BALLASTLESS TRACK STANDARD

Document Number: A1544 Version: 2.0 Published: 12/03/2024

Name Position
Approvals
Philip Magdaraog Structures Engineering Manager
Document Authors
Nathan Baker Engineering Standards Specialist – Track & Structures

Matthew Brereton Engineering Standard Manager

David Evans General Manager Strategic Asset Management

Document Endorser Richard McDonald Track Delivery Manager

Anita Wong Structures Delivery Manager

Liam Palmer-Cannon Head of Engineering – Track and Structures

Approving Manager Phil Ellingworth Chief Engineer

Amendment record
Periodic review. Updates to references, template and alignment to current organisational structure.

Preface
About MTM Engineering Standards
MTM Engineering Standards, a collection of Standards, Specifications and Technical Notes, are developed and approved in
accordance with MTM’s Engineering Standards Development Procedure (A1225). They set the minimum requirements within
which assets can be built or altered, taking into account the physical, functional and performance characteristics of assets and
their components to ensure assets are safe, functional, managed and maintained.

Currency and Application of this document

It is imperative to check the currency of this document on the Metro Document Portal at
[Link]
Contemporary Engineering Standards shall be applied. Where a project has adopted a Standard Baseline, Engineering
Standards shall be applied in accordance with the Application of MTM Engineering Standards for Projects Guideline (A1128).

Waiver process
Where dispensation from a mandatory requirement within an Engineering Standard is needed, an Engineering Waiver will be
required. Please refer to the Engineering Waiver Procedure (A1212).
Note: MTM does not have the authority to grant dispensations against any requirements that relate to government
regulations or legislation, e.g. Disability Standards for Accessible Public Transport (DSAPT), Electrical Safety Act and
Regulations, etc.

Rationale and Notes

Rationale, notes and footnotes are information only and do not constitute a mandatory requirement. The rationale and notes
are indicated using italics text and in left indented. Footnotes are located at the bottom of the page.

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Table of contents
Purpose .................................................................................................................................................................................3

Scope .....................................................................................................................................................................................3

Safety and Environment ........................................................................................................................................................3

Design Requirements ............................................................................................................................................................4

4.1. General Requirements ................................................................................................................................................................ 4

4.2. Civil & Structural Requirements .................................................................................................................................................. 6
4.3. Transition Section Requirements ................................................................................................................................................ 6
4.4. Track & Wheel/Rail Interface Requirements .............................................................................................................................. 7
4.5. Noise & Vibration Requirements ................................................................................................................................................ 7
4.6. Electrical & Signalling Requirements .......................................................................................................................................... 8
4.7. Maintenance Requirements ....................................................................................................................................................... 8
4.8. Design Assurance ........................................................................................................................................................................ 8

Type Approval Requirements ................................................................................................................................................9

Construction Requirements ................................................................................................................................................10

6.1. Construction Planning ............................................................................................................................................................... 10

6.2. Concrete specifications & Special Construction Tolerances ..................................................................................................... 10
6.3. Specification of the Works ........................................................................................................................................................ 10
6.4. Demonstration Trackform Section ............................................................................................................................................ 12
6.5. Quality Management Plan ........................................................................................................................................................ 12
6.6. Construction Management Plan ............................................................................................................................................... 13

Abbreviations ......................................................................................................................................................................16

Definitions ...........................................................................................................................................................................16

Document hierarchy ............................................................................................................................................................18

9.1. Parent document ...................................................................................................................................................................... 18

9.2. Subordinate documents ........................................................................................................................................................... 18

References ...........................................................................................................................................................................18

10.1. General ..................................................................................................................................................................................... 18

10.2. MTM References....................................................................................................................................................................... 18
10.3. Australian Standards ................................................................................................................................................................. 19
10.4. Industry References .................................................................................................................................................................. 20

Appendix A – Project Documentation Requirements .........................................................................................................21

11.1. Design ....................................................................................................................................................................................... 21

11.2. Type Approval ........................................................................................................................................................................... 21
11.3. Construction ............................................................................................................................................................................. 21
11.4. Site Records .............................................................................................................................................................................. 21
11.5. Handover Documentation ........................................................................................................................................................ 21

Appendix B – Typical Testing Requirements .......................................................................................................................22

Appendix C – Typical Uses of Ballastless Track....................................................................................................................26

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Purpose
The purpose of this document is to provide the technical requirements for Ballastless Track (BLT) that forms part of the Metro
Trains Melbourne (MTM) Infrastructure Lease.
This Standard also sets out the requirements for Trackform selection, design development and delivery quality control for the
installation of BLT systems on the MTM network.

Scope
2.1. This Standard sets out MTM’s requirements for BLT and includes:
• Design requirements
• Type approval requirements
• Construction requirements
Note: This Standard does not provide requirements for inspection and maintenance. These are covered by the
appropriate Technical Maintenance Plan.
2.2. This Standard is mandatory for all proposed works in the MTM Infrastructure Lease, or for works which are
planned to become part of the Infrastructure Lease in the future.
2.3. The Standard outlines minimum requirements. MTM may accept alternative independently certified products,
materials, construction procedures or testing regimes which meet or exceed these requirements. Responsibility for
ensuring the minimum requirements are met remains with the parties undertaking the works.
2.4. This Standard does not include detailed requirements for the design and construction of reinforced concrete or
underlying structures supporting ballastless Trackforms.

Safety and Environment

3.1. The general requirements in relation to safety and the environment are included in the Safety and Environmental
Assurance Standard (A1043) and the Occupational Health and Safety Management Standard (A1051).
3.2. The design and construction of Ballastless Track shall comply with the integrated risk management requirements
outlined in the Safety and Environmental Risk Management Standard (A1046) and the Environment and
Sustainability Management Plan (A2017).
3.3. Safety and risk assessments shall be undertaken to inform the management of Ballastless Track, including the design,
construction, installation, maintenance and refurbishment of all new and existing tracks, structures and drainage. It
shall take into account safety considerations for construction and maintenance personnel and any other party,
including operations personnel, who may be required to use or access the track. Risk assessments shall be conducted
in accordance with the MTM Integrated Risk Management Procedure (A2023).
3.4. All Rail Safety Workers shall comply with Business Rules Manual for the Contracting Rail Safety Worker (A957) and
Safety and Environmental Requirements for Contractors and Third Parties (A2020).
3.5. New equipment, products and/or systems can only be used on the metropolitan train network if they have been
approved in accordance with the Type Approval Procedure (A1215).
3.6. Under RSNL (s46) MTM is required to:
a. Eliminate risks to safety so far as is reasonably practicable (SFAIRP); and
b. If it is not reasonably practicable to eliminate risks to safety, to minimise those risks so far as is reasonably
practicable
3.7. Under RSNL (s47), reasonably practicable means that at a particular time, MTM were able to demonstrate how the
risk/s can be reasonably managed to ensure safety, taking into account and weighing up all relevant issues
including:
a. The likelihood of the hazard or the risk concerned occurring;
b. The degree of harm that might result from the hazard or the risk;

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c. What the person concerned knows, or ought to reasonably know, about:

i. the hazard or risk, and ways of eliminating or minimising the risk;
ii. the availability and suitability of ways to eliminate or minimise the risk; and
iii. after assessing the extent of the risk and the available ways of eliminating or minimising the risk, the cost
associated with available ways of eliminating or minimising the risk, including whether the cost is grossly
disproportionate to the risk.
3.8. Under RSNL (s50), rail safety is a shared responsibility of:
a. Rail transport operators; and
b. Rail safety workers; and
c. Other persons who:
i. Design, commission, construct, manufacture, supply, install, erect, maintain, repair, modify or decommission
rail infrastructure or rolling stock; or
ii. Supply rail infrastructure operations or rolling stock operations to rail operators; or
iii. In relation to the transport of freight by railway—load or unload freight on or from rolling stock.

