L1-CHE-SPE-178 EARTHWORKS & FORMATION SPECIFICATION

Transcription

1 Engineering Specification L1-CHE-SPE-178 EARTHWORKS & FORMATION SPECIFICATION Version: 2

2 Approval Amendment Record Approval Date Version Description Initial Release under MTM. Supersedes the following Standards: 14/06/ PTC Heavy Rail Track Design Standard Part B 1997 (Ver. 1.3) 2. PTC Part C Heavy Rail track Construction Standards 1997 ( Version 1.3) 17/07/ Unsuitable material swell limit revised to 2.5% to align with subgrade limit. Also aligns with Vicroads Sec 204 Type b. The Plastic Limit PL (20% Max) has been removed. The Liquid Limit (LL) and Plasticity Index (PI) values remain unchanged. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 30

3 Table of Contents 1 Purpose Scope Abbreviations Definitions References & Legislation General MTM References Industry References Australian & International References Related Documents Safety & Environmental Construction Requirements General Management & Control Preparation Earthworks Finishing Requirements Proof Rolling Disposal of Materials General Testing Requirements Subgrade Materials Description Unsuitable Material Specification Subgrade Preparation & Installation Testing Requirements Compaction Finishing & Tolerances Embankment Materials Free Draining Filter Materials General Fill Materials Structural Fill Material Capping Material Description Specification Preparation & Installation Testing Requirements PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 30

4 11.5 Compaction Finishing and Tolerances Use of Geosynthetics Description Performance Requirements Preparation & Installation Testing Requirements Use of Rock Fill Materials Appendix A Documentation requirements Construction Documentation Site Records Handover Documentation List of Tables Table 1: Subgrade material testing requirements Table 2: Free draining material particle size distribution Table 3: Free draining material test requirements Table 4: Structural fill particle size distribution Table 5: Structural fill testing requirements Table 6: Capping material particle size distribution Table 7: Capping material testing requirements Table 8: Geosynthetic testing requirements PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 30

5 1 Purpose 1.1 This document outlines requirements for the construction, upgrade or modification of earthworks and formation on the Melbourne Metropolitan network. It includes materials specifications along with site preparation, testing and finishing requirements. 2 Scope 2.1 The following materials are specified in this document: 1. free draining filter materials 2. subgrade 3. general fill material 4. structural fill material 5. geotextiles and geogrids 6. capping material 7. rock fill material 2.2 This specification is mandatory for all new MTM mainline tracks. It is also applicable to the restoration or renewal of existing corridors whenever the top of formation is accessible to construction equipment. 2.3 This specification is intended to be used by persons carrying out materials procurement, track construction, testing and renewals. 2.4 The specification outlines minimum requirements. MTM may accept alternative independently certified materials, construction procedures or testing regimes which meet or exceed these requirements. The parties undertaking the works shall be responsible for ensuring the minimum requirements as detailed in this specification are met. 2.5 This specification does not include design requirements for earthworks, formation, drainage and track design. These are described in other MTM standards listed in Section This specification does not include requirements for non-ballasted or direct fix track. 3 Abbreviations AEP Annual Exceedance Probability AS Australian Standard CBR Soaked California Bearing Ratio, Standard Compaction expressed as % DLA Dynamic Load Allowance DMS Drawing Management System EPA Environmental Protection Authority MTM Metro Trains Melbourne PTV Public Transport Victoria RSNL Rail Safety National Law PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 30

6 4 Definitions Ballast Batter Slope Capping (also: Sub-ballast) Cess Area Cess Drains Characteristic Value of Density Ratio Drainage blanket Dispersive Soils Ballast is the crushed rock above the capping layer which supports the sleepers and forms part of the track. The gradient of a cutting or embankment when viewed as a cross section and expressed as a ratio of vertical to horizontal unit of length. Capping or sub-ballast is the upper layer of the formation consisting of graded crushed rock or similar compacted material that provides a sealing layer to the formation. In exceptional situations it may be designed as permeable. From the edge of the ballast profile to either the edge of the embankment or the toe of the cutting. Cess drains are surface drains located at the formation level at the side of the tracks. They remove water that has percolated through the ballast and is flowing across the capping layer towards the outside of the formation. As defined by VicRoads Test Method RC Layer of free draining filter material used during construction. Sodic soil, usually clays which disperse in the presence of nonsaline water. Dry Density Field density determined in accordance with AS Methods of testing soils for engineering purposes - Soil compaction and density tests Determination of the field density of a soil -Sand replacement method using a sand cone pouring apparatus; Earthworks Fill Formation OR AS Methods of testing soils for engineering purposes - Soil compaction and density tests - Determination of field density and field moisture content of a soil using a nuclear surface moisture Density gauge - Direct transmission mode. Both natural and man-made earthen/aggregate structures. The main purpose of earthworks is to provide a structure of sufficient strength and size to adequately support the track and of appropriate gradient to allow the rolling stock to operate. Earthworks shall be designed to ensure the rail corridor is free draining. Fill is the material used for filling the earthworks up to design surface level as indicated on the drawings, but not including subgrade material. Can consist of structural and general fill. The formed, graded and compacted material, including fill material, capping layer material and any drainage layers or materials on which ballast is laid. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 30

