afraid South Western Railway yatta, merr@raiey, Rail Soudha, Headquarters Office, orésra, oR deter, Works Branch, West Wing, 3"! Floor, rams, Fare — $80 020. Gadag Road, Hubballi-580020. No. SWRIW.S71/PCE-Circular/2021 Date:- 27/07/2021 PCE Circular No. 2 of 2024 (Revision: Sub: Design, Fabrication, Erection & Maintenance of Foot Over Bridges on S.W. Railway. Ref: PCE Circular No.2 of 2021 dated 05.07.2021. APPLICABILITY: - All FOBs being constructed on S.W.Rly. by Open Line, Construction Organization, KRIDE, RVNL, etc. 4. General Layout / GAD / Design : 1.1. Following standard drawings issued by RDSO are available on date: i, RDSO —for structural steel FOBs- a) RDSO/B-10402, and RDSO/B-10405 — for 3.00m wide FOB b) RDSO/B-10401, RDSO/B-10403, and RDSO/B-10404 — for 6.00m wide FOB ii, RDSO —for stainless steel FOBs- a) RDSO/B-10424 — for 6.00m wide FOB ~ span 25.00m to 30.00m(Trial) b) RDSO/B-10426 — for 6.00m wide FOB-span 20.00m to 25.00m (Trial) 1.2 _ In case standard drawings of RDSO are not used, then the designs & drawings shall be prepared in house by Open Line / Construction Organization and GADs shall be approved by CBE/SWR for all FOBs. However Design can be approved by concerned Chief Engineer Construction. In case designs and drawings are prepared by Consultants, it shall be proof checked by IIT/NIT/Recognised Engineering /Technology Institutions of repute or RITES, etc. and thereafter approved by SWR/HQ office of Open Line or Construction, In such designs, the Live Load on FOB shall-be taken as per Clause 2.3.2 of IRS Bridge Rules. Further, where Live Load daily peak variations are likely to be very frequent & high, the FOB may be checked for Fatigue Failure under relevant provisions of IRS Steel Bridge Code as per design requirement. 1.3 FOBs will be designed using Plate Girders or Steel Trusses in superstructure. For other type of super-structures prior approval CBE shall be mandatory at GAD stage itself 1.4. Minimum width of FOB should be 3.00m as specified by S.W-RIy's letter No. SWRIW.351/FOB dated 06.07.2018 for all Halt Stations (HG1 to HG3) as well as for non-suburban stations of category NSG5 and NSG6. For all major stations of15 1.6 47 18 1.9 1.10 1.411 1.12 24 2.1.1 SWR falling under category of NSG1 to NSG4 (Non Suburban), minimum width should be 6,00m. Any proposal of lesser width shall be permitted, only with the prior approval of GM/SWR as per Rly. Bd.’s letter No. 22018/LM(PA)/03/06 dated 09.04.2018. As far as possible, double row of steel columns shall be provided at all locations of FOB for better stability and for providing desirable redundancy to the structure. Single row of steel columns, however, may be provided in exceptional circumstances due to space constraint as intermediate support (but not at the end supports) to reduce the span length, on practical considerations. Normally staircase should not be permitted at the locations having single row of columns. However, in unavoidable locations, if the staircase needs to be provided at such locations, the stringer of staircase shall not be connected with main girder and it shall rest on independent columns. Any other type or configuration span>30m or single row of column at end support can be considered in unavoidable condition, on specific constraints to be clearly brought out by sponsoring organization or executing agency, with prior approval of CBE. ‘The Key Plan of proposed FOB at station will clearly indicate full platform lengths, also showing all other existing FOBs and enttry/ exit points of station to appreciate passenger movement through the proposed FOB Provision of future lifts, escalator, ramps, etc. shall be shown in the GAD, if required to be provided at stations, as per extant guidelines for provision of such facilities As per RDSO's letter No. CBS/Stainless Steel/FOB dated 29.07.2019, Stainless steel reinforcement bars, in coastal areas, shall preferably be used or alternatively, Fusion’ Bonded Epoxy Coating (FBCE) on MS/HYSD reinforcement bars shall be used. At places other than coastal area, any other suitable anti- corrosive coating shall be applied. ‘A method statement for execution shall be prepared by Executing agency indicating Execution Plan, Quality Control and Safely issues and approved by Engineer-in-charge. It shall also indicate requirement of barricading keeping in view passengers’ convenience, signages for passengers’ movement and safety warnings, etc. The executing agency shall submit a Safety, Health &Environment (SHE) manual which