Design Requirements
4.1. General Requirements
4.1.1. BLT shall be adopted for all elevated railway track greater than 500 metres in length. 1
4.1.2. BLT should be adopted for elevated railway infrastructure including, but not limited to bridges, viaducts and station
structures between 150 and 500 metres in length.1
4.1.3. Following an appropriate risk/economic analysis, if it can be demonstrated that there would be significant economic
benefit by adopting Ballasted Track in the design (while still assuring the equivalent level of safety, reliability,
availability and maintainability) then Ballasted Track may be used for elevated railway track structures of less than
500m in length, subject to approval by the MTM OCE.1
4.1.4. BLT shall be adopted for new tunnels longer than 500m.1
4.1.5. BLT should be adopted for new tunnels between 250m and 500m in length including, but not limited to cut and
cover tunnels, underground structures and bored tunnels.1
4.1.6. Following an appropriate risk/economic analysis, if it can be demonstrated that there would be significant economic
benefit by adopting Ballasted Track in the design (while still assuring the equivalent level of safety, reliability,
availability and maintainability) then Ballasted Track may be used for tunnel track structures of less than 500m in
length, subject to approval by the MTM OCE.1
4.1.7. BLT shall be provided for train workshop lines and washing plant lines. Refer to Appendix C – Typical Uses of
Ballastless Track.
4.1.8. BLT shall not:
a. Fulfill any bridge or tunnel lining structural function in the design, other than the carriage of trains and the
effective transmission of railway forces into the bridge superstructure / tunnel lining.
b. Be used as a method to reduce cover to buried services or other infrastructure over lengths where it is not
possible to achieve an acceptable stiffness transition at the required design speed.
c. Be designed to provide additional 'bending' or 'shear' capacity to bridge decks and is to be considered
superimposed dead load in the design of bridges

1 The adoption of this requirement is at the discretion of the State (DoT) and will generally be determined as part of the design development
phase of the works. Where adoption of this requirement is determined, this will be specified in agreed project requirement documentation.
It is noted that even where the State does not determine the requirement for ballastless Trackform the relevant design authority may still
require its adoption as part of the system solution providing for an adequately reliable, available, maintainable and safe outcome.

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4.1.9. BLT shall comply with the following requirements:

a. The minimum design life of all BLT Track components shall be 50 years subject to periodic maintenance such as
rail grinding and rail pad replacement but without renewal or structural repairs.
b. The minimum design life of all structural track slab components shall be 100 years in accordance with AS 5100.
c. Rails shall be supported and retained to the Design Top, Line, gauge, Rail Cant and track cant, within agreed
tolerances for all rail sizes.
d. The track shall be able to resist all quasi-static, vertical, lateral and dynamic loads resulting from rail traffic at
approved axle loads and speeds with no assembly or track system failures.
e. Track geometry for BLT shall comply with A1545 Tables 2 and 4.
f. The track shall have no negative impacts on communication, signalling, overhead power or other electrical
systems.
g. The track shall not cause component failure, excessive deterioration of track materials or rolling stock
assemblies.
h. Rail corrugation and additional noise shall not occur under normal operational conditions.
i. An acceptable level of noise and vibration attenuation based on environmental requirements for the specific
location shall be achieved.
j. The track shall provide for derailment containment where required in the design, in accordance with MTM
requirements and AS 5100 derailment loading. All reasonably practical measures shall be adopted to increase
the probability that derailed trains will remain upright.
k. The Trackform shall be repairable if damaged by derailment and allow for the retrofitting of additional rail
supports in the event of lost fastenings due to derailment damage or other incidents.
l. Any other specific functional requirements (line speed, headways etc.) applicable to the corridor or track
structure shall be considered.
m. The BLT design shall provide appropriate electrical insulation, to minimise risk of stray current corrosion in
accordance with an earthing and bonding electrolysis strategy approved by the Victorian Electrolysis Committee.
n. The Trackform shall make provision for trackside signalling assets such as train stops, axle counters, the fitting of
local cable connections.
4.1.10. The total track stiffness from combined resilient properties of all elements including rail pads, grouting and Floating
Trackform shall be in accordance with specific agreed project requirements.
4.1.11. BLT designs shall consider and make allowance for any site-specific risk that may impact the overall performance of
the Trackform that may include:
a. Geotechnical properties (including predicted settlement) of any track subgrade or formation under the BLT.
b. Structural properties (including movement settlement or flexure) of any tunnel lining, bridge or viaduct structure
supporting the BLT.
4.1.12. Design of the track and any underlying structure (such as viaduct) shall be integrated wherever possible to enable
cross disciplinary evaluation between track and structural design requirements.
4.1.13. Where the Trackform is designed separately to the underlying bridge or tunnel structure, or if the structure already
exists, the design shall account for:
a. Long term deformation of the structure including settlement, seasonal temperature deflections, creep and
shrinkage.
b. Structure deck stiffness including curvature of the deck deformation and rotational angles at intermediate, and
end supports.
c. Interface requirements between BLT and transitions to Ballasted Track refer to Section 4.3.
d. Differential deflections at structural expansion joints from temperature, rolling stock tractive and braking forces,
and all live or dead loads.
e. Retaining CWR rail stress without requiring rail expansion joints.
4.1.14. Materials for track in tunnels shall be non–combustible and shall comply with specific requirements for fire safety.
4.1.15. Any prefabricated, Proprietary Products or pre-cast elements such as gauge ties, sleepers, concrete plinths or block
supports, fastenings, bearings and pads shall comply with the relevant MTM, Australian and industry standards.

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4.1.16. Proprietary Products shall be subject to MTM type approval requirements and covered by the supplier’s warranty
for the proposed function.
4.1.17. Proprietary Products shall be used in accordance with the suppliers’ instructions for their proposed function and in
a manner that reduces risk of:
a. Failure of clips and/or clip bolts and rail pads.
b. Failure of insulating elements.
c. Loosening of clip bolts.
d. Loosening of Anchor Bolts.
e. Failure of fastener base plates or grout pads.
f. Failure of sleepers or other types of track supports such as plinths or blocks.
g. Any electrical failure due to build-up of rail debris in service.
4.1.18. Concrete components of the ballastless Trackform are to be considered structural components and shall be designed
and constructed in accordance with the relevant Australian Standards. They shall be reviewed as structural designs
rather than type approved products.

