contents · 8.2 rail plans 16 8.3 rail bending ... design of any tramway tracks and associated...

TRAM TRACK DESIGNGUIDELINES

SINCLAIR KNIGHT MERZ SF99137: TRMTRKDESNV1.4.DOC i

Contents

1. Introduction 11.1 Purpose 11.2 Scope 11.3 Responsibilities 11.4 Records 11.5 Referenced Documents 11.6 Definitions 3

2. Approval of Design Documentation 4

3. Survey Works 53.1 General 53.2 Control Information 53.3 Digital Terrain Model (DTM) 53.4 Detail Information 53.5 Intergraph File format 6

4. Core Samples 7

5. Tramway Track Design 85.1 Horizontal Alignment 85.2 Special Works 95.3 Vertical Alignment 105.4 Drainage 105.5 Clearances 115.6 Track Construction 12

6. Track Standards 13

7. Plan Production 15

8. Types of Drawings 168.1 Layout Plans 168.2 Rail Plans 168.3 Rail Bending Diagrams 168.4 Long Sections 178.5 Cross Sections 178.6 Level and Drainage Plans at Special Works 17


SINCLAIR KNIGHT MERZ SF99137: TRMTRKDESNV1.4.DOC ii

Document History and StatusIssue Rev. Issued To Qty Date Reviewed Approved1 1.0 Massoud Majidi 1 1/9/992 1.1 Yarra Trams 1 12/10/993 1.2 Yarra Trams 1 30/08/004 1.3 Yarra Trams 1 10/07/035 1.4 Yarra Trams 1 17/11/03

Printed: 17 November 2003 10:25 AMLast Saved: 17 November 2003 10:25 AMFile Name: I:\DATA\PROJECT\SFRA\SF99137\REP02_08.13\TrmTrkDesnV1.4.docProject Manager: Frank EngelenName of Organisation: YARRA TRAMSName of Project: DESIGN OF TRAM TRACKSName of Document: GUIDELINESDocument Version: 1.4Project Number: SF99137


SINCLAIR KNIGHT MERZ SF99137: TRMTRKDESNV1.4.DOC 1

1. Introduction1.1 PurposeThese guidelines have been prepared as a guide to the design standardsand procedures involved in tramway track design. They are to be used as aguide only and all design work will require extensive track and road designengineering knowledge, as well as a sound understanding of track and roadconstruction methods, surveying practice, and of the characteristics of eachparticular site.1.2 ScopeThis specification shall be used by Yarra Trams and any Contractors for thedesign of any tramway tracks and associated infrastructure.These guidelines set down requirements as applicable for:� Survey for design works.� Tram track design procedures.� Plan production1.3 ResponsibilitiesIt is the responsibility of the Contractor to complete all works as specified inthese guidelines and in accordance with relevant standard drawings,specifications and codes of practice.It is the responsibility of the Superintendent to ensure that all works arecarried out in compliance with these guidelines.

1.4 RecordsNil

1.5 Referenced DocumentsWhere Australian, British, or American standard specifications, rules, or codesof practice are referred to, such reference shall always be taken to include thelatest issues, together with the latest amendments and supplements It shallbe the Contractor's responsibility to ascertain the existence suchamendments and supplements.

The following documents should be read in conjunction with these guidelinesand are available from the relevant authority:VicRoads:� Standard Specification for Roadworks and Bridgeworks, July, 1992.� Road Design Guidelines Final Drawing Presentation� Standard Drawings for Roadworks



Australian Standards:� AS 3500.3 Stormwater Drainage� AS 4058 Precast Concrete Pipes

Yarra Trams Documents:� Tram Track Construction Specification

PTC Documents:� TS 94/007 Construction of Autopoints N/A� PTC Investigation Into Simultaneous Dual Track

Reconstruction, October 1994. N/A� ENG-TE-STD-2101 Track Technical Definitions N/AThe above documents marked N/A are generally not applicable to mostdesign works and are not provided with the design guidelines. Thesedocuments shall be provided or made available if they are needed tocomplete the scope of works for the project.Drawings:

TITLE DRAWING No. REVISIONTramway Structure Gauge P.15556 C1Standard Check Plate, Block & Assembly, 41 kg Rail YTS 1102 C1Track Construction, Check Plate for Curves, 41 kg Rail YTS 1103 C1Track Construction, Check Plate opposite Crossings YTS 1208 C1Track Drain Pit – Construction Details TS1304-YT C2Track Drainage – General Arrangement TS1305Track Construction – Concrete to Surface TS1401-YT C1Track Construction – Ballast Track TS1403Left Hand Crossover – for Straight Track – Layout Plan TS2804 BSwitch Spiral TS2901Plain End Spiral TS2902Alignment, Services and Drainage Plan P19612 P1Longitudinal Section P19613 P1Cross Sections P19617 P1Docklands Stage 3, Rail Plan & Rail Bending Diagrams (Sample Plan) P18750 C2Docklands Stage 1, Cast Crossings (Sample Plan) P17597 ADocklands Stage 1, 'H' Crossing & Diamond Modules, Assembly (Sample Plan) P17599 A



1.6 DefinitionsContractor: Contractor shall include tenderer and service

supplier.

Principal: Principal shall mean Yarra Trams.

Public TransportCorporation:

Public Transport Corporation (PTC) documents,including drawings, are referred to in thisdocument. The PTC documents shall be utilisedunless superseded by Yarra Trams documents

Superintendent: Superintendent shall mean the Principal’srepresentative. The term shall include anyappointed representative of the Superintendent.

Technical Definitions: Refer to document ENG-TE-STD-2101, TrackTechnical Definitions.



2. Approval of Design DocumentationDesigns shall conform to these guidelines unless otherwise approved inwriting by the Superintendent.Vertical designs and drainage designs (and horizontal designs, if applicable)shall be approved in writing by VicRoads and/or local council as appropriate.Documentation shall be submitted for review at the following stages as wellas at any time that the Contractor needs advice or guidance:� establishment of horizontal alignment.� final approval of horizontal alignment so that others can proceed with other

designs as part the project.� establishment of vertical alignment.� final approval of all plans.An allowance of 2 weeks shall be made for the Superintendent to reviewdocumentation.Allowances shall also be made for VicRoads, local authorities and/or serviceauthorities to perform their design works and/or give approvals for theContractor's designs.



3. Survey Works3.1 GeneralThe design works shall include completing a feature survey of the areacovered by this contract. It is the responsibility of the Contractor to ensurethat the survey is thorough enough to enable the design works to becompleted to the satisfaction of the Superintendent.

3.2 Control Information� Placement of station marks, of a type approved by the Superintendent,

with due regard to stability and permanence. Locality sketches shall berequired for all stations.

� The adoption of a minimum of two Bench Marks within the length of thejob and Bench Marks every 500 metres. (Bench Marks shall be ofreasonable stability and may be points on significant structures and/orespecially placed marks, but shall not to be standard Permanent Marks.)

� Survey work shall be based on the adoption of AMG zone 54/55 for thehorizontal datum and AHD for the vertical datum.

3.3 Digital Terrain Model (DTM)The design works shall be based on a DTM being a representation of theground conditions. The DTM shall be created by the placement of breaklinesalong salient features and other spot heights as deemed necessary.Breaklines shall include, but not be limited to:- rails, kerb lines, crown lines,track margins. The DTM shall extend to at least 30.0 m past the limits ofworks.3.4 Detail Information� All tram track furniture with appropriate details/comments (pits, poles, tram

stops, overhead poles with pole bonds, full details of overhead trolley wirenetwork in areas where the tracks may be realigned, etc).

� All service authorities' furniture with appropriate details/comments (pitsand poles, etc).

� All road furniture with appropriate details/comments (traffic signal polesand pits, signs, etc).

� All significant vegetation.� All drainage features, including the proving and documentation of sizes

and invert levels of pits and pipes in areas where track drainage may needto be installed.



� Line marking and traffic loops affected by the works.� Existing road boundaries, ie building lines and kerbs (top, invert and lip)

and the location of points of access to properties.3.5 Intergraph File formatThe field observations shall be reduced into an Intergraph File format, ieMicrostation drawing file (*.dgn) with detail/symbology as specified belowusing the cell library available on request from the Superintendent, or asspecified in the VicRoads Standard Drawing Guidelines.