7 Free draining filter material Geogrid Geosynthetic Geotextile Geonet General fill MTM Approved Representative Proof Rolling Shall Should Track Drainage Track Structure Reactive soil Rock Clean crushed rock, river gravel or slag composed of hard, strong and durable particles. A polymeric structure, in the form of manufactured sheet, consisting of a regular network of integrally connected elements, which can be linked by extrusion, bonding or interlacing, whose openings are larger than the fill constituents. Prefabricated sheet made of polymeric materials which can be permeable or non-permeable. This material can be used as filterdrainage (if permeable) or foundation reinforcement. It includes geotextiles, geonets and geogrid. A permeable, polymeric (synthetic or natural) textile material, in the form of manufactured sheet, which can be woven, nonwoven or knitted. A material consisting of integrally connected parallel sets of ribs overlying similar sets at various angles. Can be utilised to facilitate in-plane drainage and are generally thicker than geogrids. The lower layer of the formation below the capping layer and structural fill. An individual approved by MTM s Chief Engineer and deemed competent to assess issues and provide clarifications and direction on matters relating to the construction of track earthworks and formation. The required minimum competence may vary according the nature of the works. A process where compacted soil is checked for soft areas in order to supply a balanced support system for the rail formation. If soft spots are located during construction, they are corrected so that the density is maintained. The term Shall is used to express a clause that is mandatory to achieve conformance to the standard. The term Should is used to express a clause that is recommended however is not mandatory. Drainage of the track formation including diversion of water away from cuttings and embankments. The entire track structure, including rail, sleepers, ballast, capping & formation which is subject to rail loading. Soil that exhibits a significant volume change when in contact with water. Increase or decrease in its moisture content causes swelling or shrinkage. Materials, including boulders, which can only be removed by means of continuous drilling, blasting, pneumatic tools or ripping by bulldozers with brake power > 290 KW (or > 382 hp). Plant shall be well maintained, have suitable single or multiple ripping tynes, and used by a suitably experienced operator. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 30

8 Rock Fill Structural fill Subgrade Suitable material A material comprised of larger fragments of hard, sound durable rock containing only a small amount of fine particles, which when placed and compacted produces an embankment deriving its stability from the mechanical interlock of the coarser particles and not from the compaction of finer material. The mid layer of appropriately specified and compacted material directly beneath the capping layer All materials underneath the formation made up of the natural ground, any ground stabilising materials or suitable fill added to replace any unsuitable materials. Suitable material comprises material that meets the design and construction requirements of the formation, such as general fill, structural fill, sub-ballast material, free-draining material, rock and rock fill (as defined in Section 13), and are free from unsuitable materials. Unsuitable material Materials, which are soft, excessively wet, unstable or otherwise not suitable for the specified use. 5-foot 6-foot This includes silt, reactive/expansive materials and oversize materials including rock. More details are provided in Section 9.2. Area between two rails on a broad gauge track. Area between two tracks. 5 References & Legislation 5.1 General Mandatory requirements of AS 7638 apply Earthworks & Formation materials shall be provided and tested in accordance with this specification, other relevant MTM Standards, project requirements, Australian, Rail Industry standards and International Standards Where a conflict arises between documents, or where clarification as to the applicability of a standard, specification or a part of either is required, the matter shall be referred to the MTM Chief Engineer for determination. 5.2 MTM References Document Number Title L1-CHE-SPE-064 L1-NAM-PRO-002 L1-CHE-POL-001 L1-CHE-PRO-004 L1-CHE-PRO-001 L0-HMR-MAN-001 Ballast Supply Specification Design and Technical Review Procedure Engineering Drawings Management Policy (IFC/As Builts) Type Approval Procedure Standard Waiver Procedure Business Rules Manual For The Contracting Rail Safety Worker PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 30

9 L2-PRJ-PRO-008 L1-CHE-STD-030 L1-CHE-STD-029 L2-TRK-PRO-054 L1-SQE-STD-001 L1-CHE-STD-043 L1-INF-PRO-001 L0-SQE-PRO-014 L0-SQE-MAN-002 L0-SQE-PLA-005 L2-NAM-PRO-008 Excavation on MTM Projects. Track Drainage Standard Earthworks and Formation Standard Track Geometry Maintenance Tolerances Vegetation Planting Standard External Cable Routes Protection of Underground Assets and Services Procedure Safety & Environmental Requirements for Third Parties Working on MTM Premises. Safety Management System Manual. MTM Environmental Management Plan. Infrastructure Procedure - Recovery of Serviceable Material & Scrapping of Surplus Material 5.3 Industry References The documents included below are provided as reference only and not to be considered as alternatives to this specification. Any order of precedence between this specification and other documents shall be outlined in specific agreed contract documentation. Document Number Title - PTV Infrastructure Drafting Standards PTC Version 1.3 Heavy Rail Track Construction Standards Part C Aug 1997 T HR CI ST T HR CI SP PTC F598 V/Line NIST-2659 VicRoads Standards VicRoads Code of Practice EPA No EPA No. 441 Transport for NSW Earthworks and Formation standard Transport for NSW Earthwork Material Specification Track Formation & Ballast for Open Single Track Construction Earthworks and Drainage Standard Section 200 Series: Formation Section 205 Rock Fill RC : Assignment of CBR and Percent Swell to Earthworks Fill and Pavement Materials. EPA Soils Sampling Guideline (Off-site management and Acceptance to Landfill) A Guide to the Sampling and Analysis of Waters, Wastewaters, Soils and Wastes PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 30