4.2. Civil & Structural Requirements

4.2.1. The Trackform shall be designed to railway traffic loading, as specified in the MTM Bridge Standard (A1546) unless
otherwise agreed by DOT and MTM Chief Engineer or delegate.
4.2.2. Any permitted reduction in load shall be designed to withstand live loads from all current approved rail vehicles and
any known future rail vehicles.
4.2.3. Proposed designs shall clearly demonstrate provision for safe construction, maintenance, renewal, and
decommissioning.
4.2.4. Where a Hydraulic Bonded Layer or similar is required by the design, it shall be 150mm minimum depth.
4.2.5. The Trackform shall provide positive drainage and prevent water from pooling at the track fasteners and around the
baseplates where applicable.
4.2.6. Any Floating Trackform shall:
a. Allow for the provision, and spare capacity requirements, for all services and drainage.
b. Be of proven design with a minimum of 5 years demonstrated performance in an operating environment similar
to the MTM rail network including any pads, strip pads and bearings.
c. All bearings, pads, strip pads, and joints shall be designed in accordance with the requirements of AS 5100.4 -
Bearings and deck Joints.
4.2.7. The Trackform design shall take into account longitudinal rail creep, lateral stability, traction and braking loads.
4.2.8. The design shall ensure that any structural movement, concrete shrinkage or thermal effects, do not adversely affect
rail stress or other operational infrastructure. Construction, expansion and contraction joints shall be provided for
as appropriate.
4.2.9. The Trackform design shall provide for the accurate location of the nominated track fastening systems both
horizontally, vertically within the agreed tolerances.
4.2.10. The Trackform shall provide the appropriate pull-out capacity to ensure track fastener Anchor Bolts sustain the
required torque to resist lateral loads in service.
4.2.11. The track structure shall ensure that no enclosed metallic loops are located within 500mm of the rail foot.

4.3. Transition Section Requirements

4.3.1. Transition Sections shall be provided at interfaces with Ballasted Track or any areas where a change in the underlying
subgrade or structure results in a change in track stiffness.
4.3.2. The Transition Section shall provide the following:
a. No relative settlement between different Trackforms.
b. A progressive change in track stiffness and live load deflection over a minimum length (m) of 2 times maximum
line speed (m/s) or the longest approved vehicle bogey centres (whichever is the greatest).

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c. A Trackform which can be maintained and adjusted using the same plant, hand tools, procedures, and practices
as one of the adjoining Trackforms.
d. Continuity of drainage between the Trackform drainage and adjacent track drainage
e. A consistent track alignment with no change in geometric features such as spiral (clothoid) transitions, cant
transitions or vertical curves.
f. Continuity of derailment containment shall be allowed for in the design (where required). Derailment upstands
or guard rail terminations shall be arranged to minimise the risk of snagging from derailed wheelsets.

4.4. Track & Wheel/Rail Interface Requirements

4.4.1. Track cant design shall be based on an assessment of the full range of traffic patterns and actual speeds and
deficiencies which may occur at the location including any specific line features such as curves, junctions, grades or
signals which may impact median and Mode average train speeds.
4.4.2. Ballastless Trackforms shall suit the operational requirements for wheel profiles (new and worn) detailed in the
MTM Standard Rolling Stock Wheel Defect Limits (A2614).
4.4.3. Provision shall be made to adjust Track cant following installation.
4.4.4. Track fastening spacing shall be a maximum of 685mm centre to centre.
4.4.5. A minimum clearance shall be provided between the rail foot and the top of Trackform surface to allow for
aluminothermic welding and rail clamping without the need to lift the rail.
4.4.6. All fastenings shall be warranted for use by their suppliers at the nominated track centres.
4.4.7. Track Fastenings and supports shall accommodate all rail sections approved for use on the specific track class.
4.4.8. The Trackform shall provide for adjustment of the rail position to address maintenance issues related to rail wear
and top & line faults.
4.4.9. All Rail Fastenings and adjustable components shall be accessible and clearly visible to facilitate routine inspections.
4.4.10. For longitudinal grades >2.5%, an assessment shall be completed to determine if additional longitudinal rail restraint,
such as increased toe loads or decreased fastening spacing, may be required.
4.4.11. The Trackform shall ensure that impacts from worn wheels, flat spots and hollow treads or false flanging will not
result in an unsafe track condition. Failure of insulating elements, loosening of clip bolts, failure of clips and/or clip
bolts, shall not occur under normal service operations.
4.4.12. Rail profiling is to be applied in accordance with the MTM Rail Profiling Technical Specification (A2242).

4.5. Noise & Vibration Requirements

4.5.1. Specific noise and vibration requirements for BLT shall be agreed on a project-by-project basis.
4.5.2. For BLT in tunnels or enclosed structure environments, consideration shall be given to air-borne noise within the
enclosed environment and the impact this will have on the ability of rolling stock to comply with AS 7513 Railway
Rolling Stock Interior Environment (all parts).
4.5.3. The Trackform shall be designed to operate under the loads and vibration frequencies expected from the full range
of approved rolling stock and anticipated operational speeds on the section whilst remaining within the required
noise and vibration limits.
4.5.4. Floating Trackform shall not result in an unacceptable level of low frequency radiated noise or resonance as defined
by agreed project requirements.
4.5.5. Elastic Fastening Systems shall provide an acceptable level of rail bound noise damping as defined by agreed project
requirements.
4.5.6. The proposed Trackform shall prevent excessive noise under normal operational conditions as defined by agreed
project requirements and when maintained within standard limits.

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4.6. Electrical & Signalling Requirements

4.6.1. BLT shall meet the requirements of MTM communication, signalling or overhead power systems.
4.6.2. The track fastenings shall provide the appropriate electrical resistance between the rail and Trackform structure and
also between both running rails in all possible environmental conditions, as agreed by VEC and stipulated in A1531,
clause 11.3.5.
4.6.3. The design shall provide for earthing, bonding and electrolysis control of the Trackform and substructure in
accordance with MTM earthing and bonding standards.

4.7. Maintenance Requirements

4.7.1. BLT shall provide for all track maintenance activities such as destressing, re-profile grinding, rail milling, rail
replacement, rail welding and emergency rail clamping.
4.7.2. Any new methods, equipment or plant required shall be identified during the design phase and submitted to MTM
for review and acceptance.
4.7.3. Maintenance tolerances and inspection frequencies for BLT shall be reviewed in accordance with:
a. MTM’s track class requirements.
b. Manufacturers’ recommendations.
c. An engineering assessment of possible failure modes or indications of loss of function in the track form or
components.
4.7.4. Maintenance limits for BLT shall ensure that interventions are triggered before the track reaches an unserviceable
condition.