shall contain Hazard Identification & Risk Assessment (HIRA) with Risk matrix and checklist. The sample Risk Matrix and checklist for the same is enclosed as Annexure-I. This is indicative only. Such Risk Matrix and checklist is specific to each site and to be prepared duly identifying the conditions prevailing at each site, As per RDSO's letter No. CBS/Stainless Stee/FOB dated 05.02.2021, Stainless Steel FOBs may be provided on trial basis in corrosion prone areas. Foundation / Substructure / Superstructure arrangement : Foundation : - ‘The choice of type of foundation shall be decided keeping in view site conditions and constraints of limited working space in platform / yard. The same should be { 221.2 2.1.3 214 21.5 22 224 2.22 2.2.3 23 2.3.1 2.3.2 23.3 24 241 24.2 examined in detail at the time of preparation of General Arrangement Drawing (GAD) itself. The GAD should also indicate need of speed restriction, if any fequired for execution. The foundation pedestal shall be minimum: 60cm higher than the surrounding ground level. On platforms, foundation pedestal shall be minimum 30cm higher than platform level. No stagnation of water should be allowed over the pedestal or within column. base to avoid corrosion. The connection between the bed plate and column base shall be provided with zinc aluminium flake coated bolts and welded connections should not be used. The steel column shall not be embedded in concrete pedestal. No sitting Platform shall be provided around the column base. Substructure Only submerged arc welding shall be used for built up sections of main column. Splicing in columns shall not be permitted. In case it is unavoidable, the same shall be provided as per designed splice with HSFG bolt. No field splicing with welding shall be permitted. The bracings provided on the platform for the stability of column shall be suitably designed so as not to cause any obstruction to the movement of passengers. Accordingly, the minimum height of bracings from finished platform level should be 2.40 m, Main girder arrangements (superstructure) : Only submerged arc welding shall be used for built up sections of main girders, Splicing of web / flange will be done with HSFG bolts with DTI washers under the supervision of suitably trained personnel. In case welded splice is to be provided, the same shall be as per approved design and shall be provided with submerged arc welding only. Splicing with field welding will not be permitted. Site welding of load bearing welded connections on main members shall not be pemmitted. Secondary arrangement : - Diaphragm and cross bracing shall be bolted by HSFG bolts with DT! washers under the supervision of suitably trained personnel. The arrangement of end diaphragm and cross bracings shall be so designed that it does not adversely affect the movement of staff during maintenance and inspection.25 25.1 25.2 253 3.2 3.3 34 3.5 36 37 38 Roofing / Roof cladding : - Typical drawings issued by RDSO for roofing shall normally be used. in exceptional cases, deviation may be done with justification with prior approval of CBE. As per RDSO's letter No. CBS/Solar panel dated 26.04.2019, No. CBS/Solar panel dated 28.10.2019 and No.FV/FIM/0010/12/MMS dated 03.09.2019, no other extra loading over the roof structure (like solar panels) shall be permitted without approval of CBE. The roofing shall be projected / extended beyond the outer edge of FOB deck by minimum 300mm so that the water does not fall over the edges of deck slab, and corrosion of outer girders is prevented on this account. Further, to avoid rain water falling directly on passenger platforms and track, suitable gutter with drainage arrangement is to be provided. Fabrication of steel work : - All fabrication material &fabrication process must be as per IRS B1-2001 (Indian Railway Standard Specification for fabrication. and erection of steel girders and locomotive turn-tables). Stee! should be procured from primary manufacturer only, like SAIL, TISCO, JINDAL, RINL and tested / verified w.r.t. manufacturer's certificate& test reports. Fabrication drawings shall be prepared for accuracy of dimensions and preferably using standard software and same should be approved by the concerned Engineer-in-charge. For fabrication of each steel structural member, Quality Assurance Plan (QAP) and Welding Procedure Specification Sheet (WPSS) shall be prepared by Executing Agency, which shall be approved by concemed DEN / Sr.DEN for ‘Open Line & PSU / outside organizations, and by Dy.CE/CN