10 5.4 Australian & International References Document Number Title AS 1100 AS 1141 AS 1289 AS 1726 AS AS AS 3705 AS 3706 AS 3725 AS 3996 AS 4058 AS 4133 AS 4139 AS 4678 AS 4799 AS 5100 AS 7637 AS 7638 ASTM D4542 ASTM D4546 ASTM D4647 Technical Drawing Methods for Sampling and Testing Aggregates Methods of Testing Soils for Engineering Purposes Geotechnical Site Investigations Underground marking tape - Non-detectable tape pages Plumbing and Drainage: Stormwater Drainage Geotextiles - Identification, marking and general data Geotextiles - Methods of test - General introduction and list of methods Design for Installation of Buried Concrete Pipes Access Covers and Grates Precast Concrete Pipes Methods for Testing Rocks for Engineering purposes Fibre Reinforced Concrete Earth Retaining Structures Installation of underground utility services and pipelines within railway boundaries Bridge Design Hydrology and Hydraulics Railway Earthworks RISSB Victorian OHS Regulations 2007 Standard Test Method for Pore Water Extraction and Determination of the Soluble Salt Content of Soils by Refractometer Standard Test Methods for One-Dimensional Swell or Collapse of Soils Standard Test Method for Identification and Classification of Dispersive Clay Soils by the Pinhole Test 6 Related Documents L1-CHE-STD-039 Track Design and Construction L1-CHE-STD-029 Earthworks & Formation Standard L1-CHE-STD-030 Track Drainage Standard PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 30

11 7 Safety & Environmental 7.1 The general requirements in relation to safety are included in MTM s Safety Management System Manual L0-SQE-MAN-002. All prerequisite documentation and approvals shall be accepted and in place prior to commencing site works. 7.2 The construction of the track, formation, earthworks and drainage shall comply with the L0-SQE-PLA-005 MTM Environmental Management Plan. 7.3 All rail safety workers shall comply with Business Rules Manual for the Contracting Rail Safety Worker L0-HMR-MAN-001 and have the appropriate competencies to undertake their role. 7.4 Safety and risk assessments shall be undertaken to inform the management of track formation, earthworks and drainage, including the design, construction, installation, maintenance and refurbishment of all new and existing track formation, earthworks and drainage. The assessments shall take into account safety considerations for construction and maintenance personnel and any other parties, including operations personnel who may be required to use the track. 7.5 Where new materials or systems are to be introduced with the design and construction of the track formation, earthworks and drainage, the materials and systems shall be subject to MTM Type Approval and Engineering Change processes for use on the metropolitan train network. 7.6 Investigation shall be completed to determine the extent of any contaminated soil in the affected area. If encountered, prior to removal, contaminated soil shall be sampled and analysed in accordance with EPA Soils Sampling Guideline (Off-site management and Acceptance to Landfill) EPA No and A Guide to the Sampling and Analysis of Waters, Wastewaters, Soils and Wastes EPA No The opportunity to reuse the Contaminated Soil and/or material as a fill material on-site shall be investigated to ensure that any proposed reuse and/or disposal methods shall be acceptable to MTM, State and Federal authorities. Refer to L1-CHE-STD-029 for contamination investigation requirements. 8 Construction Requirements 8.1 General Refer to L1-CHE-STD-029 for Earthworks and Formation standard drawings and minimum requirements for Structural and General Fill depths Refer to L1-CHE-STD-029 for Site Investigation and Planning requirements Refer to Appendix A for atypical construction documentation, site records and handover requirements. 8.2 Management & Control A construction methodology shall be issued to MTM for review at an agreed time prior to site works commencing and shall include details of: a. Survey control requirements for setting out and validation of footprints, levels and slope angles; b. Material testing requirements; PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 30

