering all such restraints duly interfacing with civil & system contractors.
- The construction period proposed in the document is considering the phased manner of handing over of site.
- The Contractor has to submit the performance guarantee for a value of 5% (Five percent) of contract Value, for the performance of design of BLT and fastening system in service valid for the period of 5 years after the defect liability period.
- Please note that this performance guarantee is separate over and above the performance guarantee submitted for faithful execution of works. This Guarantee will have to be provided after completion of work but before release of Security Deposit.
- The agency will have to supply 2% of the fastening components and other replacement items which are likely to be worn out / damaged at their quoted rates. No additional cost will be paid for these spares.
- Organizing 5-days training covering design aspects, construction, maintenance, technological advancements in BLT, etc, in the country of origin with their own experts in respective fields. The quoted price will be inclusive of training cost for maximum 10 officials of Railways/IRCON. Transport, lodging & boarding will be arranged by IRCON/Railways on its own.
- There are varying provisions kept in different tunnels for adjusting BLT Track slabs. Track concrete layer (TCL) for BLT, i.e. Track slab will have to cover the entire width between pathways/drains on both sides (i.e. approx. 3500 mm) including Derailment Block/ Derailment Guard and depth up to 527mm from Rail Top (Except Cant if any) & at curve location the depth shall be measured from top of inner rail, which the bidder has to consider while quoting rates.
- The rates quoted by the bidder for laying of track slab for plain track transitions will cover reinforcement and concrete of designed grade for approximate width of 3500 mm and depth of 527mm from Rail Top, including derailing block. Any additional depth/width of filler concrete will be paid under the respective item of BOQ.
- Some of the tunnels or parts of some of the tunnels are not provided with internal drainage systems, where track side drains will be constructed. The size of drain will be standard and will not involve any hydraulic design, except for the design of drain walls & bottom slab, which will be in the scope of the agency at their quoted rates.
- The concreting & reinforcement will be paid as a separate item under respective items of BOQ. It will be the responsibility of the BLT Designer to engage adequate experience and quality staff.
- Contractor will prepare his design basis report containing design criteria and get it approved from IRCON, and then proceed with the detailed design.
- The scope of work will also include getting approval of design and drawing from IRCON/NEFR by deputing concerned design Engineer.
- Contractor will carry out the design and submit the same to IRCON or proof consultant for checking without any loss of time. They will also be prompt in clarifying the objections/doubts of the IRCON/Proof Consultant. At no stage, work at site should suffer on account of design.
- Arranging the final approval for all design & drawing will be the responsibility of the contractor. 2.27 IRCON/Railway will get the proof check done of the design submitted by the contractor by an independent design agency whose credentials shall not be less than mentioned in clause 1.2 (b) of Essential Technical Qualification Criteria.
- Ballast less track system proposed for construction on Sivok – Rangpo New BG Railway Line (SRRP) Project should be proven and being used in worldwide railways successfully. The proven design may require some modifications to suit the Indian Railways conditions. This present tender is being invited for such proven design of ballast-less track worldwide from the bidders which is suitable for construction for Indian Railways conditions.
Design Requirements:
- In designing ballast-less track for straight & curved track on Indian Railways, the following parameters may be considered for guidance.
- Ballast less Track shall be designed for the following:
- Main line for 25T axle load & speed 100 kmph (proposed for goods traffic) & 22Taxle load & speed 160 kmph (for passenger traffic)
- Loop line for 25T axle load & speed 50kmph.
- Dynamic augment may be taken as 2.5 (as prevailing on IR)
- Spacing or support to rails – preferably at every 60 cm (wherever rails are supported on sleepers / discrete supports) so that the permissible bending stress in rails is not exceeded beyond stipulated values. The values of permissible bending stress are as under:
- For LWR section – 25.25 kg/mm2 (for 90 UTS, Head Hardened Rail)
- For SWP – 30.25 kg/mm2 (for 90 UTS, Head Hardened Rail)
- For FP section – 36.00 kg/mm2 (for 90 UTS, Head Hardened Rail)
- Upward reaction/ pressure from the support base should be clearly mentioned in design.
- Design shall be as per relevant codes of practice such as BIS, EN, IRS, IRC and UIC with latest revision/edition). If for any item/work, above mentioned codes are not relevant, best available Engineering practice / International codes shall be mentioned.
- Design & details of suitable Transition System for smooth transition from ballasted track to ballastless track on both ends shall be part of the design of ballast less track.
- Design and details of Expansion / Contraction joints in ballast less track at suitable intervals shall be part of the design of ballastless track.
- Technical parameters required for foundation of Ballast less track shall be suitably considered for Indian conditions and shall be mentioned in the design along with their test code & procedure. A design monograph of varying sub-grade characteristics, if applicable, to be provided by the firm / designers.
- Design service life ballast less track should be a minimum of 60 years. Concrete for RCC structure should comply with relevant Para of Indian Standard IS:456 – 2000 & relevant Para of IRS – Concrete Bridge Code taking care of relevant durability clause for expected life of RCC as minimum 60 years.
- No cracks of width greater than the crack width approved at design phase/codal provisions or settlements or separation of parts should be developed during services in the ballast less track leading to impaired service or failure.
- Ballastless track should be designed for almost maintenance free conditions except replacement of worn-out fastening components after their service life is over. The 2% of the fastening components and other replacement items which are likely to be worn out / damaged are to be supplied as spares for need based replacement in this work. The offer of the firm / JV should be inclusive of the cost of 2% fastening components as spare. No additional cost will be paid for the spares.
- Adequate corrosion protection measures must be included in design to minimize corrosion of fastening components of proposed system for ballast less track. Test report of the proposed fastening system should be submitted as per EN 13146 –6: 2012- Test methods for fastening system – Effect of severe environmental conditions and EN ISO 9227, Corrosion tests in artificial atmospheres – salt spray tests or as per any international standard being in practice.
- The design should be cost effective serving all functional requirements expected of ballastless track.
- Any other factor considered necessary by the designer.
- Changes in the above parameters (ii) and (iii) may be considered in case the bidder is able to support it with the relevant documents and codes as per practice in other Railways.
Eligibility:
- The bidder can be a firm / Joint Venture (JV) firm / Collaboration of firms/bidder firm, from India/ abroad, who is the system provider and /or the designer and/or the designer and/or the construction executing agency and must have a written “Agreement” or “Memorandum of Understanding” to the effect that the firms shall be responsible for their portion of the works. System installer/Executing agency can have separate MOU with system provider and designer firm.
- In case of MOU done by the bidder firm with the system provider and designer, the entire responsibility for providing satisfactory track system and its design to suit Indian requirements till the satisfactory completion of the contract shall rest with the bidder firm only.
- Agreement /MOU can also be done with the system provider located abroad through its authorised representative firm / license firm located in India. In such cases the credentials of the system provider shall qualify the authorized representatives/license firm located in India to be considered as meeting the eligibility criteria. The bidder may consist of maximum three member as under:
- System Installer/Executing Agency – who has experience of construction of ballastless track systems.
- Designer firm is a firm which has experience of design of ballast less track that has been successfully in operation and who can modify the proven system to suit the Indian Railway requirement as per technical requirements for ballast less track.
- System Provider- is a firm, which has provided the proven ballast less track system or supplied proven fastening system.
The complete documents can be downloaded from https://etenders.gov.in/eprocure/app
Source: IRCON- Tender | Image Credit (representational): SCR