for Construction Organization, before starting the work. As per Railway Board's letter No: 2017/50/CE-II/Br/FOB dated: 18.12.2018, FOB can be fabricated in Private Workshop also but it shall have adequate infrastructure and competent staff to carry out steel fabrication. However to ensure quality of fabrication, QAP has to be prepared in each case which is to be approved by Sr.DEN / Dy.CE/CN (Officer of JAG level). No splicing, other than the approved splicing, in the fabrication drawing should be allowed. All welds should be done in workshop only by submerged arc welding process either by fully automatic or semi-automatic machines as approved by designer. Only approved welders shall be assigned the fabrication work. Any deviation, if required, shall be done with the prior approval of CBE. Field welding shall not be permitted. in special circumstances, however, field welding may be undertaken by competent welder in accordance with Para 26 of 81-2001 for very short runs and members of minor importance. Such locations of field welding shall be provided with proper size of weld and ensuring proper grinding. All field welds shall be tested at site as per QAP and WPSS. All field welds shall be subjected to 3" party inspection as per Para 4.0 below.3.9 3.10 3.14 42 43, 44 45 52 5.3 5.4 55 Proper record of work done as per QAP and WPSS shall be maintained, Connections of members should not créate pockets for accumulations of water and replacement should be easy. It should be possible to visually inspect all such welded joints during periodical inspections. 3" Party inspection of fabrication and erection : The quality of fabrication and erection including jointing details of steelwork for columns, staircases, bracings, roofings, etc., including girders not fabricated in RDSO approved workshop shall be ensured at each stage by employing 3° party inspection by agencies like RDSO, RITES, Welding Research Institute, Trichy (WRI) or any other expert public undertaking eg. Certification Engineers International Limited, Navi Mumbai (CEIL). The final responsibility for quality work as per specifications, however, shall rest with concerned Railway official approving the work. While approving QAP and WPSS, consultation with 3 party Inspecting Agency shall be done by concerned DEN / Sr.DEN / Dy.CE (CN), wherever deployed. Trial assembly of girders shall be done in workshop and passed by nominated Inspecting Agency. Inspection report should be submitted by 3“pary agency to Division or field construction unit for rectification & follow up action. The rectification report shall be examined and accepted by concemed Sr.DEN/Co-ord. at Divisional level or Dy.CEICN. Girders fabricated in RDSO approved workshop shall be checked for specifications, quality and acceptance by concerned Railway officials. Erection at site : The crane deployed for erection shall be of adequate capacity with at least 50%extra margin to lft the girders at specified working radius and boom length a8 per approved scheme. Crane must have Working Automatic Safe Load Indicator (ASLI) and crane must be certified fit by Third Party Administrator (TPA). Competency certificate of crane operator must be available. Provision of standby crane of adequate capacity shall always be made at erection sites. Erection shall be done at site as per launching scheme (TAD) approved in presence of sectional Sr.DEN / DEN. No gas cut holes shall be allowed to fix diaphragms / cross bracing. Joint inspection with 3 party inspection agency shall be conducted by sectional ADEN after erection to ensure that the joints are properly fitted. After erection, 3% party inspection is must. Detailed inspection proforma shall be followed for joint inspection after erection.6.2 63 64 65 66 67 68 72 73 74 Deck slab : Cast in-situ deck slab should, generally, be available for visual inspection. Corrosion resistant sheets (e.g. profiled galvalume sheets) may be used as sacrificial shuttering for casting of deck slab as per design and manufacturer's specifications. MS plates should not be used for sacrificial shuttering. Sacrificial shuttering, however, should not be used for staircases and ramps. The thickness of deck slab (RCC slab) shall be restricted to maximum 100mm. The sequence and method statement of casting shall be approved by sectional DEN /Sr.DEN. Suitable anti-slippage floor finish should be provided on the deck but total thickness of slab and finishing over girder should not be more than 135mm. No additional load, beyond the total