Method Statement For ATW of Rail Joints Rev F - Approved ICC 06122021

GOVERNMENT OF MALAYSIA
DESIGN, CONSTRUCTION, SUPPLY, INSTALLATION, COMPLETION,

TESTING, COMMISSIONING AND MAINTENANCE OF
ELECTRIFIED DOUBLE TRACK FROM GEMAS TO JOHOR BAHRU
Contract No.: _____ KP / KEW / 27 / 2016___ ____________
METHOD STATEMENT FOR

ALUMINO THERMIT WELDING
OF RAIL JOINTS
CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW-00001
Rev. F
NOVEMBER 2021
OWNER INDEPENDENT CHECKING

CONSULTANT
Government of Malaysia
Ministry of Transport KL Consult Associates Sdn. Bhd.
DESIGN AND BUILD MALAYSIA ENGINEERING

CONTRACTOR CONSULTANT
CRCC CREC CCCC GCU Consultants Sdn. Bhd.

Consortium Sdn. Bhd. in Association with Bϋro fϋr
Verkehrsingenieurbau GmbH, Berlin
(For Trackwork)
MAIN LOCAL SUB-CONTRACTOR
SIPP-YTL JV
CRCC-CREC-CCCC Design, Construction, Supply, Installation, Completion, Testing, Commissioning
and Maintenance of Electrified Double Track from Gemas to Johor Bahru
CONSORTIUM
SDN. BHD. Method Statement - Alumino Thermit Welding of Rail Joints
Doc No. CRJGR-SIPY-MsT-TWK-So. 0-inK-Am- Date :

Rev. : F Page : 2
0000f I6/11/2021
Document Title:
METHOD STATEMENT FOR
ALUMINO THERMIT WELDING
OF RAIL JOINTS
Submission Record
Revision Date Revision Information
o 01/03/18 New submission.
A 01/06/18 Revised as per commented by KLC (Ref No. : KLC/5055/CCCC/colaC/L037)

B 22/05/20 Revised due to change of standard requirements from As1085.151995 to As1085.20
2012 as er ITP
C 25/06/20 Revised as per commented by KLC

Ref No. : KLC/5055/CCCC/aA/aC/GEN/Log5 dated 23/06/20
Revised Clause 42.5(c) on required welding gas pressure and Clause 4.28 on
D 06/08/21 replacement of failed weld, inserted Clause 4.26(f) on suitable ATW portion type to be
used when connedin rail tints.
E 05/1 012 I Revised according to ICC's comment in letter ref no: KLC/5055/CCCC/ONQC/GEN/Lt48
dated 26" Au ust 2021
F 16/1, /21 Revised according to ICC's comment in letter ref no: KLC/5055/CGCC/aNQCIGEN/Li57
dated I 01h October 2021
CGCCSB IDDC
sin zenni Deputy Construction
Prepared by Signature Date 1611 1/202,
MDhamed Jizi Manager (aAQC)
Contractors Construdion's
Reviewed by Hans Van ECk Deputy Project Manager
Trackwork
Signature 17. Date 1611t/2021
Contractors Consultant's
Verified by
Rabi Kumar
Painini Resident Engineer
Trackwork
Signature \. I,
Date 20/11/2021
Contractors OAQC
Verified by HO Khee Heng Signature Date 22/11/2021
Manager .
,,
Contractors Construction's
Approved by CK Ng Project Manager Signature Date 22/11/2021
Trackwork
ICC
APPROVED Z APPROVED WITH COMMENTS . REJECTED, .

Proceed with the Proceed with the works and to comply (PIs specify) REVISE AND
works RESUBMIT
Reviewed by UTHAYAKUMAR Signature xi, VIA V\,. Date 06,122,
Verified by IR. LOH JOHN KEE Signature Date 06.12,21
IPIease tick the appropriate box)
Page 2 of 20
Design, Construction, Supply, Installation, Completion, Testing, Commissioning
CRCC-CREC-CCCC
CONSORTIUM
SDN. BHD. Method Statement – Alumino Thermit Welding of Rail Joints
Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