4. Core SamplesCore samples shall be taken at approximately 300 to 500 m intervals alongthe tracks with a minimum of two locations along the length of the works. Atleast 3 core samples to be taken at each location - 1 in each track and 1between the 2 tracks. Each sample shall be at least 500 mm deep. Thepurpose of the samples is for confirmation of existing track construction, andhence extra samples shall be taken at locations where there is an obviouschange in track construction.



5. Tramway Track Design5.1 Horizontal AlignmentHorizontal track design consists of a combination of straights and curves.There are two types of curves used in track design - circular curves (constantradius) and transition curves (varying radius). Transition curves are alwaysused in combination with circular curves, however circular curves can beused by themselves. Various combinations of circular and transition curvesare used, the most desirable being a circular curve with identical transitioncurves at each end. This is the most common usage of a transition curve(linking a circular curve to a straight), however a transition curve can also linktwo circular curves of different radii (a straight merely being a curve of infiniteradius). The purpose of a transition curve is to provide a gradual increase inboth cant and horizontal acceleration. To serve this purpose, the curve isdesigned to have a gradually varying radius with respect to arc length. Thesame radius is required at its ends, as the curves which it links.

There are five different types of transitions in use in the tramway system, eachserving its own purpose and with its own limitations.a. Euler Spiral: the ideal spiral, also known as the clothoid. This is

the preferred transition for all trackworks.b. Cubic Parabola: an approximation to the euler spiral and can only be

used up to 24°. After this the radius starts increasinginstead of decreasing.

c. Plain End Spiral: a series of constant radius arcs of decreasing value,also known as Lorains No 3 Spiral. It can be brokenat the end of any arc, but the radius of the last arcshould be larger than the radius of the circular arc.(Refer to TS2902)

d. Switch Spiral: the same as the Plain End Spiral but has the first 5°20'10" replaced with a constant radius of 45.720 m.This must be used where a switch is or may berequired. (Refer to TS2901)

e. 30.480 m Radius: a constant radius of 30.480 m for an angle of 7° 02'33". This is only used in extreme cases where thereis not sufficient room to put anything better and onlyinside depots. It is also only used where a switch is,or may be required.



5.2 Special WorksSpecial Work is any trackwork which must be pre-fabricated (ie bent orassembled) before it can be constructed on site. This includes all switches,crossings and any trackwork which needs pre-bending. FabricationDrawings shall include Rail Plans and Rail Bending Diagrams.The only transitions used in new designs are the euler spiral for simplecircular curves or switch spirals for junction designs.

Alignments shall be as smooth as practical. Straights shall be as long aspossible and the radius of any curve shall be as large as possible with dueconsideration to other constraints. Small radii (less than 50 m) shall not beused for small angles (less than 10°). Combinations of short straights andsmall curves shall not be used where a single curve can be used.Fabrication Drawings for Special Works shall not commence until theHorizontal Alignment has been approved by the Superintendent.All switches, crossings and rails (shorter than 3 m) connecting these items,shall be cast from manganese steel.Rails in special works shall be placed so that a minimum number of joints arerequired and as many whole rail lengths as possible shall be used. Pre-bentrails shall extend to approximately 3 m onto the straight past the tangent pointof the curve.Where Tee head rails are used at special works, or curves up to 325 m, therails shall be head hardened and guard rails or check plates shall be fitted inaccordance with the following table:-

HIGH LEG CHECK LOW LEG CHECKCURVE RADIUS /TURNOUT

CHECKREQUIREMENT FLANGE

GAPHEIGHT ATRAIL HEAD

FLANGEGAP

HEIGHT ATRAIL HEAD

CurveUp to 100 m R Both Rails 30 mm -2.4 mm 30 mm +3.6 mm100 to 325 m R Low Leg Rail 30 mm -2.4 mm 30 mm -2.4 mmGreater than 325 m R Not Required Not Applicable

Turnout, Opposite V CrossingZero Superelevation Both Rails 30 mm -2.4 mm 26 mm +3.6 mmWith Superelevation Both Rails 26 mm +3.6 mm 26 mm +3.6 mm

Check Plate details and construction shall comply with Drawings No. YTS1102, YTS 1103 and YTS 1208.