thickness of 135mm of concrete & floor finish, such as that of pipes, cables, hoardings, etc. shall be allowed without prior approval of HQ design cell. Corrosion resistant, protective screen as per RDSO’s drawing and specifications should be provided during construction itself A clear gap of minimum 50mm should be kept between FOB deck slab & bottom of protective screen to facilitate its cleaning & painting. The protective screen shall not be resting on the deck floor. The edge of the deck slab may be provided with “Drip Course” to avoid water contact with the steel girders Stair case : No structure shall be allowed under the staircase structure for any purpose. Entire space underneath staircases, ramps should be kept free for inspection and maintenance. All steps of staircase should be of uniform rise &treads. Anti-slippage floor finish of bumt granite / rough granite with grooved lining, on FOB steps (nosing) shall be provided. Vitrified tiles shall not be used in the staircases of FOBs of all NSG-1 to NSG-6 stations and SG-1 to SG-3 stations. However, exterior floor tiles on FOBs may be used in NSG-5 and NSG-6 stations. Metallising & Painting : All steel members of new FOBs including nuts, bolts, washers, etc. shall be metallised as per the IRBM Para 218(1). Miscellaneous : Provision of stainless steel railing of 40mm dia. Pipe as per specification of RDSO for differently abled persons should be provided on steps / ramp during construction itself.9.2 Floor should be provided with suitable camber and drainage arrangement to prevent stagnation of water / water pockets on floor slab. 9.3. Hoarding shall not be provided unless there are special circumstances. For provisions of hoardings, special permission of CBE to be obtained. 40. Inspection & Maintenance : Periodic inspection of FOB shall be conducted as per detailed proforma in IR-BMS. This supersedes PCE Circular No.2 of 2021 dated 05.07.2021. Encl.: Annexure-| sHforfor\ (S. P. S. Gupta) PCE/SWR References : i) B-1/2001, BS-110 (R). ii) RDSO guidelines for HSFG bolts BS-111 (updated). ii) Rly. Bd.'s letter No.2017/16/CE-IIVBR/Girder inspection dated 26.05.2017 — Inspection of new steel bridge girders. iv) HQ/SWR’s letter No SWR/W.351/FOB dated 06.07.2018- MEA at stations - FOBs v) Rly. Bd.’s letter No.2018/LM (PA)/03/06 dated 09.04.2018 —Comprehensive instruction for PA works. vi) RDSO letter No. CBS/Stainless Steel/FOB dated 29.07.2019 — Use of stainless steel in FOB. vil) Rly. Bd.'s letter No.2016/54/CE-IIVBR/RDSO Misc dated 15.07.2019 — Fabrication, Supply and Inspection of Steel Girders for ROBs viii) Rly, Bd.’s letter No.2017/S0/CE-IIl/BR/FOB dated 18.12.2018 - Fabrication of ROB Girder for Railway span and FOB girders ix) Rly. Bd.’s letter No.2017/50/CE-II/BR/FOB dated 27.09.2018 — Fabrication of ROB Girder for Railway span and FOB girders.ANNEXURE -1 Enclosure to PCE Circular No. 2 of 2021 (Revision 1) SAFETY, HEALTH, and ENVIRONMENT ASPECTS IN CONSTRUCTION OF FOBs ‘SAFETY WITH RISK MATRIX Activity / Task Hazard Risk Control measures Excavation for] a) Hindrance to passenger |a) Falling of a) Bamicading of the area and foundation movement on PF. passengers | erection of sufficient waming work b) Crowding of passengers. | and injury boards / flags near work area. ) Signal, communication & b) Disruption to. b) Counsel all the site personnel to power cable cutting signals, ensure proper care and communication} precaution while doing excavation and power. work. fp) Detecting presence of cable by cable Tracer. Information to S&T | and Electrical supervisors.» id) No night working. Working near | a) Hindrance to passenger @) Hitting of ja) Barricading of the area with PF by| movement on PF. machinery to | waming boards / flags / signage. excavators. Passengers. b) Counsel, examine & certify the i ‘excavator operator. | ) No night working. ) Only nominated ~—_ excavator operators to work. [Working of ja) Infringement of site by | @) May cause fa) Post Look out man with flags and | Crane over| Machinery. infringement | whistle. Platform, )- Crowding of | with train by Impose ook out caution | passengers on platform in| movement | order at work site. If the vicinity of work area and necessary, appropriate SR disruption | to be imposed to train movements | b) May cause injury to | passengers | by machinery . _hitting/ trains. _ Eee Safety of site| a) Injuryto passengers | @) May cause fa) To post look out man with flags Personnel and | b) Injury to site personnel injury to and whistle. passengers