4.8. Design Assurance

4.8.1. Parties responsible for designing BLT shall prepare documentation in accordance with

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4.8.2. Appendix A – Project Documentation Requirements, Section 11.1 and Section 11.2
4.8.3. Parties delivering BLT designs for MTM shall prepare and issue a design assurance plan prior to the design for MTM
review and approval. The design assurance plan shall describe the means by which assurance will be provided for.
This includes consideration of:
a. The requirements listed in this Standard.
b. Resistance to design vertical wheel loads including vertical loads on individual fastenings.
c. Resistance to lateral wheel loads including loads on individual fasteners from thermal rail forces and flange
steering curves (nominally under 380m radius).
d. Resistance to Longitudinal rail creep forces resulting from the effects of:
i. Vehicle traction and braking.
ii. Track grade.
iii. Structural Interaction.
e. The maximum predicted rail gap resulting from a broken rail.
f. Resilience to loading effects including deflection and damping for the full range of approved axle loads.
g. The ability of the Trackform components to withstand fatigue from cyclic loading throughout the nominated
design life.
h. The ability of the Trackform to filter frequencies associated with the formation of short-wave rail corrugations.
i. Requirements of track drainage (tunnels, open tracks and bridges).
j. Requirements for track fastening Anchor Bolts:
i. Tensile strength of the bolt to apply the required clamping force.
ii. Tensile strength to resist shear and rail overturning moment.
iii. Adequate concrete embedment resistance to pull-out and moments from rail forces.
iv. Adequate ability to maintain a minimum torque to prevent bolt loosening.
k. Documentation of any type approvals, product approvals or standard waivers required.
l. Descriptions of methodologies for testing designs against any acceptance criteria. These may include hand
calculations, factory testing, site testing, simulation or Reliability Availability Maintainability and Safety (RAMS)
modelling analysis. Supplier’s quality assurance documentation, demonstrating compliance with comparable
industry standards, may be used.
4.8.4. The following design documentation shall be issued to MTM for review and approval at an agreed point in the design
development:
a. Track alignment designs.
b. Design calculations and structural design drawings for the track structure including connection details for all
structural elements and interfaces with any underlying structures.
c. General arrangements and typical cross sections showing the entire BLT fix arrangement including rails, track
fastenings, pre-cast concrete elements, cast in place concrete layers and transition slabs.
d. Construction methodology overview outlining the pre-fabrication, installation, assembly and construction
tolerances.
e. Any relevant MTM type approval certificates (if granted) or completed applications, testing and quality assurance
documentation if seeking type approval.

Type Approval Requirements

5.1. BLT products shall type approved in accordance with the MTM Type Approval Procedure (A1215).
5.2. BLT products shall be warranted by the supplier for use in the applicable track class for each proposed location for
the required design life.
5.3. Parties proposing new BLT products for type approval shall demonstrate that the product provides for future track
maintenance activities such as destressing, rail grinding re-profiling, rail replacement, rail welding and emergency
rail clamping.

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5.4. Any new methods, equipment or plant required shall be identified and agreed with MTM Infrastructure Department.
5.5. Typical testing requirements for BLT fastenings and Anchor Assemblies are listed in the Appendix B – Typical Testing
Requirements. Suppliers may propose alternative acceptance criteria which can be demonstrated to be:
a. Outputs from an accepted design as described in this Standard.
b. Appropriate for the required design life.
c. Taken from accepted industry standards or specifications for comparable railways.
d. Representative of operational and environmental conditions on the MTM network.

Construction Requirements
6.1. Construction Planning
6.1.1. Ballastless Trackforms shall be constructed in accordance with an agreed Construction management plan using ‘Top-
down Construction’, ‘Bottom-up Construction’ methods or a hybrid.
6.1.2. Top-down Construction methodology shall ensure that:
a. Site access arrangements will enable the rails to be delivered and positioned on site ahead of the concrete pour.
b. Measures are implemented to eliminate voids appearing under the seating areas for the Rail Fastenings
c. Care shall be taken during concrete pouring, to ensure that the track components are clean and undamaged
prior to final assembly.
d. Care shall be taken to ensure that variation in ambient temperature or heating from sunlight do not affect the
accuracy of the rail positioning before during or after concreting (prior to the concrete gaining full strength).
6.1.3. Bottom-up Construction methodology shall ensure that:
a. The precise position of the Rail Fastening mounting seats regarding flatness, Rail Cant, slope, and position of
Inserts is achieved without the use of shimming and/or grinding during final track assembly.
b. Track curves, geometric transitions (spirals) and cant transitions are interfaced with the vertical alignment, and
adequately set out to ensure that the installed rail positions comply with the required construction tolerances.
c. A methodology is developed and pre-agreed to enable confirmation of the required rail fastener set out positions
and tolerances prior to the concrete pour.
6.1.4. Pre-cast elements which improve construction quality, accuracy and efficiency should be adopted in combination
with either methodology, subject to design and type approval requirements.

6.2. Concrete specifications & Special Construction Tolerances

6.2.1. In-situ concrete shall comply with AS 1379 and AS 3600.
6.2.2. Precast concrete shall comply with AS 3850.
6.2.3. All sampling and testing shall be in accordance with AS 1012.

6.3. Specification of the Works

6.3.1. A Specification shall be prepared and be issued to MTM for review prior to the works commencing.
6.3.2. Parties responsible for undertaking fabrication, construction or installation of BLT shall complete the works in
accordance with an agreed project technical specification and quality management plan.
6.3.3. Technical specifications and QMP shall be prepared, reviewed and accepted within an agreed timescale prior to
undertaking the works.
6.3.4. Parties responsible for constructing BLT shall prepare documentation in accordance with

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6.3.5. Appendix A – Project Documentation Requirements, Section 11.3, 11.4, and 11.5.
6.3.6. A description specifying the installation of BLT and outlining the works which shall include:
a. Preparing and placing reinforced concrete plinths, pads or panels on viaducts, bridge decks or prepared
formations.
b. Installing and testing rail fastener assemblies.
c. Forming of continuous welded rail (CWR).
d. A summary of the interfacing works required to accommodate the power and signalling systems.
e. Stages and interim layer tolerances required to ensure that the final rail head construction tolerances comply
with MTM Specification Track Geometry Tolerances (A1303).
6.3.7. In addition to clauses 6.2.1, 6.2.2, and 6.2.3, the following tolerances shall be included within the Specification of
the works:
a. Rail seat surface areas shall have an appropriately smooth and uniform surface free from voids and other defects.
b. Rail seat flatness when measured with a straightedge placed diagonally from corner to corner of the bearing seat
OR to within the fastening manufacturers recommended guidelines (whichever is the most onerous).
c. Rail seat elevation and Rail Cant (angle) relative to the design plane.
d. Rail seat longitudinal grade slope grade tolerance relative to the adjacent bearing seats OR the minimum
approved shim thickness (whichever is the most onerous).
6.3.8. Cross references to other applicable project documents such as:
a. Project requirements.
b. Project schedules.
c. Concrete formwork specifications.
d. Concrete reinforcement specifications.
e. Cast-in-situ concrete specifications.
f. Transition Section specification.
g. Ground-Borne vibration attenuation criteria in sensitive areas.
h. Acceptable lateral acceleration (cant deficiency).
i. Cross section of track in straight and curved sections (twin tunnels, bridges, earthworks and other structures).
j. Trackwork specifications:
i. Manufacture and Supply of Aluminothermic Rail Welding Materials and Equipment (A1505).
ii. Track Geometry Tolerances (A1303).
iii. Glued Insulated Rails Joints (A1345).
k. Traction and signal bonding specifications.
l. Trackwork electrical isolation specifications.
6.3.9. References to applicable MTM Standards, Australian Standards or industry standards.
6.3.10. Documentation to be issued prior to the works including:
a. Approved construction and assembly drawings
b. Work Plans, procedures or SWMS covering, as a minimum, the following applicable items:
i. Step by step construction sequence.
ii. Survey control plan.
iii. Material handling procedures including lifting plans for any prefabricated panels or sections.
iv. Special equipment and tools, including formworks, jigs and support details.
v. Protecting supports to allow removal after concrete installation.
vi. Method of treating holes in the concrete created by temporary supports.
vii. Concrete surface and dowel preparation.
viii. Methods of protecting existing assets, collecting and removing washed material, debris and dust during
construction.