12 c. Inspection & Test Plans; d. Proposed construction hold points where MTM s Approved Representative shall receive documentation or supervise/undertake field testing to demonstrate compliance with project requirements. As a minimum this shall include compaction and/or proof rolling and achievement of finished design levels for each layer prior to the placement of ballast. e. Assurance demonstrating that, once placed, the capping layer will remain intact and undamaged from vehicle movements f. Method Statements & Safeworking plans covering the specific activities; g. Approved construction drawings for the works For the duration of the site works, and any agreed period afterwards, parties undertaking the works shall be responsible for: 8.3 Preparation a. Undertaking supplementary geotechnical investigations if required due to unforeseen ground conditions or problem areas. b. Monitoring of any affected tracks, for settlement in accordance with the predicted design settlement values. c. Monitoring of Interfaces between new and existing tracks to ensure that changes in relative settlement, track stiffness, or deflection are managed and treated to prevent impacts on track condition or ride quality. d. Any works required to arrest and correct settlement that exceeds the agreed limits. e. Any track maintenance works (track lifting, tamping etc.) required to correct track defects which exceed the tolerances given in Section 7.9 of PTC Heavy Rail Track Construction Tolerances V1.3 Site preparation for the construction of track earthworks and formation shall be carried out in accordance with the requirements outlined below (unless agreed otherwise with MTM s Chief Engineer): Clearing and grubbing shall be undertaken as outlined below unless agreed otherwise by MTM. It shall extend 2m beyond the limit of the final constructed works, i.e. a minimum clearance of 2m from the top of cuttings or the toe of embankment, over the entire length of the works Unless agreed otherwise by MTM clearing and grubbing shall continue one metre beyond the outer edge of any proposed open drains and above any underground drainage and services Clearance of trees and obstructions a. The area within the agreed limits of work shall be completely cleared of all obstructions including vegetation (where required), refuse and obstructions down to natural surface. b. Trees shall be brought down in such manner as to avoid danger to personnel and traffic or damage to other trees, shrubs, structures or property outside the area being cleared or designated to be retained within the area being cleared. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 30

13 c. Tree branches extending over the track shall be trimmed to provide the appropriate transit space clearance for the rail corridor in accordance with MTM s current Vegetation Management Plan. Where whole branches are to be removed, an approved cutting method shall be used. d. Parties undertaking the works shall be responsible for obtaining all permits or authorisations required for the removal of trees or other vegetation Stripping of Topsoil a. After removal of all above ground obstructions, topsoil within the agreed area shall be stripped to a minimum depth of 150mm. This stripping shall remove all traces of grass, weeds, roots and other unacceptable matter: i. within the width of the formation and beneath the access tracks as a minimum ii. iii. iv. between the limits of the batters as defined by the intersection through the natural surface, extended to include any surface drains and subsurface drainage lines. by a means which avoids contamination with subsoil and does not increase the extent of unstable areas. to be placed in stockpiles or prepared areas well clear of the works in a neat, stable, well-shaped state capable of shedding water. b. Removed topsoil shall remain the property of Victrack unless agreed otherwise. Where possible topsoil should be re-used for landscaping and revegetation by spreading as soon as practicable. The topsoil shall be treated and managed, before stripping and after spreading, to remove and/or minimise the spread of weeds, pathogens and pest organisms throughout the site and to adjoining land Grubbing a. Any permits required by Federal, State and local legislation or authorities shall be obtained prior to clearing and grubbing. b. In areas where excavation is to be made, all vegetation (where necessary), refuse and obstructions shall be totally grubbed to a depth agreed by MTM. c. In areas to be covered by embankments, all vegetation (where necessary), refuse and obstructions shall be grubbed to a depth of not less than 0.3 m below the stripped surface or not less than 0.6m below the finished surface of the subgrade. d. In areas to be covered by embankments exceeding 1m in height, foundations may remain if located below the base of the Structural Fill layer and at least 1m below the proposed top of rail level. e. Pits which are no longer required shall be removed or broken back to a depth not less than 0.3m below the finished surface of the subgrade. Remaining pipe openings shall be sealed with concrete. Any remnants of pits shall be backfilled with material, compacted and proof rolled or tested. The calculation of density ratio shall be based on Standard Compactive Effort as defined in AS 1289 (or the agreed modified equivalent). PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 30

14 f. Holes resulting from grubbing shall be scarified and backfilled with material similar to the surrounding material and compacted to the same degree as the surrounding material. 8.4 Earthworks Excavation a. Appropriate assessments shall be made to prevent slips and falls of unstable masses of material outside the specified batters during excavation operations. b. Slope stability assessments shall be undertaken prior to: i. Removing any material from the toes, crest or at any point on the sloping surface of existing embankments. ii. Cutting service or drainage trenches at the top or toe of existing embankments Excavation in cut to fill zones or areas with varying CBR values shall be continued, in the form of transverse benching, across the interface for a distance sufficient to ensure that an appropriate stiffness transition is provided as agreed by the MTM Approved Representative, Excavation at the base or the footing of any structure (including signals, overhead masts, retaining walls or station platform walls) shall not be undertaken until an appropriate investigation and analysis of the effects of the excavation on structure stability has been undertaken and accepted by MTM Where fill materials are present and no records exist of its construction, it shall be assumed to be uncontrolled fill (unless agreed otherwise by MTM Approved Representative) Any use of explosives shall comply with the requirements of AS7638 and the requirements of MTM Safety Management System Filling Around Pipes, Culverts and Structures a. Filling over and around pipes, undertrack crossings and culverts shall be placed in a manner that avoids unbalanced loading and does not cause movement or place any undue load on the structure. b. Filling placed adjacent to pipes and culverts shall be compacted in horizontal layers not exceeding 150mm loose thickness and shall be thoroughly compacted by an approved method and validated to ensure compliance with compaction requirements. The level of filling on either side of such structures shall at no time differ by more than 300mm. c. Backfill of existing under track crossings shall be cement treated. Requirements for new undertrack crossings are specified in AS 4799 and L1-CHE-STD-043 External Cable Routes Access tracks a. Access tracks are to be formed of the same subgrade as the track structure and surfaced with 100mm of gravel, crushed rock or other materials agreed by the MTM Approved Representative. Tracks shall be shaped and compacted to meet the design and operating requirements. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 14 of 30