passenger) Provide effective barricading or site with warning boards / flags / | personnel signage around foundation pits | and at erection locations. :) Contractor to provide and maintain sufficient, proper First Aid equipments. *eOFOPreparation of | a) Unauthorized entry. May cause fa) The working zone shall be temporary b) Working near railway | major accident | barricaded to avoid unauthorized platform /” tracks and on platfom. | resulting in entry. ground level | c) Unauthorized operation | toppling ofp) Work shall be carried out under forthe crane | d) Poor condition of crane, crush the supervision of Site Engineer. equipment injury or fatal Hard barricading with the help of €) Loose soil / inadequate portable fencing shall be provided ground condition or in the length where the day's work surface is to be done in close vicinity. of the track and / or on platform. Ic) The operators cabin of the equipment’s shall be kept lock when not in use. Ensure valid third party. load test cerfificate for crane and lifting tools and tackles. fd) Equipment shall be checked for fitness before using it and it shouid be certified by plant in- charge. fe) The loose soil shall be compacted with 10 Tonnes capacity soil compactor. Shifting of ') Poor Platform surface [May cause '@) While transporting girders/ truss assembled condition may cause —_| major accident shall be adequately lashed to girder! truss of | toppling of girder! truss | resulting in avoid toppling FOB from from the trailer while toppling of b) FOB Girdersitruss/ are to be assembly transporting trailer, crush fied with trailer using 20mm location to b) Inadequate lashing of | injury or fatal thiok sling at two ends before erection site. girder/truss while transportation transporting with the ©) The trailers shall not be trailer. overloaded. ©)_Overloading. Loading and | a) Use ofimproper crane [May cause ®) Suitable 7 designated capacity unloading of while loading and major ig. | crane shall be used. girderitruss of | unloading of girder/steel_| amputation or b) The lifting tools used for lifting FoR. member. crush injury. and removing of girders / steel b) Uneven ground surface. ) Un-experienced driver / operator. 4) Unintended movement of the vehicle. 8) Swinging of load while lifting) ) Unstable placing of girder truss. member shall be of adequate strength and load tested by the | competent person. }) The ground for parking of crane |" and trailer to load girders / steel member shall be rigid, compact | and leve '6) The Driver / Operator engaged in craneltrailer operation shall be | experienced and.shall have valid | license. ) Flag marisignal man on either | side of crane shall be engaged during unloading activities to ensure unauthorized entries in the unloading area are prevented. 1) Only the authorized person shall give signal to the crane operator for lifting, rotating and | lowering of boomiwire rope. g) Flag manisignal_man_on either & "OPOside Of crane shall be engaged during unloading . activities to ensure unauthorized’ entries in the unloading area are prevented, hh) During iting of girder / steel member is to be connected with guide rope to control the movements of girder / steel member. Adequate capacity crane shall be used. Erection of | a) Inadequate supervision. ja) Fall of girder” | ¢) Required PPEs such as. steel plate b) Unauthorized entry at steel helmets, safety shoes, for the girder’ truss for | the workplace. ‘component staff, signal man and workers FOB ©) improper signaling by lead to engaged in work shall be the rigger. majorifatal | ensured. Reflective jackets, d) Working near the injury. whistle must be provided to all traction line. P) Electrification || signal man. ) Working near the railway ) Hard barricading track / on Railway e) Proper and suitable signals Platform. | shall be displayed. f) Rough weather condition |) Only erection work carried out (hot weather). during power and traffic block 9) Unsafe access and 9) Positioning of steel member ‘egress to the top for shall be checked. removing sling. h) Third party load test certificate h) Untested siings used for for lifting sling, rigging operation, i) The ground level for parking of i) Uneven ground surface crane and trailer to load i) Inexperienced driver / girders/steel member shall be operator. rigid, compact and level. J) The driver / operator engaged in crane / trailer operation shall be experienced and shall have valid license. &) Emergency plan shall be in place with emergency contact number of Ambulance and First Aid, medical facility. ‘Assembly of _ | a) Unsafe access and Fall of person | ) Height work permit system shall structural egress. may lead to be followed. ‘components of | b) Fall of material major incident | b) Trained and experienced FOB + |) Inexperienced and fatal. ‘workers only to be engaged. workforce. 