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ix. Mixing, transporting, forming, placing, finishing, and curing of Trackform concrete.
x. Repair procedures for non-conforming concrete.
xi. Method of measuring and repairing any voids in the bearing area in contact with the fastener assembly.
xii. Anchor Bolt torque and pull-out testing requirements including replacement procedures for damaged or
incorrectly installed Anchor Bolt and Inserts.
xiii. Equipment and methods to be used for installing rail fasteners, including the Anchor Bolt installation torque
and the sequence of shimming, torquing Anchor Bolts, installing rail clips and biscuits in accordance with
the manufacturer’s instructions.
xiv. Repair procedures for deviations in track gauge, rail levels, inclination, cant, Design Line and Top, skewed
fastener assemblies and non-conforming Insert locations.
xv. Any special requirements for turnouts or special trackwork.
xvi. Shop drawings of any sleepers or prefabricated gauge ties used to support track, fasteners and/or Inserts
prior to, during and after concrete placement.
xvii. Rail anchoring and rail welding.
xviii. CWR handling, installation, adjusting, welding and de-stressing.
xix. Field testing and inspection to confirm the quality requirements and tolerances specified.
xx. A comprehensive drainage plan for the interim and final arrangements.

6.4. Demonstration Trackform Section

6.4.1. At the direction of MTM’s Chief Engineer the proposed materials and methodologies shall be validated by
construction of a demonstration section of track for acceptance before beginning the main construction. The exact
methods proposed for use shall be employed for the demonstration section. Other requirements include:
a. Demonstration sections for standard track shall be a minimum of 36.5m long and for turnouts or special
trackwork at least one complete unit.
b. Rail fastener suppliers shall witness the construction of, and any repairs made to, the demonstration section.
c. The Supplier shall submit its approval of the demonstration section, in writing, to MTM. Any recommendation
for changes to the methodology, by the suppliers’ representative, shall be addressed.
d. If the demonstration section does not meet the agreed requirements, a revised work plan shall be submitted
and another demonstration section, or sections, constructed.
e. Non-conforming demonstration sections shall be removed or repaired using methods agreed by MTM.
f. Location of the demonstration section(s) shall be as indicated on the construction drawings.
g. The demonstration section shall include examples of the various forms of repair described in the work plan.
6.4.2. The following documentation shall be provided as a part of Main Trackform Construction prior to the
commencement of construction:
a. Approved methods and procedures as agreed and demonstrated to be used for the main trackwork construction
including the method of achieving rail head positional tolerance and any interim layer tolerances.
b. Product Data for non-shrink grout and metal corrosion prevention for MTM’s agreement prior to the planned
commencement of work.
c. In-situ pour concrete mix design. Submit the proposed concrete mix design for MTM acceptance within 30 days
prior to plan commencement of work.

6.5. Quality Management Plan

6.5.1. A Quality Management Plan (QMP) that complies with ISO 9001 (unless agreed otherwise by MTM) shall be issued
to MTM for review prior to the works and include the following requirements:
a. Procedures as specified for concrete construction and independent tests on delivered concrete batches.
b. Minimum requirements for Inspection and Test Plans (ITP).
c. Minimum requirements for witness points and hold points.
d. Track electrical resistance (for stray current protection).

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e. Installation testing. The Contractor shall either conduct testing or co-operate with an independent tester to
conduct the required site tests.
f. Minimum requirements for managing non-Conformances (NCR's) and acceptance of corrective actions by the
MTM representative.
g. Trackwork construction shall be supervised by a Supervisor and Foreman/Special Ganger with documented
experience in BLT construction and a thorough knowledge of MTM’s track construction requirements.
h. Delivery, Storage & Handling shall be in accordance with the agreed project requirements.
i. Maintenance during Construction shall be the responsibility of the Contractor until practical completion.

6.6. Construction Management Plan

6.6.1. A Construction Management Plan (CMP) shall be prepared that includes the following requirements and issued to
MTM for review prior to the works commencing:
a. Support Structure Surface: The Trackform base or bedding layer on which the track concrete is placed shall only
vary from the design elevation to within the tolerance range specified.
b. Protection of Existing Assets: Protect dowels, drainage facilities, and electrical conduits from damage and
plugging. Repair promptly all damage.
c. Formworks: Design and install forms in accordance with agreed requirements for concrete formwork.
d. Typical Pre-Pour Survey and Inspection requirements:
i. Immediately prior to pouring track concrete, the formwork and supporting ties, jigs and frames shall be
surveyed for readiness.
ii. The survey shall take place at an agreed point prior to placing track concrete.
iii. The survey shall be performed by, or witnessed by, the MTM Approved Representative.
iv. Measurements shall be taken at each support location and shall include, at a minimum, Design Line & Top,
Rail Cant of both rails, track cant and gauge.
v. The entire track section shall be fully checked for track gauge and Rail Cant compliance.
vi. Each fastener Insert shall be inspected for cleanliness and damaged coating. The Insert external surface shall
be free of grease, dirt and foreign objects.
vii. Each fastener shall be inspected for the positional accuracy in accordance with the construction drawings and
tolerances specified.
viii. No track concrete may be placed prior to repairing any deviations found during the inspection.
ix. All measurements shall be recorded and submitted to the Approved MTM representative within 24 hours of
the measurements being taken.
e. Fastener Inserts (ferrules): BLT fastener Anchor Bolt Inserts shall be cast into concrete as shown and in
accordance with approved drawings and the following:
i. All Inserts shall be free of loose scale, rust, grease, or other foreign matter.
ii. All bolts shall be stainless steel or coated with an approved anti-corrosion treatment system.
iii. All Inserts will be coated with epoxy coating. The Contractor shall inspect Insert coating before installation
and, if necessary, apply an approved epoxy paint to damaged coating areas.
iv. Approved templates shall be used to accurately locate Inserts, and positively secure the Inserts against
displacement during concrete placement. Inserts shall be placed in accordance with the required tolerances.
f. Installation of Rail Fastenings shall be undertaken in accordance with the following requirements:
i. The agreed Contractor's work plans, procedures and SWMS.
ii. Rail and fasteners shall be clean and free of all dirt, grout and other substances.
iii. Any reinforcing bar with the potential to contact an Insert shall be relocated prior to placing the concrete.
iv. Fasteners shall be located as per design requirements and at the specified spacing and tolerances.
v. Lateral adjustment provision within the fasteners shall be reserved for future MTM maintenance activities.
The Contractor shall not use more than the agreed adjustment allowance during construction and defect
repair.

