Rail Vikas Nigam Limited (RVNL) has invited bids for Design, supply, installation, testing and commissioning of Broad Gauge ballastless track (BLT), supply of ballast and installation of track (excluding supply of rails and track sleepers) between chainage 6+015 (FLS) to 125+200 (FLS) in connection with new BG line between Rishikesh and Karanprayag (125km) in the state of Uttarakhand, India.
- Tender Reference Number: RVNL/RKSH/BLT(TENR)/1/2022/CIVIL/RKSH
- Name of Work: Design, supply, installation, testing and commissioning of Broad Gauge ballastless track (BLT), supply of ballast and installation of track (excluding supply of rails and track sleepers) between chainage 6+015 (FLS) to 125+200 (FLS) in connection with new BG line between Rishikesh and Karanprayag (125km) in the state of Uttarakhand, India.
- Estimated Cost: INR 725.95 Crore
- EMD: INR 02 Crore
- Period Of Work: 42 Months (6 Months for Design and 36 Months for Construction)
- Document Download / Sale Start Date: 18th April, 2023
- Document Download / Sale End Date: 23rd June, 2023
- Bid Submission Start Date: 18th April, 2023
- Bid Submission End Date: 23rd June, 2023
- Bid Opening Date: 23rd June, 2023
Scope of Work:
Scope of this tender comprises of following major components:
- Design of ballastless track for straight, curve, transition from ballastless track to ballasted track and vice versa.
- Design of ballastless track for tunnel, Bridges, and formations
- Design of ballastless track for Turnouts taking out from straight lines as well as curved railway lines.
- Design of all turnouts for 25T axle load in straight and curved with all fittings and its approval from the RDSO.
- Design of ballastless track for switch expansion joint (SEJ)
- Design of special ballastless track fastening system i.e. fastening for SEJ, low toe load, Zero toe load fastenings for BLT track over bridges
- Design of suitable drainage system for BLT and its integration with a tunnel drainage system.
- RSI analysis for bridges, wherever required.
- Preparation of LWR plan and its approval from the competent authority of Northern Railways Headquarters and Division headquarters of concerned railway Division.
- Supply of ballastless track fastenings.
- Supply of Ballast and ballasted track fastenings.
- Installation, testing and commissioning of ballastless and ballasted railway track in tunnels, bridges and formations on entire project length.
- AT welding and FB welding of Rails.
- Transportation of P-way materials.
- Design of Ballastless track for the twin tunnels between Chainage 24+856 and 29+680 of Haryana Orbital Railway Corridor (HORC) new BG rail link project (Package-4) in the state of Haryana, using compatible fastening system as per the design specifications given in Annexure-D of this section5 (Chapter 15 of section VII-5: Employer’s requirements-Outline design specifications (ODS)- Civil and BLT).
- This includes submission of Design criteria, Calculations, Design Methodology, Detailed design, detailed drawings, construction methodology, QAP, maintenance manuals, damage rectification methodology, including all its various components as per various input parameter and characteristics of various component of fastening system, etc as a complete job and as directed by Engineer in charge.
- The design will be property of RVNL which may be used by RVNL on other projects. It includes design of BLT for:
- Track in straight and curves In tunnels including transition at approaches.
- Track in straight and curves on formations (cutting/filing) including transition portion. It includes the design of BLT on SEJ within the above chainages.
- This work is part of 125 km new Broad Gauge (BG) railway line between Rishikesh and Karanprayag and pertains to Design, supply, installation, testing and commissioning of Broad Gauge ballastless track (BLT), supply of ballast and installation of track (excluding supply of rails and track sleepers) between chainage 6+015 (FLS) to 125+200 (FLS) in connection with new BG line between Rishikesh and Karanprayag (125km) in the state of Uttarakhand, India.
- The new Broad Gauge (BG) Railway line between Rishikesh and Karanprayag is a very important development project undertaken by the Ministry of Railway. The purpose of providing Rail link between Rishikesh and Karanprayag is for facilitating easy access to pilgrimage centres situated in the state of Uttarakhand, connecting new trade centres, development of backward areas and to serve the population living in the area.
- The entire length of the new line falls in Garhwal Himalayan range. The proposed alignment from Rishikesh to Karanprayag lies between Longitude 78015’E to 79015’E and Latitude 30005’N to 30020’N and passes through 5 districts i.e. Dehradun, Tehri Garhwal, Garhwal, Rudraprayag and Chamoli in the state of Uttarakhand.
- The railway line traverses very rugged Himalayan terrain, with the alignment oriented across and sometimes sub parallel to the major thrust zones of Himalaya with complex geological conditions.
