IRCON invites tender for manufacturing & supply of CMS crossings, turnouts and HH rails for Western Dedicated Freight Corridor project

April 18, 2023 Rail News, Tender

IRCON International Limited has invited an online e-Tender for Manufacture, fabrication, inspection, supply, transportation and delivery of WDFC approved design of CMS Crossings with welded legs & UIC 33 check rails 1:12, 1:8.5, Turnouts 1:12, 1:8.5 canted (BG), EN 60 E1-A1 Thick web tongue Rail made of asymmetrical rail section of ZU 1-60 1080 HH rails with 60 Kg Rails and Weldable CMS crossing and 1 : 8.5 UIC 33 check rails with complete fittings and spring setting device (SSD) with complete fittings and 60 Kg 1:8.5 Thick web derailing switches with complete fittings for Western Dedicated Freight Corridor Project, CT P-12.

  • Tender Reference Number: IRCON/3018/DFCCIL-CTP-12/e-Tender/Turnouts-II/08-461
  • Name of Work: Manufacture, fabrication, inspection, supply, transportation and delivery of WDFC approved design of CMS Crossings with welded legs & UIC 33 check rails 1:12, 1:8.5, Turnouts 1:12, 1:8.5 canted (BG), EN 60 E1-A1 Thick web tongue Rail made of asymmetrical rail section of ZU 1-60 1080 HH rails with 60 Kg Rails and Weldable CMS crossing and 1:8.5 UIC 33 check rails with complete fittings and spring setting device (SSD) with complete fittings and 60 Kg 1:8.5 Thick web derailing switches with complete fittings for Western Dedicated Freight Corridor Project, CT P-12.
  • Estimated Cost of Work: INR 31,86,50,445 Crore
  • EMD: INR 21,93,300 Lakh
  • Period Of Work: 06 Months
  • Document Download / Sale Start Date: 15th April, 2023
  • Document Download / Sale End Date: 29th April, 2023
  • Pre-Bid Meeting Date: 21st April, 2023
  • Bid Submission Start Date: 24th April, 2023
  • Bid Submission End Date: 29th April, 2023
  • Bid Opening Date: 01st May, 2023

Scope of Supplies:

  • Turnout 1: 8.5 : 05 set 
  • Turnout 1:12 : 27 set 
  • Derailing Switch : 9 set 
  • CMS Crossing 1:12 : 100 set 
  • CMS Crossing 1 : 8.5 : 50 set

Switch Rails:

  • Switches made from asymmetrical rail sections shall be machined carefully to achieve the profile at different locations. Machining shall be done by CNC milling machine to achieve correct profile and excellence in the final product.
  • The thick web tongue rail shall be one piece with no joint within the length of tongue rail. The end of the asymmetrical switch rail shall be forged to UIC 60 KG rail profile and shall be suitable for welding or for installation of insulated glued joints.
  • Stock Rails: UIC 60 KG HH Rails. (Purchaser’s scope): The rails at required length shall be supplied at IRCON’ depot at Ancheli (Gujarat)/ Vangaon (Maharashtra.
  • IRCON will supply the Rails required for manufacturing stock rails and extension legs for CMS crossings to the supplier’s factory.
  • The turnout system shall be designed to prevent the switch lifting.
  • The switch should have provisions for all the required connections for the point machine, clamp lock and any other provisions necessary for connecting the signalling equipment.

CMS Crossings:

  • All the crossings shall be weldable CMS crossings manufactured from austenitic Manganese steel as defined in IRS T- 29-2000 with latest alterations and RDSO guidelines.
  • The Welding Extension leg for CMS crossing ( UIC 60 Kg HH Rails) is in the scope of Purchaser and will be supplied at the Manufacturer’s factory.
  • Spring Setting Device( SSD) Shall be provided as per RDSO DRG. T- 6216, if found suitable or any other alternatives which has been consented by Engineer/ Principal employer and approved by RDSO during technical design submission by the agency to ensure proper setting.
  • Elastic Fasteners: The design of the fastenings for the turnout shall be suitable for 25 Tonne axle loads and 60 Kg UIC section of rails on PSC sleepers confirming to UIC code or other international code of practice, Fastening for the turnouts shall be elastic type and compatible with main line rail to sleeper fastening system:
    • ERC Mk – V RDSO RT- 5919 
    • GRSP – Composite 10 mm RT- 7010 
    • Metal Liners RT 8254 & RT 8255 

SSD:

  • As per approved design & drawing.
  • ERC & Metal Liners for the lead portion of turnout is not in the scope of supplier.

