06 Track Technical Specification
06 Track Technical Specification
CONTRACTOR:                                               EMPLOYER:
(1) CHINA COMMUNICATION CONSTRUCTION                      MALAYSIA RAIL LINK SDN
    COMPANY (10000000040563-1)                            BHD
    N0. 85, Deshengmenwai Street,                         (Wholly-owned by Minister of
    Xicheng District, Beijing, P.R. China                 Finance Incorporated)
(2) CHINA       COMMUNICATION             CONSTRUCTION    (Registration no. 1203035-K)
    COMPANY               (M) SDN BHD (Registration no.   Level 15, Menara 1 Dutamas,
    1007413-M)                                            Solaris Dutamas
    E-8-15, Plaza Mont Kiara,                             No. 1 Jalan Dutamas 1
    N0. 2, Jalan Kiara, Mont Kiara,                       50480 Kuala Lumpur
    50480 Kuala Lumpur
EAST COAST RAIL LINK (ECRL) PROJECT
                                                                     CONTENTS
CONTENTS .................................................................................................................................................... 2
1           Track work Design Criteria ............................................................................................................ 3
2           Relevant Standards and Codes ..................................................................................................... 3
3           Design principles ............................................................................................................................ 4
4           Main Line Ballasted Track ............................................................................................................. 5
4.1         Rail ................................................................................................................................................... 5
4.2         Rail fastening system ...................................................................................................................... 5
4.3         Concrete Sleepers ........................................................................................................................... 6
4.4         Ballast bed ....................................................................................................................................... 6
5           Main line Ballastless Track ........................................................................................................... 7
5.1         Rail ................................................................................................................................................... 8
5.2         Fastening System ............................................................................................................................ 8
5.3         Concrete Supporting Blocks ........................................................................................................... 8
5.4         Ballastless Bed ................................................................................................................................ 8
5.5         Rubber Boots and Micro Porous Rubber Pads .............................................................................. 9
6           Spur line Ballastless Track ............................................................................................................ 9
6.1         Rail ................................................................................................................................................... 9
6.2         RAIL FASTENING SYSTEM ................................................................................................................ 9
6.3         Concrete Sleepers ........................................................................................................................... 9
6.4         Ballast bed ....................................................................................................................................... 9
7           Station line Track ........................................................................................................................... 9
7.1         Rail, Rail fastening and Concrete Sleeper ................................................................................... 10
7.2         Ballast bed ..................................................................................................................................... 10
7.3         Turnout .......................................................................................................................................... 10
7.4         Buffer Stop .................................................................................................................................... 11
8           Continuous Welded Rail (CWR) .................................................................................................. 11
8.1         Long Welded Rail Arrangement of CWR ..................................................................................... 11
8.2         Design Stress‐free Rail Temperature ........................................................................................... 11
8.3         Arrangement of Rail Creep Observation Piles ............................................................................ 12
9           Track Auxiliary Equipment .......................................................................................................... 13
9.1         Track Strengthening Equipment .................................................................................................. 13
9.2         Installation of Guard Rail ............................................................................................................. 13
9.3         Track signs and Markers ............................................................................................................... 13
9.4         Track spare parts .......................................................................................................................... 13
(1) Continuously welded rail shall be laid for the entire mainline and spur line. Bolted rail shall be used for
low speed areas, such as sidings, yards, depot and stabling lines, etc.
(2) Ballasted track shall be adopted for the majority of the mainline, although low vibration ballastless
track shall be laid in the Genting tunnel. Transition sections shall be arranged between ballasted track and
ballastless track.
(3) Ballasted track shall be used for spur lines, station line and other related lines.
(5) TB10424‐2018 Standard for Constructional Quality Acceptance of Railway Concrete Engineering
        (7) Q/CR9230‐2016 Observation and Evaluation Specification for Settlement Deformation of Railway
Engineering
(8) Drawing number: TongHao (2016)9031 Integrated Grounding System for Railway
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(12) Q/CR 481‐2015 Type Ⅶ fastening system for heavy‐haul railway with 30 tons axle load
        (14) TJ/GW 152‐2016 Temporary technical conditions for track components for low vibration
ballastless track in tunnels for passenger and freight railway
(22) Overall layout plan for #12 single turnout 60kg/m rail (dwg no: ZX4249)
(23) Overall layout plan for #12 single turnout 50kg/m rail (dwg no: ZX4257)
(24) Overall layout plan for #9 single turnout 50kg/m rail of 92 enhanced model (dwg no: CZ2209)
3 Design principles
        (1) The track gauge shall be 1435mm, which is the distance between the inner faces of rail heads and
               is perpendicular to the track centerline, measured from the inner face 16 mm below the rail
               head.
        (2) Design speed shall be 160km/h for passenger trains and 80km/h for freight trains, and 25 km/h in
               depot, yard or stabling areas.
        (4) Horizontal radius target is 2000m plus in general case, and 1600 plus in difficult case. Minimum in
               tightest location is 600m, where land is not otherwise available.
