Quality In The Construction of
Turnouts
Trackwork Services Alliance
Charles Vuong & David Nguyen
22 - 23/05/14
Quality In the Construction Of Turnouts
Agenda
1. TSA – Who we are? What do we do?
2. How is quality ultimately achieved i...
TSA – Who We Are?
TSA – What we do?
Objectives:
1. Service delivery of turnout renewals
2. Rail industry objectives
Construction Methods
How Quality Is Achieved in Construction
Work Methodology
Increased efficiency
Quality Assurance
Cultu...
How Quality Is Achieved in Construction
Quality of the end product will be influenced by:
Fix it here
How Quality Is Achieved in Construction
Design:
• Design for constructability
• Design for manufacturability
How?
• Constr...
How Quality Is Achieved
Manufacturing:
• Suitability of ordered components to site
• Manufacturing tolerances and design r...
How Quality Is Achieved
Manufacturing:
• Procurement of materials to suit site requirements
Turnout to be
renewed
End of s...
How Quality Is Achieved
Cost:
• Truck Costs: $1400
• Modification of plates: $5750
• Safe Working: $1000
• Site Supervisor...
How Quality Is Achieved
Prebuild
Case Study: Lithgow 77A/B, 78A/B, 79 &
81A/B Turnout Renewal
Quality In Design
Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B
Quality In Design
Quality In Manufacturing
Manufacturing inspection conducted:
1. Victoria
2. New South Wales
3. Queensland
Case Study: Lith...
Quality In Manufacturing
Customised Inspection Checksheet:
• Actual measurements recorded
• Acceptance only once manufactu...
Quality In Prebuild
Prebuild on level surface
• Entire shift prior to prebuild used to level surface
Quality In Prebuild
Self performing team
Quality In Prebuild
Prebuild 16th – 24th January, 6 weeks & prebuild inspections: prior to welding
Quality In Construction
Lithgow 77A/B, 78A/B, 79 & 81A/B Points Renewal
Quality In Construction
Track Scope of Works
• Renewal of 7 point ends
• Full depth recondition
• Installation with PEM LE...
Quality In Construction
Signalling Scope of Works
• Replace existing points motors
• Replace existing ESML with EOL
• Circ...
Quality In Construction
OHW Scope of Works
• Major OHW adjustments to
suit new track arrangement
• Installation 22off OHW
...
Quality In Construction
• Safe & reliable product at end of possession
• No late possession handback
Quality In Construction
Quality During Construction:
• Prior testing of material
• Allowing for contingency
• Customised I...
Quality In Construction
Quality In the Construction Of Turnouts
Outcomes
– Reduction in number of defects
– Reduced the risk of late possession ha...
THANK YOU
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Charles Vuong & David Nguyen - Trackwork Services Alliance - Case study session: Quality in the construction and installation of turnouts

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Charles Vuong & David Nguyen delivered the presentation at 2014 RISSB National Rail Turnouts Workshop.

The RISSB National Rail Turnouts Workshop gives all those involved an in-depth forum for discussion and the sharing of expertise. A key element of this workshop is participation and knowledge sharing from audience as well as the workshop leaders. It is a chance for you to bring your experience and to take away new approaches for best practice.

For more information about the event, please visit: http://www.informa.com.au/railturnoutsworkshop14

Published in: Engineering, Business, Technology
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Charles Vuong & David Nguyen - Trackwork Services Alliance - Case study session: Quality in the construction and installation of turnouts

  1. 1. Quality In The Construction of Turnouts Trackwork Services Alliance Charles Vuong & David Nguyen 22 - 23/05/14
  2. 2. 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
  3. 3. TSA – Who We Are?
  4. 4. TSA – What we do? Objectives: 1. Service delivery of turnout renewals 2. Rail industry objectives
  5. 5. Construction Methods How Quality Is Achieved in Construction Work Methodology Increased efficiency Quality Assurance Culture and Behaviours
  6. 6. How Quality Is Achieved in Construction Quality of the end product will be influenced by:
  7. 7. Fix it here
  8. 8. 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
  9. 9. 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
  10. 10. 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)
  11. 11. 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
  12. 12. How Quality Is Achieved Prebuild
  13. 13. Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B Turnout Renewal
  14. 14. Quality In Design Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B
  15. 15. Quality In Design
  16. 16. Quality In Manufacturing Manufacturing inspection conducted: 1. Victoria 2. New South Wales 3. Queensland Case Study: Lithgow 77A/B, 78A/B, 79 & 81A/B
  17. 17. 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
  18. 18. Quality In Prebuild Prebuild on level surface • Entire shift prior to prebuild used to level surface
  19. 19. Quality In Prebuild Self performing team
  20. 20. Quality In Prebuild Prebuild 16th – 24th January, 6 weeks & prebuild inspections: prior to welding
  21. 21. Quality In Construction Lithgow 77A/B, 78A/B, 79 & 81A/B Points Renewal
  22. 22. Quality In Construction Track Scope of Works • Renewal of 7 point ends • Full depth recondition • Installation with PEM LEM’s • Welding • Resurfacing
  23. 23. Quality In Construction Signalling Scope of Works • Replace existing points motors • Replace existing ESML with EOL • Circuit modifications • Relocation of signals
  24. 24. 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
  25. 25. Quality In Construction • Safe & reliable product at end of possession • No late possession handback
  26. 26. Quality In Construction Quality During Construction: • Prior testing of material • Allowing for contingency • Customised ITP’s • Live Survey • NCR tracking • PEM LEM
  27. 27. Quality In Construction
  28. 28. 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
  29. 29. THANK YOU

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