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Quality In The Construction of
Turnouts
Trackwork Services Alliance
Charles Vuong & David Nguyen
22 - 23/05/14
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Quality In the Construction Of Turnouts
Agenda
1. TSA – Who we are? What do we do?
2. How is quality ultimately achieved in construction through:
• Design
• Procurement/Manufacturing
• Prebuild
• Construction
3. Case study – Lithgow
4. Conclusion
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TSA – Who We Are?
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TSA – What we do?
Objectives:
1. Service delivery of turnout renewals
2. Rail industry objectives
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Construction Methods
How Quality Is Achieved in Construction
Work Methodology
Increased efficiency
Quality Assurance
Culture and
Behaviours
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How Quality Is Achieved in Construction
Quality of the end product will be influenced by:
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Fix it here
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How Quality Is Achieved in Construction
Design:
• Design for constructability
• Design for manufacturability
How?
• Constructor input / feedback at design stage
• Greater accessibility between constructors and
designers
• Collaborative design
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How Quality Is Achieved
Manufacturing:
• Suitability of ordered components to site
• Manufacturing tolerances and design requirements are
met
• Compliance to design
How?
Site inspections before procurement
Manufacturing quality inspections
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How Quality Is Achieved
Manufacturing:
• Procurement of materials to suit site requirements
Turnout to be
renewed
End of stockrail
(Aluminothermic weld)
Existing joint (flash butt)
600mm from end of stockrail
Plain line track not
to be renewed
Glued Insulated Joint
Cost:• Closure
• Weld
• Time
Impact on Quality
(additional weld in
track)
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How Quality Is Achieved
Cost:• Truck Costs: $1400
• Modification of plates: $5750
• Safe Working: $1000
• Site Supervisor: $1300
• Labour: $1500
Total Cost = ~$11,000
Manufacturing:
• Ensuring No Manufacturing Defects through Inspections
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How Quality Is Achieved
Prebuild
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Case Study: Lithgow 77A/B, 78A/B, 79 &
81A/B Turnout Renewal
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Quality In DesignCase Study: Lithgow 77A/B, 78A/B, 79 & 81A/B
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Quality In Design
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Quality In Manufacturing
Manufacturing inspection conducted:
1. Victoria
2. New South Wales
3. Queensland
Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B
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Quality In Manufacturing
Customised Inspection Checksheet:
• Actual measurements recorded
• Acceptance only once manufacturing
tolerances and design requirements met
• Rectification list provided to manufacturer’s
post inspection
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Quality In PrebuildPrebuild on level surface
• Entire shift prior to prebuild used to level surface
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Quality In Prebuild
Self performing team
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Quality In PrebuildPrebuild 16th – 24th January, 6 weeks & prebuild inspections: prior to welding
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Quality In Construction
Lithgow 77A/B, 78A/B, 79 & 81A/B Points Renewal
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Quality In Construction
Track Scope of Works
• Renewal of 7 point ends
• Full depth recondition
• Installation with PEM LEM’s
• Welding
• Resurfacing
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Quality In Construction
Signalling Scope of Works
• Replace existing points motors
• Replace existing ESML with EOL
• Circuit modifications
• Relocation of signals
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Quality In Construction
OHW Scope of Works
• Major OHW adjustments to
suit new track arrangement
• Installation 22off OHW
footings
• Erection 11off new OHW
structures
• Removal 6off redundant
OHW structures
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Quality In Construction
• Safe & reliable product at end of possession
• No late possession handback
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Quality In ConstructionQuality During Construction:
• Prior testing of material
• Allowing for contingency
• Customised ITP’s
• Live Survey
• NCR tracking
• PEM LEM
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Quality In Construction
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Quality In the Construction Of Turnouts
Outcomes
– Reduction in number of defects
– Reduced the risk of late possession handback
– Reduction in the cost of rework
– Increased scope deliverables
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THANK YOU