FTN design & development specification (D&D)

SP FTN (D&D) 004

Renovation and Construction of New Cable Route

Issue 9.2, Feb 2009 · FTN D&D specs & typical drawings

Route-works specification for FTN/GSM-R contractors: how to build new lineside cable route (DI-SAC, concrete troughing, elevated route, ducts, manholes, cabinets) and renovate existing troughing. Designers use it to know what the detailed design must specify.

Clause map — what each clause deals with

1	Abbreviations	List of acronyms used in the spec (GLT, DI-SAC, UTX, BOP, etc.).
2	General	Background to the FTN/GSM-R route works, who produces the detailed design, contractor material and Product Acceptance duties, intended route design life.
3	Cable Route	What counts as cable route and the contractor's handover duty for a clean, dressed route.
3.1	General	Types of route covered and the requirement that works follow the detailed design.
4	Contractual Limits of Work	What tendered rates include, site supervision expectations and temporary ownership of the route under handover/handback.
4.1	Renovation of Existing Routes	Pointer to section 8.
4.2	Construction of New Route	Pointer to section 7.
4.3	Route Material Depots	Contractor's responsibilities for depot security, receipt, damage records, stock control and sorting returned materials.
5	Extent of Network Rail's Assistance	What Network Rail provides: liaison representation and drawings.
6	Possession of Running Lines	Possessions are dealt with in the tender documents, not here.
7	Construction of New Cable Route	Main section on building new route of all types.
7.1	General	Siting rules for new route: distance from running rail (table), reduced clearance near structures, concessions, catch points, buffer stops, ballast cleaner access, ramped supports past drains.
7.2	The Extent of the Works	List of work activities included in new route construction: excavation, posts, duct routes, manholes, metalwork, supports, vertical routes.
7.3	Double Insulated Super Armoured Optical Fibre Cable (DI-SAC)	Everything about laying DI-SAC as a surface-secured fibre route: product, securing, interfaces, crossings, hazards, suppliers.
7.3.1	Introduction	What DI-SAC is and where it is approved for use (fibre-only areas).
7.3.2	Product Overview	Cable construction summary and the closure kit used for jointing; jointing instructions are in 005.
7.3.3	Installation	Installation objectives, end sealing, bending radius limit, scratch burying to avoid trip hazards, marking anchor points.
7.3.4	Securing the DI-SAC	Spacing of securing positions on straight and curved track, ground anchor depth and testing, stainless ties, J-hangers at platforms, approval for fixing on structures.
7.3.5	Interfaces with Cable Routes	How DI-SAC enters existing troughing via knockouts or open ends, sill protection, sealing against vermin, anchoring before entry, crossing sidings in GLT.
7.3.6	Interfaces with Bridges and Viaducts	Options for taking DI-SAC across structures and the approval route for fixing methods.
7.3.7	Interfaces with UTX and URX Manholes	Keeping DI-SAC continuous through under-track and under-road crossings without extra joints.
7.3.8	Interfaces with Cable Joint Bays	Joint bay arrangement for a DI-SAC joint (figure) and anchoring either side of the bay.
7.3.9	Sheath Gaps	Why sheath gaps are needed in DI-SAC, where their positions come from, and the trough and anchoring used to house them.
7.3.10	Foot Crossings and Farm Crossings	Using existing ducts or troughing at crossings, or burying DI-SAC in split duct where no capacity exists.
7.3.11	Vehicular Access Points	Burying DI-SAC in twin HDPE ducts at vehicle crossings, with a sealed spare bore and inspection pits.
7.3.12	Creation of Hazards and Obstructions	Keeping DI-SAC clear of SPTs, lineside telephones, cabinets, standing areas and bridge parapets.
7.3.13	DI-SAC Product Supply Details	Supplier contacts for ground anchors and stainless steel ties.
7.3.14	DI-SAC Ancillary Photographs	Photos of a ground anchor and a J-hanger.
7.4	Directly Buried Sub-duct (DBS)	DBS is largely withdrawn; residual rules for vehicle crossings and supplier details for sub-duct, lubricant and pulling grips.
7.4.1	Introduction	Sub-duct no longer used as primary trackside protection except short buried runs.
7.4.2	Occupation Crossings, Foot Crossings and Farm Crossings	DBS not used at these crossings; points to 7.5.1.12.
7.4.3	Vehicular Access Points	Burial depth, allowable deflection and spare sealed duct at vehicle crossings.
7.4.4	Creation of Hazards and Obstructions	DBS must not create hazards or obstructions.
7.4.5	DBS Product Details	Supplier contacts for sub-duct, couplers, lubricant, pulling grips and fused swivels.
7.5	Reinforced Concrete Troughing	Rules for laying concrete GLT, joint bays and node entries.
7.5.1	General	Troughing supply, breakages, machine cutting, lid stagger, set-in height, buried route use, crossings, vandal areas, ballast, traction bonds, route supports.
7.5.2	Joint Bays	Joint bay construction for copper (parallel bays) and fibre (GCO2-F closures, drawings), green zone access, sealing T-pieces.