Rev. : F Page : 3
00001 16/11/2021
TABLE OF CONTENT
1.0 INTRODUCTION 4
2.0 OBJECTIVE 4
3.0 SCOPE OF WORKS 4
4.0 WORK METHODOLOGY/SEQUENCING 5
5.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENT 15
6.0 PLANT, MACHINERY AND EQUIPMENT 18
7.0 QUALITY ASSURANCE & CONTROL REQUIREMENT 20
8.0 OTHER RELATED DOCUMENTS 20
9.0 APPENDICES 20
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1.0 INTRODUCTION
1.1 This Method Statement (MS) is to elaborate procedures associated with Alumino Thermic
welding for rail joints in respective of Design, Construction, Supply, Installation, Completion,
Testing, Commissioning and Maintenance of Electrified Double Track from Gemas to Johor
Bahru (EDTP Gemas – Johor Bahru). In which procedures stated in this MS shall be adapted
throughout the project implementation and (when required) maintenance of completed double
track lines, until issuance of Certificate of Practical Completion (CPC).
1.2 The Alumino Thermic Welding will be undertaken by qualified welders to maintain the quality of
welding and skilled labourers (assistants) trained in the techniques and appropriate procedures
to carry out the work in an efficient and safe manner.
1.3 This MS has to be read in conjunction with all others relevant project documents and related
method statement. Where information detailed in such documents will not be repeated, except
in any circumstances whereby necessity of additional details or due to specific work procedure
that need to be adapted for execution of activities stated in this MS.
2.0 OBJECTIVE
2.1 As one of the option, laid short rails on practically completed track shall be made into long lengths
and follow with to form continuous welded rail (on track) and also used for turnouts, trap switches
and glued insulated joints as well as replacing defective welds exist on operational railway lines.
Short rails shall not be laid on track and jointed to form long welded rails except for constraint
area that required to utilize short rail (FBW Satellite Depot). Long welded rails shall be form at
FBW Depot only. In which one of method joining these rails are by using Alumino Thermic Welds
with “short pre-heating (SKV). The process whereby mixed of iron oxide, aluminium, ferroalloys,
etc. is ignited in a crucible to turn into yield molten steel. This is poured into a mould enveloping
the rail ends’ gap. Subsequently, the molten steel transform to cooling solidified in the mould,
resulting the two rail ends bounded together.
2.2 The above methodology shall apply for joining rails with different hardness of steel i.e. Normal to
Normal, Normal to Head Hardened and Head Hardened to Head Hardened either it is BS 80A or
54E1 rails respectively which are uses for installation of tracks within the project. Similar
procedures are also to be used during process of rails de-stressing work. This Alumino thermic
welding process conforming to Australian Code AS1085.20 2012 in which the welding work will
be executed by the short preheat SKV-F process using welding portions.
3.0 SCOPE OF WORKS
3.1 This MS will put up validation of recommended Alumino Thermic Welding practices for joining of
rails through specified testing of test samples which are accordingly prepared at the work site.
Each set of test samples shall be depending on Rail Sections, Rail Hardness, combination of
Rail Hardness and Alumino Thermic product manufacturer as well as the batches of product.
3.2 Concurrent with the above, test samples are also to justify for qualification of welders at site prior
to proceeding with routine Alumino Thermic Welding work.
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3.3 The validated practices base on this MS, the certified products and qualified welders are the
conditions to support the execution of routine Alumino Thermic Welding work for required rail
joints at site.
4.0 WORK METHODOLOGY/SEQUENCING
4.1 Prerequisite
4.1.1 The welders employed for this work will have requisite experience in Alumino- Thermic
Welding of which welder shall have Level I Welding Certificate and Welding Supervisors
shall have Level II Welding Certificate. Qualification weld shall be made by each welder
and their tested qualification test records shall be furnished. Then, they are authorized
to carry out welding independently whereby Level I Welding Certificate is authorities to
carry out welding works under supervision of Level II Welding Certificate.
4.1.2 The numbers of test welds to be prepared and type of test to be conducted shall be as
per AS1085.20 2012, Table N-2.
Test as detailed in the AS1085.20 2012 shall be conducted for type testing of welds
manufactured from samples of prototype weld portion.
Apart from type testing, the manufacturer shall carry out routine proof testing on
batches of manufactured weld portions.
4.1.3 Ensure Alumino- Thermic Welding kits are carefully handle and store at dry place.
4.1.4 Routine Alumino Thermic Welding work shall only commence only upon all above tests
are satisfied and obtaining approval to proceed.
4.2 Welding Process
4.2.1 Preparation of the rail ends to be welded
a. Remove fishplates, clamps and required numbers of rail fasteners (installed during
installation of track structure) within both ends of rails to allow for adjustment of
joint’s vertical and horizontal alignment (stated in Clause 4.2.3 below).
b. No rail end will be located nearer than 150mm from the edge of a sleeper. This will
enable ample space for the Alumino Thermic Welding work. Adjusting of the
distance of rail ends will be made by moving the nearest sleepers within the spacing
tolerance and/or cutting of the rail ends.
c. In case of the rail ends are required to be cropped, the cutting shall be done
vertically with a rail saw or abrasive cutting discs such that the rail ends perfectly
cut squared (90º vertical and horizontal of sides and top/underneath of rail) do not
deviate the cut by more than 2mm transversely nor vertically. No gas cutting of rail
is allowed.
d. Welding of the rail string shall not be located closer than 6.0 meters from the center
of shop welds or other joints in the same rail.
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e. Clean both rail ends using steel wire brush or cup brush (adapt to hand-hold grinder
machine). The cleaned area shall extend at least 150mm from rail ends and shall
include the entire rail surface. In case of used rails, where necessary to correct
misshapen of rail head, execute careful grinding to reestablish rail head profile.
f. Clear ballast to allow sufficient room for welding activities within sleepers and
underneath the rails where welding of joints is to be carried out.
g. No welding shall be undertaken if rain is anticipated. In case of rain after welding