15 8.4.8 Benching & keying-in a. Where fill is to be placed against existing fill or against surfaces which have a slope steeper than 1V:4H the existing surface shall be cut progressively in the form of benches over the full area to be covered by new filling unless agreed otherwise by the MTM Approved Representative. b. The width of each bench shall be such as to permit safe and effective operation of plant and shall be not less than 1m. c. Each bench shall be formed in a manner that ensures that the bench itself and any plant mounted on it will remain stable throughout the excavation works. Each bench shall be filled with compacted material or the bank reinstated at the end of each shift to an agreed minimum distance from the toe of any bench or batter to the nearest existing track centre. d. The new filling shall be placed and compacted in layers as specified until the surface reaches the top of the vertical face of each bench, and then a new bench shall be cut; this process shall continue for the full height of the fill. e. Keying-in to any existing track formation shall be undertaken in accordance with an agreed design and methodology. 8.5 Finishing Requirements All earthworks shall be finished to smooth and uniform surfaces which shall conform to the lines, levels and cross-falls shown on the approved construction drawings, within specified tolerances Between the limits for the whole distance specified, the railway formation shall be formed, compacted, graded, boxed, trimmed and drained as shown on the approved drawings, specifications and as described in this document The work includes filling and cutting to the required heights and widths, and constructing drains where existing drains are affected by new embankments and cuttings Compaction requirements specified in this document are based on: 8.6 Proof Rolling a. defining the required number of roller passes; b. mandated proof rolling and c. soil tests Where specified, proof rolling shall be required to confirm that material compaction and strength have been achieved. All earthworks layers shall be compacted so they are capable of withstanding proof rolling. The final method of proof rolling (and whether it is required for each layer) shall be as specified in approved design documentation or as directed by the MTM Approved Representative Unless a higher standard is specified by the geotechnical designer, proof rolling shall be conducted by a minimum of 3 passes by one of the following: Pneumatic tyred plant with a mass of 20 tonnes or more with a ground contact pressure under either the front or rear wheels of not less than 700kPa per tyre. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 30

16 Static smooth steel wheeled rollers with a mass of 12 tonnes or more and a load intensity under either the front or rear wheels of not less than 6 tonnes per metre width of wheel Other such heavy vehicle as approved by the MTM Approved Representative Proof rolling shall be undertaken in accordance with the agreed construction methodology and witnessed by the MTM Approved Representative. Where there is visible deformation or springing of the layer being tested the material shall be deemed unsuitable. If it is determined that the layer being tested is unsuitable, then it shall be either removed and replaced with suitable fill material (as defined in this standard) or reworked and improved by an agreed method. Upon completion of the remediation works, the area shall be re-proof rolled and the process repeated until a satisfactory outcome is achieved MTM s Approved Representative may direct installers to validate proof rolling results by compaction testing if visual witnessing is deemed inadequate Upon achievement of a satisfactory proof rolling result, subsequent earthworks layer construction shall begin within 2 days. If two days is exceeded, the approved MTM Approved Representative shall determine if the weather in the period between proof rolling acceptance and construction commencement, or any other activity or occurrence, has had any detrimental effect on the performance of the subgrade, and at their sole discretion, further proof rolling maybe required. 8.7 Disposal of Materials All materials unsuitable for incorporation in the work shall be disposed off-site, unless approved for re-use on site for non-structural purposes Unless specified otherwise all surplus and serviceable materials shall remain the property of VicTrack Contaminated or potentially contaminated materials should be tested prior to transportation off-site and disposed of in accordance with relevant legislation. 8.8 General Testing Requirements Samples of material proposed for use in rail earthworks and formation shall be laboratory tested and the results considered in the final selection of material Samples of earth materials for laboratory testing shall be taken and handled in accordance with AS 1726, and AS 1141, section Tests shall be carried out at an approved NATA registered laboratory accredited for the specified tests. 9 Subgrade Materials Specific requirements for subgrade materials are listed below. 9.1 Description Subgrade shall consist of material compacted to a minimum Characteristic Value of Density Ratio of 98% when assessed using a standard compactive effort as determined by AS1289 Tests and (Standard Compaction). PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 16 of 30