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vi. All fastener components shall be installed to ensure the field side of the rail base will be tight against the
outside shoulder.
g. Typical Requirements for Support Prior to and During Concreting:
i. The installation support method shall ensure, both prior to and during concreting, that track is adequately
supported at the Design Line and Top by supports specifically manufactured for this purpose.
ii. The track shall be supported for an agreed distance beyond the track section being concreted in such a
manner that will ensure that the rail stress free temperature will not be affected.
iii. The supports shall be capable of withstanding thermal expansion and contraction loads, and effects of
construction personnel, tools, and equipment that the Contractor uses prior to and during concrete
placement.
iv. Each support shall, as a minimum, provide the following functional requirements prior to and during
concreting:
o Hold both rails to the required gauge, grade, level, Rail Cant, Design Line and Top, and track cant.
o Allow the track to be adjusted by provision of threaded screws or similar continuous means of
incremental adjustment.
o Be supported directly on to the support structure. The use of precast concrete, or similar, for the gauge
supports may be permitted under the canted rail on curves if the method is approved
o Be removable without disturbing the track.
o Allow for monitoring the track continuously during concrete placement to make sure it is not
misaligned by temperature, vibration, or other causes.
o Prevent movement of the rails and fastenings by not being removed until the concrete has cured and
attained the required compressive strength.
h. The portion of the gauge supports that will be temporarily concreted in shall be coated/protected using an
approved method.
i. All holes left by the gauge supports in the track base after concreting shall be cleaned, prepared, and filled by an
approved non-shrink cement grout. The surface finish of the grout shall be to the same standard of surface finish
as that of the finished track base.
6.6.2. Shims shall be used to adjust height only where approved and up to the maximum specified height. Shims shall be
as designed or approved by the rail fastener Supplier. Shims shall be used in a way that ensures the rails remain co-
planer.
6.6.3. Concrete Finishing and Final Adjustments shall be undertaken in accordance with the agreed Concrete Finishing
specification.
6.6.4. Trackform Completion shall include the following requirements:
a. Standard MTM track construction tolerances where applicable.
b. Remove any remaining forms or temporary works.
c. Expose the entire rail fastener bearing seat of every fastener for inspection.
d. Check for voids in the rail fastener bearing seats.
e. The fastener assembly, including shim(s) shall not be indented or recessed into the concrete.
f. Within the footprint of the rail, the rail, fastener rail seat, and shims shall have a minimum agreed contact
between surfaces.
g. The fastener rotation about the transverse fastener centreline shall be within agreed angle to the rail base plane.
h. The difference in rail inclination between adjacent Rail Fastenings shall be within the agreed tolerances.
i. The fastener skew (angle to a line normal to the rail) shall be within the agreed tolerances.
j. Difference in height between adjacent rail fastener seats shall be within agreed tolerances of the same plane.
k. The top of Trackform concrete shall be free of depressions that will cause water to pond.
l. The concrete between adjacent rail fasteners shall be within tolerance as measured with a straight edge.
m. All rail seat areas shall be finished in accordance with a plan submitted to and approved by the Chief Engineer.
6.6.5. Final Adjustments shall include the following requirements:

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a. Set Anchor Bolts with calibrated torque wrenches according to the fastening manufacturers’ guidelines.
b. Power wrenches shall be adjusted to stall or cut-out at the selected torque
c. If manual torque wrenches are used, the torque indication corresponding to the calibrating tension shall be
noted and used in the installation of all bolts of the tested lot.
d. Bolts shall be in tightening motion when torque is measured.
6.6.6. Displaced, Damaged or Misaligned Inserts, or Inserts replaced as a result of failure to pass field tests shall be carefully
replaced or removed by an approved means in a manner that will prevent spalling or compromising the structural
integrity of surrounding concrete. The Contractor shall manage failures and repairs in accordance with the agreed
Quality Management Plan and shall submit a procedure for resetting the Insert, including grout materials for setting
the Insert and alignment method. All displaced or misaligned Inserts shall be reset at no cost to MTM.
6.6.7. Field Tests: Inserts shall be undertaken during the construction period in accordance with the agreed Quality
Management Plan.
a. Should any Insert fail to meet the above tests, six additional Inserts from the same Insert lot shall be tested.
Failure of any of these Inserts to pass the tests will signify that the installation procedure is defective and 100%
of the remaining lot will be rejected. Additional tests as specified above, and other tests as required shall be
performed on concrete and other materials associated with Insert installation to determine cause of defective
installation. Further Insert installation shall not proceed until the cause of failures has been determined and a
modified procedure ensuring satisfactory installation has been established. Remedial Work shall be performed
at no additional costs to MTM.
b. Failure of a reset Insert shall be investigated by the Contractor prior to any remedial work and any additional
Inserts shall not be reset without the MTM Approved Representatives approval.
c. The MTM Approved Representative shall be notified 24 hours in advance of the location and time of Insert
testing. Results of Insert tests shall be made available.
6.6.8. Agreed Milestones, hold points and witness points shall be agreed prior to commencement of works.

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Abbreviations
BLT Ballastless Track

CMP Construction Management Plan

CWR Continuous Welded Rail

DMS Drawing Management System

DOT Department Of Transport

MTM Metro Trains Melbourne

MTM OCE Metro Trains Melbourne Office of the Chief Engineer

PTV Public Transport Victoria

QMP Quality Management Plan

RSNL Rail Safety National Law

SFAIRP So Far As Is Reasonably Practicable

SWMS Safe Work Method Statement

VEC Victorian Electrolysis Committee

VQI Victorian Quality Index

Definitions
Anchor Assemblies An arrangement of Anchor Bolts and their Inserts, usually held in position by a jig or template.

A bolt or threaded rod (most typically) that holds a fastener to the supporting concrete. An
Anchor Bolt
Anchor Bolt is fastened into an Insert in the supporting concrete.

The term Ballastless Track applies to all forms of Direct Fix, floating slab, plinth or embedded
Ballastless Track
rail track.

In Bottom-up Construction the concrete formwork is the primary physical reference to obtain
Bottom-up
the correct grade, cant, and profile for the concrete. In some cases, templates are used to
Construction
hold the anchor Inserts in place, other cases, they are drilled in and grouted later.

The required horizontal mid-ordinate offset from a 10m or 5m chord. The offset is zero for
Design Line straights, the versine value for uniform curves and a value between zero & versine value for
transition curves.

The required vertical mid-ordinate offset from a 10m chord based on the low rail levels plus
track cant where required.
Design Top
Note: Vertical curves usually have such a large radius that a 10-metre length of track may be
considered planar, and Design Top is therefore zero.

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A system of fixation of track directly to a structure or continuous concrete invert, concrete

Direct Fix
deck, floating slab or open deck structure without the use of track or bridge ballast.

Elastic Fastening Fastening systems designed especially for rigid Trackforms with Elastic Polyurethane (PU),
Systems Natural Rubber or other synthetics pads.

Floating Trackform A Trackform which is isolated from the ground or supporting structure using resilient
(Or floating slab) bearings, pads and strip pads.

Hydraulic Bonded The base layer of the Trackform, prepared using a mixture of cementitious / asphaltic
Layer materials and soil, which set and harden in the presence of water.

The Land and Infrastructure as defined in the Train Infrastructure Module of the MR4
Infrastructure Lease
Franchise Agreement.

An internally threaded (female) component that is designed to anchor a threaded fastener

Insert (ferrule)
such as an Anchor Bolt into a concrete support.

Mode (average)
The most frequent speed operated over a specific track section.
speed

An individual nominated by MTM’s Chief Engineer and deemed competent to assess issues
MTM Approved
and provide clarifications and direction on matters relating to the construction of the
Representative
Ballastless Track.

Products that are produced in accordance with designs that will remain owned exclusively
Proprietary Products
by an individual or business.

The angle at which running rail is inclined from vertical to the plane of the track towards the
Rail Cant track centre line. Rail Cant is equal to a slope of 1 in 20 except at some turnouts or special
crossing work assemblies.