4) Working at height. ©) All workers should have complete PPES. d) Safety net shall be placed to arrest the fall of the material over platform areas. te O4 ©PROJECT INVOLVEMENT OFFICER Railway Officers Sr.No. Designation Name Mobile No. 1 | Sr DEN/ Dy.CE 2 | ADEN/AXEN 3 | SSE/JE Contractor | 4 | Project Manager Safety Officers 5 | Safety in-charge Emergency Contact No. Hospital at. Name of Hospital. (Dr. Name. Fire Brigade Station: Nearest Fire Station (Name.. Emergency Vehicle available at site during operation of block, Mobile No... Ambulance : Mobile No... Utility Site Vehicle: Mobile No... Site Vehicle: Mobile No. ‘Sr.DENICo-ord, Sr.DEN Project Manager Contractor Pye@ 4@HEALTH and WELFARE ASPECTS: 1. The Contractor shall ensure that his employees/ workers will be physically fit and shall not permit anyone to enter the work area under influence of alcohol or any other drug, Further smoking is prohibited as per Railway regulations. Contractor shall provide one First Aid Box for every hundred workers at site and same should be distinctly marked “FIRST — AID” and should be equipped with all articles as per the norms. Contractor should take all necessary steps to prevent mosquito breeding at site, () Provision of covered water storage tanks. (i) Contractor at periodic interval shall arrange fumigation’ spraying of insecticides to prevent mosquito breeding at Labor camps. Contractor shall ensure that noise generated by work carried out during day time shall not exceed maximum permissible noise level of 90 dB(A). ‘When Diesel Generator (DG) Sets are used for operation of equipment and machinery, then ‘Standards and Guidelines for control of Noise Pollution from Stationery DG Sets’, under Environment (Protection) Act, 1986 shall apply. The Contractor shall ensure effective arrangement to provide drinking water with minimum quantity of 5 liters per workman per day as per National Standards on Public health. Further drinking water facility shall be easily assessable within a distance of 200 mitrs from the place of work. Contractor shall provide sufficient latrine and urinal accommodation to all employees! workers,ENVIRONTMENTAL ASPECTS — 10. " 12. Housekeeping is the act of keeping the working environment cleared of all unnecessary waste, thereby providing @ first-line of defense against accidents and injuries. . Contractor shall understand and accept that improper housekeeping is the primary hazard in any construction site and ensure that a high degree of housekeeping is always maintained. Indeed ("Cleanliness is indeed next to Godiness’. Proper and safe stacking of material are of paramount importance at yards, stores and such locations where material would be unloaded for future use. The storage area shall be well laid out with easy access and material stored/ stacked in an orderly and safe manner. All wooden scrap, empty wooden cable and other combustible packing materials shall be removed from work place to identified location(s). The Contractor shall take all necessary precautions and use construction equipment to minimize and / or control air pollution. There should not be any unacceptable air pollution impact due to contractor's equipment or methods of working After commencement of construction activity, if contractor's equipment or methods of working are causing unacceptable air pollution then remedial action shall be taken without any delay. Contractors transport vehicles and other equipments shall confirm to specified noms of emission standards fixed by Goverment of India or’ Statutory Agencies, Contractor shail establish and maintain records of routine maintenance programme for internal combustion engine powered vehicles and equipment used at site, Contractor shall cover loads of dust generating from debris or due to transportation of loose construction materials like clay, sand, soil, rock dust, aggregates, etc, Contractor shall seek to accommodate archeological and historical preservation, as per the site conditions. - Contractor shall maintain ecological balance by preventing deforestation and defacing of natural landscape. ‘Contractor shall use and maintain equipment so as to conserve energy by use of energy efficient de F hope OF @