17 9.2 Unsuitable Material The following materials are considered as unsuitable for rail subgrades or general fill: a. topsoil, organic soils, such as severely root-affected subsoils, peat, logs, stumps; topsoils containing organic materials; b. free draining material susceptible to scouring or piping such as very fine clean sand, windblown sand and non-cohesive silt; c. Silt and clay with California Bearing Ratio less than 2% (unstrengthened); d. Reactive materials, such as basaltic clays, which undergo volume changes equal to or greater than 2.5% as determined in accordance with ASTM D Standard Test Methods for One-Dimensional Swell or Collapse of Soils, Test Method A.. These materials shall either be removed as spoil or treated by additives as agreed by the MTM Approved Representative; e. dispersive soils; f. materials that contain substances which can be dissolved or leached in the presence of moisture such as gypsum and sodium chloride; g. contaminated materials containing toxic substances which may be harmful to environment, water supply or agriculture; h. collapsible soils; i. fill that contains wood, metal, plastic, boulder or other deleterious materials, in sufficient proportions to affect the required performance of the fill; j. saline, chemically aggressive or polluted soils, and carbonate soils where acid disposal may occur Unsuitable materials may be reused following suitable treatment. Prior to re-use a report shall be submitted to the MTM Approved Representative detailing suitable treatment and evidence or testing certifying compliance with the specified requirements for a particular use. The report shall be approved by a qualified geotechnical engineer and shall demonstrate that the treated materials shall not adversely affect the performance of the earthworks or formation throughout the design life. Acceptance for the proposed re-use shall be received from the MTM Approved Representative prior to commencing the works. 9.3 Specification Subgrade material shall comply with the criteria listed in Table 1. Any material not conforming with these requirements shall be not be used without a waiver or prior agreement of the MTM Approved Representative Any collapsible soils in foundation proposed for use as subgrade shall be treated and subject to acceptance by the MTM Approved Representative before being used. 9.4 Subgrade Preparation & Installation For track being constructed on embankment: a. Any surface on which fills are to be constructed shall be proof rolled. Unstable areas detected by test rolling shall be removed, reworked and/or improved as agreed by the MTM Approved Representative. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 17 of 30

18 b. Where general fill is to be placed directly over the subgrade, the subgrade (including any replacement materials) shall be compacted to a minimum Characteristic Value of Density Ratio of 98% when assessed using a standard compactive effort as defined in AS (or agreed equivalent modified compaction). c. Where structural fill is to be placed directly over the subgrade, the subgrade shall be scarified to a depth of 200 mm and re-compacted to a minimum Characteristic Value of Density Ratio of 100% when assessed using a standard compactive effort as defined in AS For track being constructed in soil cuttings: a. Excavation at the base of cutting shall be finished at a level to suit the capping thickness, with cross falls and cess drains provided. b. Where rail subgrade CBR is equal to or greater than 8, compaction of the top 150mm layer in the base of cuttings shall achieve a minimum Characteristic Value of Density Ratio of 100% when assessed using a standard compactive effort as defined in AS c. Where rail subgrade CBR is less than 8 the material shall be treated by an agreed method or removed and replaced by rail structural fill material in accordance with depths outlined in L1-CHE-STD-029. The subgrade shall be treated and compacted (including spreading and compacting all replacement materials, if any, in layers not exceeding a compacted thickness of 200 mm) to a minimum Characteristic Value of Density Ratio of 100% when assessed using a standard compactive effort as defined in AS d. Where the cutting is interspersed with varying subgrade quality, to achieve homogeneous longitudinal stiffness along the subgrade, the cutting floor may require ripping or loosening to a specified depth below designed floor level and re-compacting. Typical depth may vary from 200 mm to 300 mm. The maximum dimension of any particles in the ripped or loosened zone shall not exceed 150 mm. e. Batter slopes in cuttings shall be carried around curves in an even and regular manner. For minor works or works being undertaken in railway occupations alternative methods of estimating CBR values maybe agreed by the Office of the Chief Engineer For track being constructed in rock cuttings: a. The rock surface shall be excavated and all materials removed to a minimum of 150mm below the underside of the rail capping layer; b. Any materials classified as Highly Weathered (HW) or worse, or with clay pockets existing 150mm below underside of rail capping layer shall be removed to a depth of 350mm (i.e. 500mm below top of rail capping layer) or as agreed by the MTM Approved Representative. c. All loose materials and soil from the floor of the cutting and from the undulations and crevices between the rock shall be removed to provide a clean and stable surface d. Class 3 20mm crushed rock shall be placed in layers not exceeding 150 mm, to the underside of the capping layer, and compact. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 18 of 30