has commenced, light-weight hood complete with supports for easy fixing on the
ground must be erected for protection of welds against rain until 30 minutes after
welding completed. It shall be ensured that crucibles, moulds, thimbles, portions
etc, remain dry during the entire operation.
h. In cases where routine Alumino Thermic Welding needs to be carried-out on

operational railway track, it shall be implemented accordingly during pre-arranged
line block. In which all activities are to be exercised in accordance with work on or
near the railway track and procedure stated in MS for Existing Track Condition
Survey, Track Monitoring and Rectification Work (Ref. No:
CRJGR/CCC/SIPY/QA/TWK/MS001)
4.2.2 Ensuring appropriate gap and rail end alignments
a. Carry out adjustment of rails longitudinally to set the spacing between both rails end
to a distance within 24mm to 26mm, concurrently these rail ends shall be roughly
aligned (longitudinally of rails’ top and side). Gap gauge of 25mm +/- 1mm should
be used during these setting.
b. While maintaining the spacing between both rails’ end to a distance within 24mm to
26mm, carry out aligning of rail’s top and side (at rail foot and head) by using 1-
meter straight edge. Refer to diagram in Diagram 4.2.2.b: Finishing Tolerance of a
Welded Joint. Adjustment of these alignments shall be facilitated with numbers of
wedges between sleeper and rail’s beneath (for adjustment of rail’s top) as well as
between sides of rail foot and cast in fastening adaptor or temporarily fix sleeper’s
screw (for adjustment of rail’s sides). Do not remove any in used wedges and these
rails end are secured firmly as to ensure the set alignment is maintained. Keep both
rails undisturbed until completion of welding process, except subsequent activities
that need to be carry out meticulously.
c. Upon completion of the above (as stated in Clause 4.2.2.):
• Execute confirmation of spacing between both rails end using measuring

scale. The spacing shall be within 24mm to 26mm throughout.
• Execute confirmation of alignment of rail’s top using 1-meter straight edge and
“filler gauges’’. Refer to diagram 4.2.2.b.
• Execute confirmation of alignment of rail’s side (at rail head) using 1-meter
straight edge and “filler gauges’’. Refer to diagram 4.2.2.b.
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• Ensure setting of above rails joint is withstanding firmly for subsequent