All rails associated with special work and curves with a radius less than 325 mshall be pre-bent and a pre-bent check plate shall be fitted to Tee head railsprior to installation.5.3 Vertical AlignmentVertical alignment design shall not commence until the horizontal alignmenthas been approved by the Superintendent. In some cases the verticalalignment may affect the horizontal alignment.Longitudinal sections shall be drawn for the two outer rails for most verticaldesigns - other rails also need to be drawn when determining levels throughjunctions. Grades and vertical curves shall be kept as long as possible andshould be calculated wherever possible. In extreme cases, grade changes ofnot more than 0.3% may be used without a vertical curve.On normal straight track the inner rails are 6 mm above the outer rails with alevel difference of 50 mm between the two tracks to suit the general crossfallof the road. The higher track may slope down towards the lower track whenthere is a steep crossfall.

In places where there is heavy cross traffic, the four rails shall be kept in oneplane if possible, and a traffic line should be plotted to check the affect oncross traffic.Through junctions, including crossovers, the rails shall be kept in one plane toensure that each rail has an even longitudinal profile.

On curved track the outer rail shall be higher than the inner rail. Thetheoretical cant requirement depends on the radius of the curve and thevelocity of the tram. However, in most cases the overall shape of the roadgoverns the amount of cant which can be applied to a curve.Equilibrium cant is the amount of cant which enables the tram to travelaround the curve without any sidethrust on the wheels. However, this amountof cant is usually too large for road conditions and a certain amount ofsidethrust is tolerated.

5.4 DrainageTram track drainage shall be provided at changes of longitudinal grade fromnegative to positive, ie low points. Track drains shall also be provided on thehigh side of major cross roads and/or on the high side of passenger loadingareas where there is a long run (300 m) with no other track drainage. Atspecial works all switches shall be drained and extra drains shall be providedapproximately 3 m on the high side of any special works. The road motor boxof automatic points shall also be drained.



Track drains usually have the invert of the pipes at least 400 mm deep withthe pit floor being 100 mm deeper. The frames and covers for track drainsare of standard design while the pit is cast as an integral part of the trackslab.The pits for points drains are provided as part of the points assembly andpipe inverts are also approximately 400 mm deep.The pits containing the motors for automatic points are approximately 700mm deep and these shall be drained from the bottom to ensure that themotors remain as dry as possible.Points drains and track drains normally get sand washed into them andspecial care must be taken to ensure that sand and other rubbish cannot bewashed into the pit containing the road motor box for the automatic points.All drains shall be reconnected to existing drains. If new connections to stormwater drains are needed then full details shall be provided and negotiatedwith the relevant local authority.Refer to Drawing No. TS1305 for general drainage arrangement in concretetrack.Refer to Drawing No. TS1403 for general drainage arrangement in ballasttrack.Refer to Drawing No. TS1401-YT for sub-surface drainage requirements inconcrete track.Drainage design shall cater for 1 in 100 year flood.5.5 Sub-Surface DrainsPavement drains are generally provided along the line between an existingpavement and a new pavement (ie track slab) where pavement depths orpermiabilities could create a moisture trap.Special reference is to be made to VicRoads Design Guidelines Section 7.51997.Sub-surface drainage shall be wrapped in geotextile to prevent siltation.Drawing TS1403 shows a typical ballast track cross section with sub-surfacedrainage.Drawing TS1401-YT shows a typical concrete track cross section with sub-surface drainage.



5.6 ClearancesFor safety considerations it is necessary to maintain minimum clearancesbetween trams and other trams, other vehicles and structures.On straight track, track centres of 3.353 m ensure that a minimum clearanceof 0.6 m between trams is maintained.Clearance to other vehicles is provided by a 100 mm broken yellow fairwayline at 900 mm offset, measured from running edge of rail to the outside edgeof the line.Clearances to structures are shown on the diagram on Drawing No. P.15556.The horizontal alignment design shall allow for the maintenance of standardclearances. Clearances to structures and other road traffic shall be checkedto ensure that the standards are maintained. The Superintendent shall beinformed of any instances where standard clearances cannot be maintained.5.7 Track ConstructionTram Track Construction Specification provides details of constructionrequirements.Drawings No. TS1401-YT and TS1403 provide details of requirements forconcrete and ballast track construction respectively. TS1407-YT providesdetails of requirements for concrete construction at points and crossings. Atmajor arterial road crossings a stronger structure like TS1407-YT withreinforcing mesh shall be provided.If these constructions can not be achieved, then drawings showing specialconstruction methods shall be produced and approved by theSuperintendent before they are used in any track construction.