The assembly inclusive of resilient grout pads, rail pads, baseplates, insulators and clips
Rail Fastenings
which connect the running rails to the sleeper or concrete support surface.

The term shall is used to express a clause that is mandatory to achieve conformance to the
Shall
standard.

Is used as the descriptive word to express a requirement that is recommended in order to

Should achieve compliance. ‘Should’ can also be used if a requirement is a desirable but not a
mandatory requirement.

In Top-down Construction, the running rail or a surrogate is fixed in place first, with the Rail
Fastenings or surrogate templates attached to it. Anchor Inserts, supported by adjustable
jigs, braces or ties allow the rails to be placed at the proper geometric relationship to the
Top-down agreed datum. Special plates may also be used to ensure surface quality at the rail seats.
Construction
If adequately controlled this method will ensure the rails are accurately inclined and gauged
at the correct Design Line and Top prior to concreting. When the reinforcing bars and forms
are in place, the concrete is placed and finished.

The ballasted or Ballastless Track system including rails, sleepers, gauge ties, fastenings,
Trackform ballast or supporting concrete. It does not include capping, formation, bridge deck or
substructure.

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A section of track located between conventional ballasted and Ballastless Tracks which has
Transition Sections been specifically arranged to prevent abrupt changes in track stiffness, settlement,
deflection or ride quality.

Document hierarchy
9.1. Parent document
• Quality Policy (A7721)
• Risk Management Policy (A7726)

9.2. Subordinate documents

Nil.

References
10.1. General
10.1.1. Track materials shall be provided and tested in accordance with this Standard, other relevant MTM Standards,
project requirements, Australian Standards, rail industry standards and International Standards.
10.1.2. Where a conflict arises between standards, or where clarification as to the applicability of a Standard or a part of a
Standard is required, the matter shall be referred to the MTM Chief Engineer for determination.

10.2. MTM References

DOCUMENT DOCUMENT TITLE

NUMBER

A957 Business Rules Manual for the Contracting Rail Safety Worker

A1051 Occupational Health and Safety Management Standard

A1212 Engineering Waiver Procedure

A1215 Type Approval Procedure

A1303 Track Geometry Tolerances

A1345 Glued Insulated Rails Joints

A1505 Aluminothermic Rail Welding Materials and Equipment

A1531 Electrical Network Systems Standard

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DOCUMENT DOCUMENT TITLE

NUMBER

A1545 Track Design & Construction

A1546 Bridge Standard

A2017 Environmental and Sustainability Management Plan

A2020 Safety and Environmental Requirements for Contractors and Third Parties

A2023 Integrated Risk Management Procedure

A2242 Rail Profiling Technical Specification

A2614 Rolling Stock Wheel Defect Limits Standard

A7721 Quality Policy

\ Risk Management Policy

10.3. Australian Standards

DOCUMENT NUMBER DOCUMENT TITLE

AS 1012 Methods of Testing Concrete

AS 1085 Railway track material

AS 1100 Technical Drawing

AS 1379 Supply of Concrete

AS 1530 Methods for Fire Tests on Building Materials, Components and Structures

AS 1683 Methods of test for Elastomers

AS 3600 Concrete structures

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DOCUMENT NUMBER DOCUMENT TITLE

AS 3850 Prefabricated Concrete

AS 5100 Bridge Design

AS 7513 Railway Rolling Stock Interior Environment

AS/NZS ISO 9001:2008 Quality Management Systems – Requirements

10.4. Industry References

DOCUMENT NUMBER DOCUMENT TITLE

ASTM D297 Standard Test Methods for Rubber Products

ASTM D412 Standard Test Methods for Vulcanised Rubber and Thermoplastic Elastomers – Tension

EN 13146 (All Parts) Railway Applications – Track – Test methods for fastening systems

PTV-NTS-006:2019 Track and Structure – Railway

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Appendix A – Project Documentation Requirements

11.1. Design
11.1.1. All Design Drawings shall be produced in accordance with the conventions detailed in MTM Documentation A1897
As-built Drawing Management Procedure & AS 1100 Technical Drawing.
11.1.2. For all projects design documentation shall include the following:
a. A Design Assurance Plan addressing the requirements of this Standard.
b. Adequate specification and drawings to enable the proper planning, tendering, execution and supervision of the
construction works.
c. DMS compliant plans, sections and elevations clearly showing the full area of the works including any transition
slabs.
d. Identification of any areas which require specific treatments.
e. Design calculations including any stability or settlement assessments.

11.2. Type Approval

11.2.1. A Type Approval application shall be produced in accordance with the MTM Type Approval Procedure (A1215) and
the specific requirements outlined in this Standard.

11.3. Construction
11.3.1. A Specification, QMP and CMP shall be produced in accordance with the requirements outlined in this document.
11.3.2. Records shall be kept during construction, including conditions encountered, works as executed, as built drawings,
testing records and details of repairs or replacement works. Any agreed alterations to the works plan,
methodologies specifications or drawings shall be documented.

11.4. Site Records

11.4.1. Daily diaries and detailed drawings of works as executed should be maintained and updated throughout the
works. Typical site records include the following:
a. Signed off Inspection & Test Plans
b. For Large projects: a daily site report.
c. For Small projects: a construction summary report.
11.4.2. Clarification as to whether a project is categorised as Large (change category level 3 or 4) or Small (change
category level 1 or 2) should be sought by consulting the MTM Management of Change procedure (A2030).

11.5. Handover Documentation

11.5.1. As a minimum the following handover documentation shall be provided to MTM:
a. Certified ‘As in Service’ drawings to DMS requirements
b. Test certificates
c. Acceptance certificates
d. Monitoring reports referenced against predicted settlement values
e. Ongoing monitoring requirements (if needed)
f. Non-conformance reports
g. Signed inspection records
h. Other site records
i. Any Special maintenance requirements during the design life
j. Other documentation as specified in the contract

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Appendix B – Typical Testing Requirements

Typical type approval testing requirements for track fastenings and Anchor Assemblies are listed in Table 1, Table 2 and Table
3 below. This list may be altered or expanded as directed by MTM.

NAME DESCRIPTION REFERENCE ACCEPTANCE CRITERIA

Static, low frequency & high A force is applied normal to EN 13146-9: Section 6 To be agreed for specified
frequency stiffness tests the test pad and the design load.
(Or agreed equivalent)
displacement is measured.

High & low temperature A force is applied normal to EN 13146-9:2009+ Section 6 To be agreed for specified
stiffness tests the test pad over a specified design load.
(Or agreed equivalent)
temperature range and the
displacement is measured.

Tensile Strength & Ultimate Used as a general measure ASTM D412 250N/m
Elongation Tests (pads only) of the material quality.
(Or agreed equivalent) &
350 percent, minimum.

Accelerated Aging Test Used to forecast the effects EN 13146-6 Test requirements specified
of the environmental should be site-specific and
As a minimum to be
conditions on a pad or based on probable site
augmented based on
grout. conditions.
probable site conditions
To accelerate the effects of
natural aging, materials are
applied many cycles over an
intensive period of time.

Resistance to Ozone To confirm the rate of AS 1683.24 The elastomer shall not
Cracking Test deterioration when exposed exhibit cracking at the end
(Or agreed equivalent)
to naturally occurring levels of a 100-hour exposure
of ozone.
(Or agreed equivalent)
This test can be considered
optional if the supplier can
demonstrate the presence
of antioxidants in the pads.