19 e. For over excavation greater than 200mm or small crevices and undulations, which prohibit the effective placement and compaction of crushed rock, shall be filled with Class 3 20mm 3% cement treated crushed rock in layers not exceeding 150mm or a layer of 10 MPa lean mix concrete. An equivalent dry premix for localized filling with some wet down during compaction may be proposed subject to agreement by MTM, f. At the interface location between rock subgrade and soil subgrade, or for localised presence of clay seams or pockets the clay shall be removed and replaced in accordance with the approved drawings and specifications. Where the drawings do not address the as exposed condition the advice of the MTM Approved Representative shall be sought prior to placing any material on the rail subgrade. g. Where the exposed rock surface at the underside of the Rail Capping Layer is without any clay holes greater than 500mm deep or clay seams and is suitably smooth, as defined on the drawings and capable of draining freely to the adjacent cess drain/s, any clay holes shall be cleaned and backfilled with Class 3 20mm crushed rock in layers not exceeding 150mm or a 10MPa lean mix concrete prior to placing the capping layer. h. Subject to acceptance by MTM a rationalised capping arrangement that provides a compliant drainage crossfall and meets the above requirements may be considered. An acceptable stiffness transition into the standard track structure shall be provided. 9.5 Testing Requirements The tests in Table 1 shall be carried out on subgrade material and imported materials used to replace unsuitable subgrade to confirm compliance Table 1: Subgrade material testing requirements Test Reference Criteria Soaked CBR specimen soaked for 4 days prior to testing and by application of a 13.5 kg maximum surcharge load during testing AS 1289 Test Plasticity Index AS1289 test Dispersion determination of pin hole dispersity classification Dispersion determination of Emerson class Number of a soil Collapse Strain (wetting induced) AS1289 test ASTM D4647 3% min Nominal (Refer to L1-CHE-STD-029 Table 2 for further details) 9-20% ND1 or ND2 AS 1289 test Not to be Class 1 or 2 ASTM D To be agreed by Approved MTM Geotechnical Engineer PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 19 of 30

20 Free swell index ASTM D % max. Soil soluble salt content ASTM D % max. Organic content (dry weight) ASTM D % max All recommended tests shall be carried out as one test per 1000m 3 of the material. If the volume of the material to be used is less than 1000m 3 at least one set of tests shall be carried out. For larger construction works a lot testing methodology may be agreed by the MTM Approved Representative. 9.6 Compaction Relative compaction specified for field tests shall be achieved over the full depth of the layer. Each compacted layer shall have a uniform thickness. The methods of excavation, transport, depositing and spreading of any required fill material shall be selected so as to ensure that the placed material in any lot is homogeneous. The material shall be free of unsuitable materials Compaction shall be carried out at a moisture content which allows the specified compaction to be achieved. Where necessary water shall be added uniformly or drying carried out. Bond between layers is to be ensured, if necessary by wetting or scarifying. 9.7 Finishing & Tolerances Subgrade on embankments and cuttings (other than rock) shall be installed to within +40 mm to -40 mm of the approved design surface level Subgrade in rock cuttings shall be installed or finished to within +0mm to -80mm of the approved design surface level The width and slopes of subgrade preparation and layers (including following final trimming) shall be no less than the dimensions specified in the approved design i.e. negative tolerances are not permitted The cutting and embankment batters shall be no be steeper than specified in the approved design i.e. negative tolerances are not permitted. 10 Embankment Materials This section details the specification for embankment materials and their testing requirements. The types of embankment materials include the following: Free draining filter material General fill material Structural zone fill material All materials shall be transported in a manner which does not affect the required physical properties of the material. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 20 of 30

21 10.1 Free Draining Filter Materials Specific requirements for rail free draining material are listed below Description Free draining filter material used for the construction of drainage blankets shall be made of clean crushed rock, river gravel or slag composed of hard, strong and durable particles to satisfy the requirements of this specification Specification Particle size distribution of material for free draining material shall be in accordance with Table 2. Table 2: Free draining material particle size distribution Description Criteria % %passing 53.0 mm sieve 100 % passing 37.5 mm sieve 90 to 100 % passing 26.5 mm sieve 20 to 55 % passing 19.0 mm sieve 0 to 5 % passing 75 μm sieve Preparation & Installation a. Where designed, a drainage blanket consisting of MTM approved free draining filter materials shall be installed on the base of the prepared embankment in accordance with the approved design drawings and/or specifications. An approved geotextile shall be laid along the base and around the layer of free draining filter material to a nominal depth of 300mm (or as agreed by the MTM Approved Representative). Manufacturer's instructions concerning installation of the geotextile shall be followed. Spall protection at the outlet shall be provided in accordance with L1-CHE-STD-030. b. Free draining filter material shall be spread in uniform layers to give the specified compacted thickness in such a manner as to avoid damage to the fabric. c. Additional remediation works to address bad ground, seepage or springs encountered during embankment preparation works shall require agreement by the MTM Representative Testing Requirements The tests in Table 3 shall be carried out on the free draining filter material to confirm compliance: Table 3: Free draining material test requirements Free draining filter material test Reference Compliance Criteria Particle size distribution AS 1289 Test See Table 1 Soft and friable particles AS Max. 5% Clay lumps AS Max. 0.5% PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 21 of 30