activities and the set alignments will be disturbed until completion of welding
process (or the weld has accordingly cooled down).
• Remove dust, if any, by air blowing
d. In case of the above (as stated in Clause 4.2.2) compliances are not meet, repeat
activities stated in Clause 4.2.2.a, 4.2.2.b and 4.2.2.c.
4.2.3 Fixing of moulds
a. Only exact set of mould match the rail sections, shall be used.
b. Check each mould form any damages such as fracture/cracks or any incompatibility.
Ensure pouring channels and air vents are clear. Check the mould halves for any
projections against rail surfaces by moving each mould against the rail and where
required, carefully smooth any projections (which causes the mould to not fit the rail
to satisfaction).
c. Using the setting gauge (distance from rail’s end to the fixing position), fix the
universal clamping device onto the rail’s head appropriately upright without tilting.
d. Mould must be in positioned in two fragments, with each one inserted into steel
casing. Place the first (half of) mould on the side of rail (outside of track gauge),
whereby this halve of the mould must be positioned at the center of rails and the
longitudinal center of mould should be at the center of weld gap. Use (initially
installed) universal clamping device to uphold this first half of mould in positioned.
e. Fit the second (half of) mould on the side of the rail (opposite to initially fitted the
first half of mould), check and make it flush with the first (half of) mould. This second
mould also shall be inserted into steel casing.
f. Check fitting at the underside of both moulds and proceed with securing the
universal clamping device assembled to uphold this first and second half of moulds
in position. These clamps must be tightened to satisfaction.
g. Cover the rail head and the weld gap with card board piece to protect any unwanted
fragments fall inside the weld gap.
h. Apply luting sand to seals gaps between each mould casings, between casing and
parts of rails (all surrounds), These seals (with luting sand) must be properly packed
to satisfaction to prevent miss run of liquid weld metal. The luting sand must be
uniformly moist throughout (6%). Luting sand shall be moist but not too wet.
i. Using a torchlight, examine the inside of mould (weld gap) for presence of dust and
luting sand (open up covered boards for this checking). If any, these particles must
be blow out. Luting sand shall not be allowed to drop into the fixed moulds.
j. Fix slag trays at both side of steel casings (where hook is provided) for depositing
of outflow of slag/liquid weld metal. Also place a tray under the whole this welding
setting. Follow with place prefabricated rail head protector on both sides of set
welding moulds.
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k. Carry out final check for the whole set-up to the satisfaction and place “crucible
stand” accordingly as part of universal clamping device.
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Diagram 4.2.2b: Finishing Tolerance of a Welded Joint
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4.2.4 Preparation and Loading of Crucible
a. Ensure the crucible (long life crucible) intended for used is in usable conditions, it
must be cleaned and dried accordingly after every thermit reaction once the
deposited slag has been removed completely from the wall of the lining. Where
required, this crucible shall be pre-heated by very soft burner flame from inside until
the temperature of the outer shell has reached 100C.
b. If welding joints is to be done for many joints repetitively in single operation (after
one to another joint), minimum of two crucibles shall be used alternately to avoid
excessive heating and early start of the reaction.
c. Simulate use of crucible by placing (empty crucible) onto “crucible stand” and swing
this assembly over the fixed moulds. Ensure center of crucible is in-line with center
of the fixed moulds. Where required adjust the bottom of crucible to required height
within 25-30mm from top of the fixed moulds. Once it is acceptable, position the
crucible away over the fixed mould by swinging the “crucible stand”.
d. Execute mixing of Alumino Thermic portions thoroughly in a non-metallic, inert and

dry container. During this mixing dry and clean gloves shall only be used.
e. At any point of time, priority to use the oldest stock of portion is adhered and portion
should not be time expired. Moist portions shall be rejected. They shall not be used
even after drying. The welding portions and luting material shall be used before
expiry of their shelf life.
f. Install automatic thimble and fill the crucible with readily mixed Alumino Thermic
portion (soon after activity stated in Clause 4.2.4.d). Pouring of this portion shall be
carried out carefully to prevent possibility of spill over. Upon completion, place the
cover on top of crucible.
g. Prior to proceeding with subsequent activities, exercise affirmation that all activities
stated in Clause 4.2.1., Clause 4.2.2., Clause 4.2.3. and Clause 4.2.4. are precisely
carried out.
4.2.5 Preheating the rail ends to attain the designed temperature
a. Carry out inspection and checking of the preheating torch intended for use, this is
inclusive of hoses (right from gas cylinders to torch assembly, flashback arrestor
and all its fittings).
b. Tryout to position the torch handle onto bracket provided (as part of universal
clamping device) and the gap of nozzle with rail heads at pre-determined distance.
This ensures rail ends are uniformly preheated throughout with specially designed
gas burner to attain a sufficient temperature and within sufficient time to ensure full
fusion of the joint. The gap between nozzle and rail head shall be recorded for the
purpose of future reference during the next preparation of test samples or routine
Alumino Thermic welding work.
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c. Trial of torch setting (burner flame and gas out flow from nozzle) must be carried
out to satisfaction where pressures for mixture of oxygen (approx. 350kPA and LPG
propane (approx. 100kPA) is set accordingly. The burner flame must never be an
oxidizing flame.
d. Upon completion of the above (stated in Clause 4.2.5.a, and Clause 4.2.5.b.),
execute preheating of rail heads inside the fixed moulds using preset ignited torch
(stated in Clause 4.2.5.c). Make sure this preheating torch flame is central to the
weld gap. Whereby flames should rise from the air vents of the moulds. During this
process of rising of rail ends’ temperature, full removal of moisture that would exist
at the rail ends as well as to ensure “pouring plug” is dry by heating the plug in the
riser flames:
• A stopwatch shall be used for controlling the preheating time.
• Preheating time and temperature shall be defined accordingly based on type of