- Total length of the new Single BG electrified line is 125 kms and comprises 19 tunnels (including tunnels in yards), 19 Major Railway bridges and 12 new stations. National highway NH-58 connecting Ghaziabad in Uttar Pradesh to Mana in Uttarakhand runs along the proposed project meeting at important places like Shivpuri, Guller, Byasi, Kaudiyala, Devprayag, Lachmoli, Maletha, Srinagar, Dhaari, Tilani, Gholtir, Gaucher and Karnprayag.
Ballastless track:
- Rishikesh-Karanprayag rail line section is on a hilly terrain with multiple tunnels with limited open space in between the tunnels. The Ballastless track is to be provided in all the tunnels.
- For providing the Ballastless track in between tunnel locations on various major bridges, embankment /open-area, yard etc, detailed study of the L-section of the alignment shared by the Employer is to be performed for feasibility of LWR and Ballastless track.
- The Contractor must clarify the reason for opting for the ballasted or ballastless track in design. A feasibility report shall be submitted with detailed justification for approval of the proof consultant/Employer.
- Rail Structure Interaction (RSI) studies for LWR/CWR track over the bridges (if, required) as per relevant provisions of Indian Railways and UIC codes. In case a bridge is passing in RSI analysis, then LWR/CWR shall be laid on that bridge.
- In case the bridge is failing in RSI analysis, the track shall be designed with low toe load fastenings or rail free fastenings. If still requirements of laying LWR/CWR are not met then, REJ/SEJ shall be designed in such a way that LWR/CWR can be continued through the bridge.
- Preparation of LWR/CWR plans for the track and getting approval from NR/RDSO through RVNL for the entire length of the project.
- The detailed design of Track Structure System (BLT) including compatible fastening system, should not deviate from the system which is submitted for eligibility and qualification criteria by system provider [form no. EXP-2(a)(3) of section 4: Bidding Forms] in the bid based on which the proposal was accepted.
- However, the Eligible System will have to be suitably modified as per works requirement given in section 5 of the contract document.
- Submission of the details of the approved fastening system of the Ballastless track structure with all the relevant standards and codes which includes:
- Component drawings clearly showing dimension details of each component.
- Material composition with tolerances and specification for each component along with relevant codes, standards and acceptance criteria.
- Inspection and test plan of each component along with relevant codes, standards and acceptance criteria.
- Inspection and test plan for complete fastening system assembly.
- Detailed design of ballastless track system with approved fastening system for 60 Kg rails in tunnels, on bridges, in yards, on formations and in transition portion from, Ballastless track to ballasted track and vice versa; including arrangement for prevention of derailment like concrete slab/block and mitigation arrangement for noise and vibration.
- Design of track slab including derailment guard should be such that it is possible to do in situ AT welding in case of rail/Weld failure.
- The design shall be for BLT track on straight, track on curves, track on gradients with or without shear keys.
- The Design shall be for all types of turnouts including arrangement for fixing of point driving machines, 2nd drive and any other arrangement required for fixation of S&T and OHE equipment as prevailing in Indian Railways.
- The design shall be based on latest international standards/codes/proven practices.
- Detailed design of the turnouts for 25T axle load. The turnouts to be designed for straight and curves (LH & RH) with all necessary fittings. The design shall be approved from RDSO and it is solely the responsibility of the contractor to get the design approved from the competent organisation or authorities.
- The design of turnouts shall be completed in all aspects i.e., from design to approval within 180 days of the issue of the LOA.
- Turnouts shall be designed as per the latest EN codes. All turnouts designed for the Ballastless track should be canted and should be laid with a slope as that of the main line towards the centre of track. Designed turnout should have adequate speed potential and angle not sharper than the instruction issued by the Indian Railways and allow for installation of continuous welded track.
- Design and details of Expansion / Contraction joints in Ballastless track.
- Detailed designs of Ballastless track system with Rail-free fastening/low To Load Fastenings.
- Design of C-clamps for holding the joggled fish plates for emergency protection of rail/weld in Ballastless track during the track operations.
- The C-clamps used in Ballasted track require more clearance below the rail for clamping the joggled fish with the rail. The C-clamps are to be customised in the manner that they can be provided for protection of rail/weld in Ballastless track with available clearance between concrete surface and bottom of rail. The design of a customized C-clamp should be suitable for 25T axle load.
- The detailed design & drawings shall be submitted to the Proof consultant, appointed by RVNL at its own cost, for approval. Arranging the final approval from Proof consultant for all the designs & drawings will be the responsibility of the contractor.
- The contractor shall be prompt in clarifying the objections/doubts of the Proof consultant/RVNL. At no stage, work at site should suffer on account of design. The Contractor will be responsible for providing all necessary software / specification and other documents required for evaluation of design and drawings by the Proof consultant.
- Submission of detailed drawings including material specifications, technical parameters and characteristics, manufacturing tolerances, etc of all the components of BLT (Ballastless Track) including of fastenings system.
- Submission of construction methodology including QAP for installation of ballastless track.