22 Los Angeles Value (A) AS Max. 30% Particle density AS , The point load strength index Is(50) AS AS 1141 Min.2.3t/m 3 1MPa (min.) a. The minimum frequency of testing shall be carried out as follows: i. one test per 50 m 3 of material ii Compaction at least one test if there is less than 50m 3 of material Compaction shall be obtained using at least 8 passes of a vibratory roller or static drum load of 6 tonnes or as agreed by the MTM Approved Representative Finishing & Tolerances The free draining material shall be spread in uniform layers in such a manner as to avoid damage to the geofabric and shall be installed to within +40 mm to -40 mm of the approved design surface level General Fill Materials Specific requirements for rail general fill materials are listed below Description a. General fill shall consist of suitable material that shall be compacted to a minimum Characteristic Value of Density Ratio of 98% when assessed using a standard compactive effort as determined by AS1289 Tests and (Standard Compaction). b. Unsuitable material: Refer to section 9.2 for details of materials considered unsuitable for use as fill Specification a. General fill material shall comply with the criteria listed in Table 1 (Subgrade material testing requirements). b. Any collapsible soils proposed for use as fill shall be treated and accepted by the MTM Approved Geotechnical Representative before being used Preparation & Installation For track being constructed on embankment: a. Any surface on which fills are to be constructed shall be proof rolled. Unstable areas detected by test rolling shall be removed, treated and accepted by the MTM Approved Geotechnical Representative. b. Refer to b for subgrade preparation requirements Testing Requirements Tests and frequencies for subgrade materials outlined in Table 1 of this standard shall also be carried out on samples of general fill material to confirm compliance. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 22 of 30

23 Compaction Compaction requirements for subgrade listed in Section 9.6 shall apply to the placing of general fill. In addition all layers of general fill material shall be compacted to a minimum Characteristic Value of Density Ratio of 98% when assessed using a standard compactive effort as defined in AS Finishing & Tolerances Finishing and tolerances for subgrade listed in Section 9.7 of this standard shall also apply to the placing of general fill Structural Fill Material Specific requirements for rail structural fill material are listed below Description Structural zone fill material requires a higher strength quality than general fill or subgrade and shall comply with the specification requirements detailed below Specification The particle size distribution of material for structural fill shall be: Table 4: Structural fill particle size distribution Description Criteria % %passing 53.0 mm sieve 80 to 100 % passing 2.36mm sieve 15 to 100 % passing 0.425mm sieve 0 to 70 % Passing mm sieve 0 to Preparation & Installation The CBR of the underlying subgrade shall be assessed to determine the required depth of structural fill material as set out below: a. Where the rail subgrade CBR is greater than 8 the removal and replacement of materials below the rail subgrade level is not required. The Contractor shall scarify the surface to a depth of 200 mm below the top of the subgrade design level and compact to the requirement specified below. b. Where the rail subgrade CBR is less than 8 structural fill material shall be placed in accordance with the depths nominated in L1-CHE-STD-029. c. Where the rail subgrade CBR 2% or less the unsuitable material present in the rail subgrade shall be treated in accordance with methods agreed by the MTM Approved Representative. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 23 of 30

24 Testing Requirements The tests in Table 5 shall be carried out on samples of the structural fill material to confirm compliance: Table 5: Structural fill testing requirements Test Reference Criteria Soaked CBR (specimen soaked for 4 days prior to testing and by application of a 4.5kg surcharge load) during testing AS 1289 Test % min compacted to 100% standard dry density Particle size distribution AS 1289 test See Table 4 Liquid limit AS 1289 test or AS 1289 test 3.9 Plasticity Index AS 1289 test AS 1289 test % Max. 20% Max. Dry Density AS 1289 test t/m 3 Min The minimum frequency for the tests listed above shall be no less than: a. three tests per 1000m 3 of material b. three tests if there is between 500m 3 and 1000m 3 of material c. at least two tests if there is less than 500m 3 of material For larger construction works a lot testing methodology may be agreed by the MTM Approved Representative Compaction a. For cohesive soils: All layers of structural fill material shall be compacted to a minimum Characteristic Value of Density Ratio of 100% when assessed using a standard compactive effort as defined in AS b. For rock fill or cohesionless soils: no visible deflection of surface under 10 tonne vibratory rollers after eight passes Finishing & Tolerances a. Prior to placing capping layer the finished rolled top of structural fill shall be free of depression and ruts and shall be within +0mm to -35mm of the approved design surface level. b. The structural fill shall be within +0mm to +50mm of a 3m straightedge laid on the final structural surface parallel and perpendicular to the centreline. c. The prepared slope batter shall not be steeper than specified in the approved design i.e. no negative tolerances are allowed. d. Formation width shall not be less than design width. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 24 of 30