Check Rails:

  • The turnout shall be provided with check rails as per UIC 33 Rails (UIC 33 Rails for check rail is in the scope of supplier)
  • Check rail connections for all CMS crossings shall be by means of specially designed brackets, bolts and bearing plates.
  • Check rails in all turnouts shall have the facility of adjustment in order to increase the nominal clearance up to 10 mm.
  • The end of each check rail shall be suitably flared by machining.
  • Gauge: 1676 mm

PSC Sleepers:

  • The turnout shall be suitable for pre-stressed concrete (PSC) sleepers with separate layouts (Fan shaped) for sleepers with left hand and right hand turnouts and shall have provision of elastic and anti creep fastenings and other relevant fastenings and fixtures.
  • The turnouts shall be laid at site such as to permit the use of standard on-site tamping and lining equipment for maintenance purpose.
  • Supply of PSC sleepers for turnouts and D. Switches are not in the scope of this tender. However, for the testing and inspection of turnout and Derailing switches suppliers shall arrange the PSC sleepers set at their factory. The top surface of the sleeper shall be flat.
  • LWR/CWR shall be carried through the turnout assembly, keeping in view the provisions of international codes and practices.
  • The turnout shall meet with all the provisions set out in Para 12.40 of chapter XII of Indian Railways Signal Engineering Manual( IRSEM).
  • Inspection & Testing of Turnouts through the approved inspecting authority by RDSO guidelines and providing necessary testing facilities to the inspecting authority.
  • Delivery at nominated locations as per enclosed bill of Quantity, including packing, loading and transportation Delivery by road of the using appropriate equipment, Tools & Tackles as per specifications.
  • Loading Turnout materials at manufactures factories is in the scope of the supplier. Unloading at delivery point is in the scope of the purchaser.

Inspection of the Turnouts:

  • The turnouts and weldable CMS crossings shall be manufactured in supplier’s factory as per approved design, QAP and RDSO specifications for CMS crossings. The supplier is required to obtain the concurrence of the existing inspection agency( RITES) and indicate about the same in his tender along with inspection charges payable to them.
  • The supplier shall give advance notice of at least fifteen days to the inspecting authority/IRCON about the programme of inspection. The representative of IRCON and the client may also witness the inspection of Turnouts. The supplier shall provide all the facilities to the entire inspection team for carrying out the inspection of turnouts.
  • On inspection of the turnouts & D. Switch, the inspecting authority shall issue an inspection  certificate indicating the lot no. date of manufacture, quantity of turnouts inspected, passed and rejected with identification mark etc and other documents as per the approved inspection plan. The rejected components shall be immediately separated from the passed components meant for transportation and under no circumstances the rejected components shall be supplied.

Inspections and Tests:

  • The Supplier shall at its own expense, and at no cost to the Purchaser, carry out all such tests and/or inspections of the Goods and Related Services as are specified in SCC and Technical Specifications of this bid document.
  • The inspections and tests may be conducted in the premises of the Supplier at the point of production/ delivery, and/or at the Goods’ final destination, Subject to SCC Sub-Clause 13.2.3, if conducted in the premises of the Supplier, all reasonable facilities and assistance, including access to drawings and production data, shall be furnished to the inspectors at no extra charge to the Purchaser.
  • The Purchaser or its designated representative shall be entitled to attend the tests and/or pre dispatch inspections referred to third party in SCC Sub-Clause 13.2.2, provided that the Purchaser shall bear all of its own costs and expenses incurred in connection with such attendance including, but not limited to, all travelling, boarding and lodging expenses.
  • Whenever the Supplier is ready to carry out any such test and inspection, it shall give a reasonable advance notice of at least one week, including the place and time, to the Purchaser.
  • The Supplier shall obtain from any relevant third party or manufacturer any necessary permission or consent at their own cost to enable the Purchaser or its designated representative to attend the test and/or inspection.
  • The Purchaser may require the Supplier to carry out any test and/or inspection not required by the Contract but deemed necessary to verify that the characteristics and performance of the Goods complying with the technical specifications codes and standards under the Contract, provided that the Supplier’s reasonable costs and expenses incurred in the carrying out of such test and/or inspection shall be added to the Contract Price.
  • The Supplier shall provide the Purchaser with a report of the results of any such test and/or  inspection.
  • The Purchaser may reject any Goods or any part thereof that fail to pass any test and/or inspection or do not conform to the specifications. The Supplier shall either rectify or replace such rejected Goods or parts thereof or make alterations necessary to meet the specifications at no cost to the Purchaser, and shall repeat the test and/or inspection, at no cost to the Purchaser, upon giving a notice pursuant to SCC Sub-Clause 13.2.4.
  • The Supplier agrees that neither the execution of a test and/or inspection of the Goods or any part thereof, nor the attendance by the Purchaser or its representative, nor the issue of any report pursuant to SCC Sub-Clause 13.2.6, shall release the Supplier from any warranties or other obligations under the Contract. 