7.5.3	Cable Route Interface with Nodes	Cable entries into nodes per the detailed design and node entry drawings.
7.6	Elevated Cable Route	When elevated route is used and how it is built.
7.6.1	General	Elevated route only where GLT is unsuitable; materials, storage on site, buried services search before posts.
7.6.2	G.R.C., G.R.P. and U.P.V.C Route Construction	Post setting, bracket height, vertical routes on racking, approvals, non-metallic clamps, lid stagger, vandal banding, metalwork protection.
7.7	Retaining Walls for Joint Bays & Cabinets	Embankment platforms preferred over retaining walls; wall materials and thickness; concrete ballast boards; buried services search.
7.8	Construction of New Manholes	Manhole construction materials and a table of sizes, cover classes and drawings by location.
7.8.1	General	Materials for manholes, acceptance of alternatives, and the location/dimension/class table.
7.8.2	Covers and Frames	Cover and frame standard and the test loads for each class.
7.9	Buried Duct Routes	Requirements for new duct routes in platforms, walkways, public crossings and under track.
7.9.1	Requirements for All Duct Routes (Except DBS)	When new ducts are justified, duct type, UTX warning tape, bedding/backfill drawing, bend limits, mandrel testing, draw rope.
7.9.2	Routes Through Station Platforms	Cover depth, offset from platform edge, reinstatement timescales, manholes at ramp top and toe, spur feeds to buildings, site protection.
7.9.3	Hard Surface Walkway Duct Routes	Cover depth and reinstatement rules for ducts in hard walkways.
7.9.4	Public Crossings	Duct works across public rights of way: statutory requirements and cover depth.
7.9.5	Undertrack Crossings	UTX built to the company standard and drawing; under-track boring needs civil engineer approval.
7.10	Installation of Distribution Cabinets, DSL Repeater Housings and Pole-Mounted Boxes	Free-issued cabinets and BOPs, concrete bases, positioning beside the route, cable entry from below, no drilling, when hard-standing is needed.
7.11	Installation of Plant for GSM-R Tunnel Repeaters	Route, joint bays and closure mounting for tunnel repeater feeds; bend radius control for cables and tubing.
8	Renovation of Existing Cable Routes	Minimum-intervention approach to getting cables into existing troughing and elevated routes.
8.1	General	Prefer tilting the lid to insert cables where route condition allows; lid tilting tool.
8.2	Renovation of Existing Reinforced Concrete Troughing	Full renovation tasks: exposing route, replacing damaged units, imperial to metric swaps, protecting cables, fragile signalling cables, lifting/relaying, realigning, clearing out, manholes, bonds, earth farm tests.
8.2.6	The Lifting and Relaying of Existing Ground Level Concrete Troughing Routes	Preconditions and finish quality for lifting and relaying GLT, protecting cables while out of route.
8.2.7	The Realigning of Existing Ground Level Concrete Troughing Routes	Realignment is defined by survey and design; same protection and finish rules; moving apparatus cases needs approval.
8.2.8	Clearing Out Route	Removing debris, recovering materials, refurbishing UTX/URX, platform routes, supports, ballast boards and retaining walls.
8.2.12	The Renovation of Existing Manholes	What manhole renovation typically covers and when covers and frames get replaced.
8.2.13	The Demolishing and Rebuilding of Existing Manholes	Manholes beyond renovation are rebuilt.
9	Work in Tunnels and Restricted Areas	Civils approval, possessions, materials handling, lighting, limited space, and cable support in tunnels (hangers vs continuous support, DI-SAC on hangers).
10	Timbering	Shoring and support of excavations and when it may be left in place.
11	Anti-Corrosion Protection for Ferrous Metalwork	Galvanising and protective treatment of installed and site-fabricated steelwork.
12	Surplus and / or Scrap Material Recovery and Disposal	Contractor responsibility for surplus, scrap and spoil.
12.1	Disposal of Spoil	Where and how deep clean spoil may be spread on level ground, embankments and cuttings (figures); method statement.
12.2	Waste Water	Mostly removed; contractor to describe waste water and sludge disposal method.
13	Materials Supplied by the Contractor	Pointer to section 2.
14	Materials Supplied by Network Rail	Free-issue schedule available on request.
15	Security and Conduct of Staff on Site	PTS, COSS safe system of work, PPE, keeping walkways clear.
16	Access	Access via private land, notifying access points, fence ladders, fencing, station access.
17	Handling of Materials Containing Asbestos	Approved sub-contractor, notification, disposal as special waste, handback after air monitoring.
18	Buried Services Searches	Follow the company process for locating buried services before breaking ground.
19	Reference Documentation	Table of referenced standards with old and new reference numbers.
20	Definitions	Meaning of route materials, rules of the route, main route and spur route.
App A	Drawings	List of route support, node entry, UTX/URX, retaining wall, staging and crossing drawings referenced in the spec.

Clause map — what each clause deals with

Standards this one points to