(6) Continuously welded rail with welded turnout shall be laid for the entire mainline and spur line.
(7) Ballasted track shall be adopted for the majority of the mainline, except for Genting tunnel.
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        (8) For Genting tunnel, to facilitate the convenience of maintenance, low vibration ballastless track
               shall be used instead.
(9) 25m long, U75V, 60kg/m rail without bolt holes shall be installed on the mainline.
        (10) Type Ⅲ concrete sleepers shall be used for ballasted track on the main line with 1667
               pieces/km.
(11) The width of the top of the ballast bed on the main line shall be 3.4m.
        (12) Turnouts type 12 (CHN) shall be installed on the main line and the arrival‐departure lines, and
               turnouts type 9 (CHN) shall be installed on other lines.
        (13) Low vibration ballastless track shall be installed in Genting tunnel. Low vibration track shall be
               composed of supporting block, rubber boot and track concrete slab, etc.
4.1 Rail
Selecting rail type is not only a technical issue, but also an economic issue. The rail type selection should be
determined according to relevant regulations, operating conditions, and rational maintenance periods.
CHN 60kg/m, 25m long, Grade U75V, new rails without bolt holes shall be installed on the Main Line
straight tracks and curved tracks greater than 1200m centre line radius. For curved tracks less than or equal
to 1200m centre line radius the rails shall be heat‐treated.
Type II rail fastenings shall be installed on the Main Line. Small resistant rail fastenings shall be installed
where needed after calculation checks have been made of the continuously welded rail (CWR) on bridges.
The Type II rail fastening shall conform to Chinese Standard TB/T 3065‐2020 Type Ⅱ fastening system.
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2.6m long, type IIIa prestressed concrete sleepers shall be installed on the subgrade and tunnel of the Main
Line with 1667 pieces/km; 2.6m long, new type III concrete bridge sleepers shall be installed on the bridges
and subgrade retaining wall where needs to install with 1667 pieces/km.
The concrete sleeper shall conform to Chinese Standard GB/T 37330‐2019 Sleeper for ballasted
track‐Concrete sleeper.
      The ballast bed shall be laid in a single layer. The thickness under the sleeper of the ballast bed will be 30
cm on the sand subgrade, 35 cm on the hard rock subgrade and 35 cm on the bridges and tunnels (except
Genting tunnel).
      The top width of the single‐track bed shall be 3.4m on the Main Line straight track and on curved tracks
having centre line radius not less than 800m. For curved tracks, less than 800m centre line radius, the width of
the top surface shall be increased by 0.10m on the outside of the curve.
      The ballast side slope shall be 1:1.75 and the height of the ballast shoulder shall be 15 cm, again with slopes
at 1:1.75.
In the bridge section, the gap between the ballast shoulder and the ballast retaining wall shall be filled up with
ballasts; In the tunnel section, the gap between the ballast shoulder and the side wall (or the ditch on the high
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side of the track or the cable tray) shall be filled up with ballasts.
The top surface of the ballast bed shall be level with the top surface of the middle of Type III, concrete sleepers,
but it shall be 3 cm lower than the surface of the support rails of the concrete bridge sleepers.
Crushed stone shall be used for the ballast bed, with a technical specification as follows:
Ballast supplied shall be produced from the crushing of granite or other approved igneous rock.
The ballast shall be clean, angular in shape in all dimensions, with all dimensions nearly equal and free from
deleterious matter.
The ballast shall be subjected to the following tests in authorized testing laboratory and the results shall be
submitted for inspection and approval:
      (1) The wet Attrition value shall not be more than 6% as per test carried in accordance with EN standard
            (BS EN 932‐6:1999‐ Tests for general properties of aggregates), or the Los Angeles Value by Abrasion
            shall not be greater than twenty‐five percent (25%) (ASTM C‐131‐1981)
(2) The Crushing Value (ACV) shall not exceed thirty percent (30%) (BS 812, part 110/1990);
(3) The Impact Value (AIV) shall not exceed twenty‐five percent (25%) (BS 812, part 112/1990);
      (4) The maximum permissible Flakiness Index shall not exceed fifty percent (50%) (BS 812, part
            105.1/1989);
      (5) The maximum permissible Elongation Index shall not exceed fifty percent (50%) (BS 812, part
            105.1/1989);
(6) The maximum permissible passing material passing 0.1mm sieve shall be 1 percent (1%)
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track can better adapt to the settlement caused by foundation and has better operation and maintenance.
LVT shall comprise rails, rail fastenings systems, concrete supporting blocks, rubber boots, elastic plates under
the blocks with reinforced concrete bed slabs, etc.
5.1 Rail
The technical requirement of rail which is used in the Genting tunnel is the same with main line ballasted track
Item 4.1 rail.
Type VII fastenings shall be installed to the LVT ballastless slab track in the tunnel. Generally, the spacing of the
fasteners shall be 600mm for major sections with spacing appropriately adjusted in accordance to construction
needs from 575mm to 625mm. The static stiffness of the under‐rail pads is 100~120kN/mm.