- Construction, as per approved design/drawings, of ballastless track which includes supply, installation, testing and commissioning. It shall include the following:
- Surveying including traverse & levelling, fixing of intermediate control points, adjusting track alignment if required, setting-out final alignment etc, picking up as build co-ordinates of the tunnel.
- Construction of side drains as per drawings.
- Filler concreting below track slab.
- Complete track work such as linking, greasing, painting etc.
- Welding of 60E1 1175 HT rails to be used for main line and 60E1 R260 grade rails proposed for loop line using the specified latest welding techniques as per RDSO approval and as per IRS-T-12-2009.
- Provision of shear connector.
- Dewatering as per site requirement.
- All other works incidental thereto for completion of the work
- Preparation of welding plans with minimum permissible number of AT welds and getting approved by RVNL. AT welds shall be used only at de-stressing of rails locations. Any deviation shall have to be approved by the Engineer.
- Flash Butt Welding of rails with Mobile flash Butt Welding plant at site (in open and in tunnels) for making Rail Panels as per approved welding plan including all lifting, loading handling / re-handling, shifting etc. with placing of panels to its location. The Contractor shall arrange his own mobile flash butt welding plant. QAP approval and standardisation of welding parameters for individual machines by RDSO will be mandatory as per para 5.6 of RDSO flash butt-welding manual – 2012 or latest.
- In situ AT welding of rails in track with latest welding technique approved by RDSO. Design of the derailment guard should be such that it is possible to do in situ AT welding in case of rail/Weld failure.
- Transportation of Rails, Turnouts & its fittings etc. from nearest stockyard to work site.
- Supplying, Laying, Testing & Commissioning of Turnouts, SEJs, Glued Joint, etc.
- Provision of duct crossings in BLT for electrical, signal & telecommunication etc. cables in longitudinal direction as per drawings. Duct crossings in the transverse direction shall be avoided.
- Ten sets of special gadgets/ inspection kit/equipment for measuring the toe load and various other track parameters like Gauge, cross level, alignment, longitudinal level, rail wear, etc. in service shall be provided. Cost deemed to be included in the quoted rate.
- In case, the Contractor wants to set up a pre-cast factory, for pre-cast component of BLT, then a “Factory set up” report is to be prepared by the Contractor and get it approved from the Engineer. The cost for setting up of the factory shall be deemed to be included in the quoted price. The Factory set up report shall include the following but not limited to:
- Detail Plan of the factory
- Requirements of plant and machinery
- Lab and testing equipment’s
- Production supervision and Testing Facilities requirements
- Quality Assurance and Quality control manual for the production
- Design, detail drawing of Shuttering and moulds for Pre-casted elements
- Estimation of manpower requirement for production.
- Supervision of Pre-casted elements including Quality Assurance/Quality Control
- Precast factory production and supervision shall be under the officials belonging to the original firm (OEM) whose technology is used for the production of precast components.
- Details of employment and salary slip shall be submitted as proof.
- All QA-QC documents shall be signed by these officials.
- Similarly, if the production of a proven fastening system is done in India, then its quality control certification from the OEM (original fastening manufacturer) shall be submitted.
- The Employer’s representative/Engineer shall verify/oversee the production in the precast fabrication factory. The staying arrangement for the two personnel at the factory pertaining to QA/QC civil engineering shall be made by the Contractor.
- The stay arrangement shall include a well-furnished room of size 12x 10 feet with a facility of two rooms, study table, two chairs with attached bathroom.
- The work front will be provided in stages and not in one go depending upon the site clearance at that time. The contractor shall arrange sufficient no. of working teams for BLT construction at different working sites for timely completion of the work as per agreed works programme.
- Based on the requirement of progress of work, working teams can be increased as per availability of working faces. 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. In case an approved Ballastless track system is based upon precast units, then the contractor shall establish gantry cranes for handling of precast slab components inside the tunnel for laying of ballastless track.
Eligibility:
- Minimum average annual construction turnover in equivalent INR 414.83 Crores Calculated as total certified payments received for contracts in progress or completed, within the last three financial years (refer note below the table).
- Minimum average Net Worth (Total Assets – Total Liabilities) should not be less than INR 145.19 Crores during the last three financial years (refer note below the table).
Specific Construction experience:
- Execution as contractor, or subcontractor approved by the employer, of work which has been successfully or is substantially completed within the last seven years before the deadline for submission of the bids, and that is similar to the proposed work.
- The similar work here shall be that which includes at least following key activities:
- Execution of at least one work, which involves installation of Ballastless track system for a minimum total length of 10 Km, or
- Execution of at least two works, each of which involves installation of Ballastless track system for a minimum total length of 7 Km.
Tender documents can be downloaded from website https://rvnl.org/active-tenders-new
Source: RVNL- Tender | Image Credit (representational): DFCCIL