Switch Rails:

  • The work involves manufacturing, fabrication of Thick Web Switches made from Asymmetrical rail section of ZU 1-60 1080 HH Rails conforming to IRS: T – 10 – 2000  with latest amendments. (Rails for Tongue rail included in the scope of Supplier).
  • 60 Kg 1080 grade HH Rails for stock Rail imported from Japan will be supplied by IRCON to the supplier’s factory.
  • Switches made from asymmetrical rail sections shall be machined carefully to achieve the profile at different locations. Machining shall be done by CNC milling machine to achieve correct profile and excellence in the final product.
  • The thick web tongue rail shall be one piece with no joint within the length of tongue rail.
  • The end of the asymmetrical switch rail shall be forged to UIC 60 rail profile and shall be suitable for welding or for installation of insulated glued joints.
  • The tolerance on the dimensions, straightness, and weight shall comply with IRS T-12-2009 or UIC specification 860/0-1986 with updated corrections/amendments, or any other equivalent international standards.
  • Each thick web switch set shall consist of 2 stock rails (LH&RH), 2 switch rails(LH&RH) along with all fittings (Slide chairs, base plate/ special base plate, brackets, rail pads, insulating bushes, washers, stretcher bars, various blocks, bolts & nuts, Spring setting devices etc. complete as per the relevant drawings.
  • The switch shall provide suitable flange way clearance, between the stock rail and switch rail at the end of head in open position.
  • In the cleared position, the switch rail shall house properly against the stock rail and shall bear evenly against all the distance blocks and slide base plates.
  • Spring Setting Device( SSD) shall be provided as per RDSO DRG. T- 6216, if found suitable or any other alternatives which has been consented by Engineer (PMC)/DFCCIL and approved by RDSO during technical design submission by the agency to ensure proper setting.
  • The turnout system shall be designed to prevent the switch lifting.
  • The switch should have provisions for all the required connections for the point machine, clamp lock and any other provisions necessary for connecting the signalling equipment.

Crossing Assembly:

  • All the crossings shall be weldable CMS crossings manufactured from austenitic Manganese steel as defined in IRS T- 29-2000 and RDSO guidelines with latest amendments.
  • All weldable CMS crossings shall have welded leg extensions of 60 Kg1080 HH rails imported from Japan (Rails will be supplied by IRCON to the supplier’s factory. Weldable CMS crossings consist of three parts i.e. the CMS crossing casting, an intermediate piece and connecting rail.
  • CMS crossing shall be manufactured as specified in (i) above
  • Connecting rail – 60 Kg 1080 HH rails imported from Japan shall be used for welding. The rail shall be cut to proper length providing an extra length of 15 mm since during the welding process rail burn off takes place.
  • The cut shall be performed at an angle of 900 +/- 0.50 to the longitudinal axis. All cutting shall be deburred before welding.
  • Intermediate piece – Intermediate piece profile shall be prepared matching the shape of rail. It shall normally be either cast or rolled to the shape of rail.
  • The cross section of the intermediate piece shall be normally kept larger by around 0.5 mm at head and web portion and around 1.5 mm at rail foot to take care of the grinding after the welding.
  • The design of the crossing shall have the prior consent of Engineer/Employer before commencing manufacture.
  • Standard fixed nose crossing shall be provided on all crossings.

Elastic Fastenings:

  • The design of the fastenings for the turnout shall be suitable for 25 Tonne axle loads and 60 Kg UIC section of rails on PSC sleepers confirming to UIC code or other international code of practice, Fastening for the turnouts shall be elastic type and compatible with main line rail to sleeper fastening system:
    • ERC Mk – V RDSO T- 5919 
    • GRSP – Composite 10 mm T- 7010 
    • Metal Liners RT 8254 & RT 8255 
    • SSD: as per approved design
  • Note: (ERC & Metal liners for lead portion is not in the scope of manufacturer)
  • The turnouts shall be designed to withstand rail induced forces from the CWR. Anti- creep devices shall be installed on the turnouts rails as required.
  • The turnout rail shall incorporate insulated joints according to the signalling and traction return current requirements.
  • Both types of turnout shall incorporate pre-stressed concrete sleepers with appropriate layout for ease of tamping. The sleeper spacing shall not exceed 600+/- 25 mm
  • The top surface of the sleeper shall be flat.
  • LWR/CWR shall be carried through the turnout assembly, keeping in view the provisions of international codes and practices.
  • The turnout shall be suitable for pre-stressed concrete (PSC) sleepers with separate layouts for sleepers with left hand and right hand turnouts and shall have provision of elastic and anti creep fastenings and other relevant fastenings and fixtures.
  • The turnouts shall be laid at site such as permit the use of standard on-site tamping and lining equipment for maintenance purpose. (PSC sleepers not in the scope of supplier).
  • The turnout shall meet with all the provisions set out in Para 12.40 of chapter XII of Indian Railways Signal Engineering Manual( IRSEM) 
  • Prior to mass manufacturing of the turnouts, at least one turnout of each type shall be manufactured and completely pre- assembled for inspection and consent by the Engineer and approval of the Employer.
  • Once the sample turnout is accepted by the Engineer/ Employer, mass production can  commence. Consent of the Engineer and /or approval from the Employer of the sample turnout shall not relieve the manufacturer of their responsibility to produce the entire lot of turnouts in full conformity with the approved designs and drawings.

The complete documents can be downloaded from https://etenders.gov.in/eprocure/app

Source: IRCON- Tender | Image Credit (representational): MoR