6. Track Standards

HORIZONTAL ALIGNMENTTRACK GAUGE- straight and curved track (except turnouts)- straight track through Diamonds and H crossings- turnouts, (turnout move) opposite V Crossings- turnouts, (through move), opposite V Crossings where superelevation

is applied

1.435 m1.430 m1.438 m

1.438 mTRACK CENTRES- normal straight track- straight track with centre poles

3.353 m4.000 m

RADIUS- minimum main line- minimum city streets

350.000 m25.000 m

TRANSITIONS- type- desirable main line length- desirable city streets length

Euler Spiral25.000 m10.000 m

Desirable minimum straight between reverse curvesStandard crossover angleStandard switch radius

10.000 m11°25'00"45.720 m

FLANGEWAYSCheck Plates - normal straight and curved track

- through and opposite crossingsIn Concrete - sloped

30 mm26 mm25 – 50 mm

VERTICAL ALIGNMENTGRADE- maximum- minimum

6.67 %0.25 %

RADIUS- desirable minimum- absolute minimum:- under curve- absolute minimum:- over curve

760 m500 m500 m

SUPERELEVATION- tangent track, inner rail above outer rail- maximum- desirable development rate- maximum development rate

6 mm100 mm1 in 6001 in 300

LEVELS - DIFFERENCES- desirable outer rail above margin- maximum outer rail above margin- desirable range between inner rails- maximum between inner rails

15 mm30 mm20 - 50 mm100 mm



VERTICAL ALIGNMENTGUARD RAIL OR CHECK PLATE- height at rail head (except low leg of turnout curve)- height at rail head for total length of low leg of turnout curve- height at rail head for total length of high leg of turnout curve

Level3.5 mm above2.5 mm below

CLEARANCESTRAM TO TRAM- standard straight track- minimum on curves

600 mm250 mm

TRAM TO STRUCTURES- minimum to permanent structures (1420 to rail)- minimum on curves

750 mm450 mm

TRAM TO OTHER VEHICLES- standard clearance line (900 to rail) 200 mmNOTE:Measurements from rail apply to straight track only, extra distances must be stipulated toallow for extra overhang of trams on curved track.

SPEEDStraight Track- Depends on regulatory roadway speed as applicable to Trams- Maximum 70 km/hCurves- up to 100 m radius- 101 to 240 m radius- 241 to 430 m radius- greater than 430 m radius

15 km/h30 km/h45 km/h60 km/h

Through special work 15 km/h

MISCELLANEOUSTram loading- per axle 9 tAxle centres- 2 per bogie 1.8 mBogie centres- 2 or 3 per vehicle 8.5 m



7. Plan Production

The final drawings must be clear, legible and understandable to theengineering and construction personnel. The drawings shall contain all thenecessary data and details to permit a Contractor to submit a realistic tenderand then later to set out and construct the project.The ‘A' series of sheet sizes have been adopted with the `A3' sheet being thestandard drawing sheet. A copy of the 'A3' title sheet will be supplied onfloppy disk to the successful tenderer.All drawings with trackwork shall have chainages increasing from left to righton the sheet. Chainages in the tramway system generally run from the cityoutwards. AMG and AHD values together with a north point shall be shownon each drawing if applicable.References to other relevant information, surveys or drawings shall beincluded in the reference column on the drawing. Where the drawingcontinues onto another sheet, a continuation note shall be placed on thesheet near the edge where the other sheet joins.Minor alterations to a finished drawing may be made and shall then be listedin the amendment column. The letter of the amendment shall also be addedto the drawing number. A finished drawing here refers to one that has beensigned off by the Superintendent.Major alterations may require a complete redraw including a new drawingnumber.All drawings shall be numbered and a block of numbers shall be issued bythe Superintendent.All final drawings shall be plotted on drafting film.Text styles to be used are helvetica, iso and isoeq with heights of 1.8, 2.5 and3.5 mm.All drawings shall be provided to the Superintendent in Microstation (*.dgn)format on 3½" diskettes, with details/symbology as specified on the attachedsheets.