Determination of resistance To confirm the ability of AS 1683.23 To be agreed.

to liquids pads to withstand exposure
(Or agreed equivalent)
to specified liquids.

Metal Adhesion Test To confirm the strength of AS 1683.24 The elastomer tears before
any elastomer to metal the bond to the metal parts.
(Or agreed equivalent)
bond.
This test is only required
where fastener designs

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NAME DESCRIPTION REFERENCE ACCEPTANCE CRITERIA

include a bond between

metal and elastomer
components.

Flame Spread and Smoke To confirm the ability of AS 1530.3—1989 To be agreed.

Generation Test fastening materials to
Where applicable
ignite, propagate flame;
release heat once ignited
and their tendencies to
release smoke.

Specific Gravity verification Used as a quality control ASTM D297 The specific gravity of the
benchmark for production elastomer shall be
(Or agreed equivalent)
elastomers, requiring the determined. The specific
same specific gravity within gravity of subsequent tests
a fairly small tolerance for shall be+/- 0.02 of the
all produced elastomers. original value.

Table 1: Testing of resilient pads and grouts

NAME DESCRIPTION REFERENCE ACCEPTANCE CRITERIA

Insert Pull-out Test Measures the capacity of AS 1085.18 2003 No evidence of concrete
the Anchor Bolt. cracking or failure of bond
Appendix D
between the bolt, Insert or
Insert’s resistance to being
concrete.
pulled out of the embedding
concrete.

Pull-out Test Measures the capacity of To be agreed No evidence of concrete

the Anchor Bolt Insert to cracking or failure of bond
(Minimum thread)
restrain tensile load of the between the bolt, Insert or
bolt for the manufacturers concrete.
specified minimum thread
engagement.

Torque Test Determines whether the AS 1085.1 2003 No evidence of Insert

Insert is sufficiently rotation, cracking of the
Appendix E
interlocked with the concrete, or any permanent
concrete to prevent rotation deformation at the agreed
under torque. torque.

Table 2: Anchor Assembly Tests

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NAME DESCRIPTION REFERENCE ACCEPTANCE CRITERIA

Vertical Load Test To develop the quasi-static EN 13146-9:2009+A1:2011 Compare results to target
load-deflection curve and design Stiffness value.
Section 7.1
stiffness value for the
assembly.

Vertical Uplift Test Measures the tensile spring AS 1085.19 2003 The assembly clamping
rate of the elastomer and force shall exceed the
Appendix F
the rail clip toe load and the minimum agreed value.
clip’s mounting integrity to
The fastening system shall
the top plate.
support a maximum test
load without failure.

Lateral Load Test Demonstrates the ability of AS 1085.19 2003 After removal of the agreed
the fasteners to resist loading, the difference
Appendix D
lateral loading and retain between the original and
gauge. final positions of the gauge
line shall not exceed 1.5mm.
Fasteners shall not show
any signs of failure or
slippage.

Longitudinal Restraint Test To determine the maximum EN 13146-1:2012 No more than 5mm during
longitudinal force that can the initial 3 min and
Or
be applied to a rail, secured 0.25mm of further
by a Rail Fastening AS 1085.19 2003 movement of the rail during
assembly, without the remainder of the test
Appendix E
displacement of the rail period. (AS only).
occurring.

Electrical Resistance Test To test stray current EN 13146-5:2012 Measured resistance for
mitigation. each test, in ohms
Or
compared to agreed design
AS 1085.19 2003 requirements.
Appendix C

Electrical Impedance Test Determines whether the To be agreed As agreed by the Head of
fastener has sufficient Engineering – Signalling.
impedance for track circuits.

Corrosion Test To determine the EN 13146-6:2012 Part E Change in appearance (if

fastenings’ ability to any) of each component
(Or agreed equivalent)
withstand corrosion and the during test.
effectiveness of any
Any failure to dismantle or
corrosion protection
re-assemble the fastening
treatments.

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 BALLASTLESS TRACK STANDARD

Document Number: A1544 Version: 2.0 Published: 12/03/2024

NAME DESCRIPTION REFERENCE ACCEPTANCE CRITERIA

assembly with the tools

provided.

Vertical and Lateral To model the effect of BS EN 13146- The fastener shall withstand
Repeated Load (fatigue) repeated horizontal and 4:2012+A1:2014 the specified number of
Test vertical loading over the cycles with no evidence of
Or
design life. failure. No component of
AS 1085.19 2003 the fastener shall show any
To represent design life
evidence of failure by
loading and number of Appendix G
slippage, yielding, abrasion,
cycles that will be
fracture, or bond failure.
determined based on a
The rail shall exhibit no
statistical analysis of
evidence of wear that could
predicted traffic loadings,
contribute to failure of a
including excessive loading
rail. The rail clip shall not
from wheel defects.
exhibit any evidence of
vibrating loose from the rail
clip holder.

Repeated Load Test with As above with one bolt As above As above.
One Anchor Bolt Loosened loosened by 5mm for a
reduced no of cycles
(representative of 1 year
service).

Uplift Repeated Load Test To confirm that the fastener As per AS 1085.19 2003 No component of the
assembly has adequate load fastener shall show
Repeated for agreed no of
capacity in an upward evidence of failure by
cycles
direction under repeated yielding, abrasion, slippage
loading. or fracture.

Rail Fastening Stiffness For determining the static EN 13146-9:2009+A1:2011 As agreed.

and dynamic stiffness of the (E) Section 7
Must be with range
Rail Fastening assemblies.
specified by the design.

Table 3: Fastener Assembly Tests

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 BALLASTLESS TRACK STANDARD

Document Number: A1544 Version: 2.0 Published: 12/03/2024

Appendix C – Typical Uses of Ballastless Track

13.1. BLT systems may be used on the MTM network and are commonly used for the following reasons:
a. In new tunnels where BLT may enable a smaller tunnel profile to be used by increasing track fixity and reducing
maintenance tolerance deviation.
b. Where ongoing maintenance requirements are to be minimised or where improved attenuation of noise and
vibration is required.
c. To improve vertical clearances to existing tunnels or overbridges to enable the use of larger rolling stock and/or
increased speeds.
d. On new or existing viaducts, bridges or underpasses with depth constraints or where maintenance of Ballasted
Track is not practicable (subject to loading considerations for existing structures.
e. In locations where is not practicable to maintain Ballasted Track.
f. At other locations where a level of noise and vibration attenuation, greater than that provided by Ballasted Track,
is required.
g. On existing tight radius curves with a history of lateral stability problems or new proposed curves where the risk
of lateral creep or rail buckling requires reduction.
h. Locations where reduced maintenance over the life cycle of the asset is considered essential due to access
limitations or operational criticality.
i. Where required to increase track fixity on steep grades.
j. Where rising grades require the depth from bridge soffit to top of rail needs to be minimised.
k. At passenger station platforms where gaps between train and platform are to be minimised or where the
maintenance intervention tolerances are difficult to maintain.
l. Within Depots or Stabling areas where on-track vehicular access is generally required, or train wash facilities are
located.
m. Where prescribed by MTM’s Chief Engineer as a solution for existing structural clearance infringements.

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