The Type VII rail fastening shall conform to Chinese Standard Q/CR 481‐2015 Type Ⅶ fastening system
for heavy‐haul railway with 30 tons axle load.
The concrete supporting blocks shall conform to Chinese Standard TJ/GW 152‐2016 Temporary technical
conditions for track components for low vibration ballastless track in tunnels for passenger and freight
railway.
The design life of main structure of ballastless track is normally 60 years based on TB10005‐2010 Code for
Durability Design of Railway Concrete Structures.
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The C40 concrete shall conform to Chinese Standard GB 50010‐2010 Code for design of concrete
structures and TB 10005‐2010 Code for durability design on concrete structure of railway.
The steel of reinforcement shall conform to Chinese Standard GB/T 1499.1‐2017 Steel for the
reinforcement of concrete‐part 1: Hot rolled plain bars and GB/T 1499.2‐2018 Steel for the reinforcement
of concrete‐ part 2: Hot rolled ribbed bars.
The technical requirements of rubber boots and micro porous rubber pads should meet the requirements of
the temporary technical conditions for track components for low vibration ballastless track in tunnels for
passenger and freight railway (TJ/GW 152‐2016)
The Type I rail fastening shall conform to Chinese Standard TB/T 1495‐2020 Type I fastening system.
The concrete sleeper shall conform to Chinese Standard GB/T 37330‐2019 Sleeper for ballasted
track‐Concrete sleeper.
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EAST COAST RAIL LINK (ECRL) PROJECT
                                      Concrete ‐
                         Type         sleeper                   Prestressed Type III a   New TypeⅡ        New TypeⅡ
        2    Sleeper
                         Number Concrete Nos./km                           1667          1520             1440
                                sleeper
        3            Rail fastening system                              Type II               Type II             Type I
        Note: The rail joint bolt of the rail without bolt and holes adopts 8.8 grade and above high‐strength
joint bolt, the nut adopts 10 grade high‐strength nut, and the washer adopts single layer spring washer.
7.3 Turnout
The design criteria of turnouts comply with the following table:
            Rail                                                                   Turnout              Fastening
 Serial                      Drawing                                               sleeper              system
                                               Name
 number                      number                                                drawing
                                                                                   number
                  60kg/m                                                           Special line         Type II
                                      Special line          60kg/m‐12# single      3399
 1             Concrete
                                      4249                  turnout
               sleeper
          60kg/m                                                     CZ577Z              Type II
                                             60kg/m‐#9 single
 2        Concrete         CZ577
                                             turnout
          sleeper
          50kg/m                             50kg/m‐12# single       Special line        Type I
                           Special line
 3        Concrete                           turnout                 (01)3423
                           4257
          sleeper
          50kg/m                             50kg/m‐9#               CZ2209Z             Type I
 4        Concrete         CZ2209            improved single
          sleeper                            turnout
Note: KTMB railway standard is adopted for turnouts of the existing meter gauge line. The main line and the
arrival‐ departure line use No. 15 turnout (54kg/m, a=16.384m, b=20.725m), and the other station lines use
No. 9 turnout (54kg/m,a=11.706m,b=13.193m).
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 strength and stability of the CWR track, the CWR on bridge for calculation of rail broken gap, rail strength
 and stability. Besides, CWR track on the bridge shall also meet the requirements for relative displacement
 between bridge and rail.
 The design stress‐free rail temperature shall be in line with the following requirement:
 The design stress‐free rail temperature of ballasted track should be calculated by the following formula:
 Where
  Te : design stress‐free temperature of rail, higher value should be selected on the curve with small radius
 and low value should be selected in the region with larger annual rail temperature variation;
  Tmax : annual local maximum rail temperature;
  Tmin : annual local minimum rail temperature;
                                                       Tmax  Tmin
                                                Te                 Tk
                                                            2
 Where
  Tk : correction of design stress‐free temperature of rail, 0~5 deg C as usual.
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  expansion                       joint
    joint
                                                   Each railway administration has 1 set reserved for every 1~100
                                 Sleeper
                                                                         sets for each type.
                     Switch rail (including the
                  supporting fastening and spare   Each workshop has 1 pair reserved for 1~20 sets for each type.
                               parts)
                      Stock rail (including the
                  supporting fastening and spare   Each workshop has 1 pair reserved for 1~20 sets for each type.
                               parts)
                                                   Each railway administration have 2 set reserved for every 1~100
                          Main line turnout
                                                    sets for each type. Include Left and Right direction each one.
                         Other type turnout                    Each type 1 set reserved for whole line.
   Turnout                                         Each railway administration have 2 set reserved for every 1~100
                           Turnout Sleeper
                                                    sets for each type. Include Left and Right direction each one.
                                                     Determine by the turnout type and quantity(For number 12
                           Turnout fastener          turnout, each set reserve 3 fasteners, for other type turnout
                                                                         determine by need )
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