8. Types of Drawings

The drawings to be produced are - Layout Plans, Long Sections, CrossSections and Rail Bending Plans for pre-bending of curved trackwork.Samples of plans are attached.8.1 Layout PlansScale shall be 1:500 or 1:250 depending on detail to be provided. Generally1:500 is used for straight tracks and 1:250 is used for junctions or curves.These plans shall show the following:� Alignments of trackwork - including curve details and relevant coordinates� Limit of works� Feature survey background - reference file� Locations of services within 5 m of trackwork - reference file� Locations of track drains� Locations of Rail Bonds and Pole Bonds� Coordinates of survey bench marks.Notes to be included on relevant layout plans include but are not limited to:� RAIL BONDS TO BE INSTALLED AT POLE Nos. ____� POLE BONDS TO BE INSTALLED AT POLE Nos. ____� ANY OTHER POLE BONDS, IF FOUND, TO BE TESTED AND

REINSTATED OR DISCONNECTED� YARRA TRAMS PITS AFFECTED BY THE WORKS SHALL BE REINSTATED� WARNING, BEWARE OF UNDERGROUND SERVICES, THE LOCATIONS

OF UNDERGROUND SERVICES ARE APPROXIMATE ONLY AND THEIREXACT POSITION SHOULD BE PROVEN ON SITE. NO GUARANTEE ISGIVEN THAT ALL EXISTING SERVICES ARE SHOWN.

8.2 Rail PlansScale shall be 1:250.Rail Plans shall show the distribution of rails, crossings and switches as wellas all dimensions necessary, including lead distances and offsets to thecrossings, TP - TP distances, AMG coordinates.8.3 Rail Bending DiagramsRail Bending Diagrams are drawn NOT TO SCALE.Rail Bending Diagrams show the chords, offsets and spreads necessary forthe bending of rails and the casting of crossings.



8.4 Long SectionsScales shall be 1:1000 horizontally and 1:100 vertically.These plans shall show the following:� Vertical profile along the centreline of double tracks� Chainages, existing and design levels:− every 10 m along the alignment− at tangent and transition points of horizontal curves− at low points

� Vertical alignment details - including chainages, levels, grades/radii andlengths.

8.5 Cross SectionsScales shall be 1:250 horizontally and 1:50 vertically.These plans shall show the following:� Sections every 10 m and at tangent, transition and low points� Offsets from the design line, with existing and design levels for each rail.Information from cross sections shall also be summarised in a tabulationformat.8.6 Level and Drainage Plans at Special WorksScale shall be 1:250.Level and drainage plans shall show design and existing spot levels anddrainage details at special works.Levels shall be shown on the rails at tangent points, transition points andsecants of curves as well as at equal divisions of circular arcs not exceeding10 m in length and at equal divisions of transitions not exceeding 5 m inlength. Levels are also to be shown at the tangent points and heels of allswitches and at the intersections of all crossings at points on the adjacentrails opposite single crossings. The spacing between levels shall not exceed10 m.The layout of drainage pipes, pits and connection points shall also be shownon this plan.

...\Elect_Stds\P15556.DGN 23/07/2003 09:04:46 AM

...\Drawings\P17597_A.dgn 25/07/2003 11:33:20 AM

...\Drawings\P17599_A.dgn 25/07/2003 11:45:57 AM

...\Standards\Drawings\p18750.dgn 25/07/2003 03:30:09 PM

...\Drawings\P19612_P1.dgn 28/07/2003 08:58:33 AM

...\CAD02_07.19\TS-1304_C2.dgn 23/07/2003 11:59:43 AM

...\Standards\Drawings\TS1305.dgn 11/11/2003 01:54:42 PM

...\CAD02_07.19\TS1401_C1.dgn 23/07/2003 01:47:24 PM

...\Standards\Drawings\TS1403.dgn 25/07/2003 09:38:50 AM

...\Drawings\TS1407-YT.dgn 11/11/2003 02:13:49 PM

...\Drawings\TS2804_B.dgn 11/11/2003 02:29:58 PM