Double Track Railway

UNIVERSITY OF MALAYA

Rawang-Ipoh Double Tracking Project

Introduction Single Track Double Track

Double Electrified Track

Case study  Rawang to Ipoh Electrification & Double-tracking Project Keretapi Tanah Melayu Berhad (KTMB) ►main rail operator in Peninsular Malaysia. ► ►Headquarters located in Kuala Lumpur ►consists of two main lines (West Coast line & East Coast line) and several branch lines.

Encik Suhaimi Ahmad

Overview 1700km

Route Length= Track Gauge=

1000mm

Electrified

Double Tracking

-

:Route length

150 km Seremban 105km Klang 45 km

:Rawang:Sentul-Port

Intercity services  22 Intercity and Regional services    

nationwide Popular route KL – Singapore Construction of Electrified Double Track between Rawang Ipoh to link Kuala Lumpur-Ipoh Travel time between KL – Ipoh will be reduced to 2 hours 15 minutes

Commuter services services daily expansion: Tanjung Malim Service Rawang - Ipoh

>Approximate 247 Commuter trains >Future :Rawang by 2008 :Rapid Train between by 2008 :Sentul - Batu

objective  to upgrade existing rail infrastructure for the increase in track capacity for commuter, intercity and freight trains.

 to extend the existing commuter service from Seremban - Rawang sector to Seremban - Tg. Malim sector with an average number of service of 100 trips a day.

 introduction of a rapid intercity service, between Ipoh – Sentral KL for 16 services a day and ultimately 32 services a day.

Partially completed Electrification System sub station for Rawang – Ipoh Project

Project brief & contract Integrated project System - Signaling, communication electrification, supply item

Infrastructure - station, track work, bridges, culvert, civil work

-This project use existing single track route >modify & upgrade – add 1 track beside – become doubletrack & electrification system

Project brief & contract (cont’d)  Commencement Date:17 July 2000  Completion Date: 31 December 2007  Cost: original contract show 2.6 billion infrastructure work + 1.6 billion system work : UEM Construction Sdn Bhd take over – extra 766 million Total sum: 4.966 billion

Project brief & contract (cont’d)  Infrastructure works originally awarded to DRB-Hicom Berhad in

2000 (35months contract )– due to delay & contractual disputes – government appointed UEM Construction Sdn Bhd from 1 June 2005 (19months contract )  System main contractor: Mitsui of Japan  Sub-contractor : ♥ System : 1) Siemens-balfour Beatty Consortium ► Siemens Transportation Turnkey Systems Sdn Bhd (signalling) ► Balfour Beatty Rail Sdn Bhd (electrification) ► Siemens Malaysia Sdn Bhd (communication) ♥ Infrastructure: ► Emrail Sdn Bhd for track works ► IJM Corporation Berhad for the construction of stations ► UEM Construction Sdn Bhd for the construction of bridges ► Perspec Prime (Malaysia) Sdn Bhd for civil works

Organization Chart

General design concept  Design concept:Modern Railway Concept  Objective: Major components service Life 50 years  Type: Flat-bottom rail  Upgrade existing single track to electrified double track system – change wooden sleeper to precast concrete sleeper  Design speed of track is 160km/hr, achieve full speed –2 mainline of platform (at the mainline) – straightway

General design concept (cont’d)

 Have 14 stations  Early day: have interlocking >> no interlocking, train need to wait station manager permission  Nowadays: before train come to signal, automatic switch and detected by track circuit >> electric bond

Construction techniques overview    

Machinery more than manual Using precast material Jointing – welded Concrete Sleeper- rail to fasten

Flat-bottom rail type

Project

layout

Construction Stages of Electrified Double Track Project – Civil & Track - 10 stages

STAGE 1 LEGEND CONDITION BEFORE WORK CARRIED OUT IN THIS STAGE WORK CARRIED OUT IN THE PREVIOUS STAGE

STAGE 2

STAGE 3

STAGE 5

STAGE 4

STAGE 6

STAGE 7

STAGE 9

STAGE 8

STAGE 10

TAKE OVER OF FORMATION (Part formation for one track)

BOTTOM BALLASTING

SLEEPER SLEEPER

TOP BALLAST

BOTTOM BALLAST FORMATION

Bottom ballasting by ballast box

Bottom ballast by paver

Compaction of bottom ballast

Laying of sleepers

Laying of depot welded 144M Rail Panels

LWR Train

LWR Laying

Threading of rails by wide wheel tractor

Fresh Flash Butt Weld

Insitu Flush Butt Welding

Top Ballasting prior to Tamping

Unloading of ballast hoppers at site

Loading of hopper tain in ballast depot

Track Tamping: Lifting, lining & levelling

Tamping tynes close up Compaction of top ballast by dynamic track stabiliser

Ballast regulation

Destressing and at welding

Destressing-pulling of rail by tensor

At Welding

Cut & Slew for operation

Track auditing

Completed track

Track QA/QC

During Construction

Material Testing

Finished Track

ITP of Processes & Track

Static Measurements Dynamic Measurements

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