rails and recommendation of Alumino Thermic product’s manufacture.
• Preheating time recommended by Alumino Thermic product’s manufacture for a

particular production batch shall be used as guideline and validation of this
prescribed time shall depend on the test welds results (for prepared samples as
stated in Clause 4.1.4.). Validated preheat time shall then be put into practice for
all at site routine Alumino Thermic Welding work except when same batch of
tested weld’s portion has exhausted. Norm preheating time used at previous
work site are as tabulated in Fig 4.2.5 d (below)
Rail Sections Time Required (Minutes)

BS 80A 3-4
54E1 5-6
Fig 4.2.5.d: Preheat Time for Different Rail Sections
• Temperature of rail’s head at the end of preheating time shall be affirmed by

means using rail thermometer at appropriate place on rail. Except during
preparation of test welds, one-time calibration of rail temperature versus
preheating time (in a dry mould) shall be exercised. For other welds preheating
shall be governed by preheating time as validated (by results of test samples
execute as stated in above clauses).
e. Terminate preheating process when specified preheating timing come to the end by
detaching and take away the preheating torch from provided bracket (as part of
universal clamping device). Ensure the set-up of moulds are still intact.
4.2.6 Ignition of Thermit Portion
a. Before igniting the mixed Alumino Thermic portions, it shall be seen that the rail
ends are properly heated and the gap has neither reduced nor increased due to
expansion or contraction of rails.
b. On completion of preheating process, fit the moulds plug and swing the crucible
assembly over the center of the fixed moulds.
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c. Immediately ignite the ignition tape lit with preheating torch through top of crucible
cap.
d. Let Alumino Thermic portion inside the crucible set alight and react by itself.
Observe the automatic thimble allowing yield molten steel filling the moulds via the
pouring plug. The crucible shall remain in positioned centrally over the weld gap and
shall not move during the reaction. Follow with spillover of the lighter molten slag
into the slag pans provided (at sides of fixed moulds).
e. Let the process stated in Clause 4.2.6.d. be completed and reserve 3-4 minutes for
cooling of molten steel.
f. Ensure the usage of appropriate portion type during the Alumino Thermit Welding
process where:
• Type Z90 portion is to be used at joints between both R260 Rails.
• Type Z110 portion is to be used at joints between both R350HT Rails
• The lowest of portion or Type Z90 portion is to be used at combination joints

between a R260 Rail and a R350HT Rail.
Sample of portion types are shown in Figure 4.2.6.f below.
Figure 4.2.6.f: Type of Weld Portion Type Z110 (Left) & Type 90 (Right).
4.2.7 Removal of Moulds and Accessories
a. Remove used crucible and place them at designated location as hot parts may
cause harm to workers working nearby, this may also cause fire. The crucible shall
be kept for subsequent use.
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b. Take away slag pans from each side of moulds and remove all deposited slag.
These slag pans are to be kept at designated place/storage for subsequent use.
c. Remove universal clamping device and other fixed accessories followed with mould
casing removal.
d. Carefully break up top part of mould (filled with solidified metal) using hammer and
ballast fork. Then, use hydraulic shears to remove remains of moulds (filled with
solidified metal) from rail head and its sides.
e. Also remove metal risers protruding from the foot of the rail (solidified metal formed
within air vents) by striking inwards and towards the rail head. Alternatively, a hot
set chisel and hammer may be used for removal of remaining unwanted metal.
f. Remove tray initially placed underneath the moulds (as stated in Clause 4.2.3.j.)
g. Proceed with rough grinding to remove weld protruding parts until it is almost flushed
with existing rails’ top and gauge side.
h. After completion of rough grinding, execute removal of left over mould on sides and
underneath of rail joint. This removal may be carried out by using chisel and hammer
follow with wire brush.
i. As the temperature of rail joint cools, remove all wedges which were installed during
setting of rail joint’s alignment (as stated in Clause 4.2.2.) and carry out resetting of
rail onto sleepers (inclusive of cleaning of rail sit, placing of rubber pad, securing of
fastenings and other associated activities as required). Check the alignment of track
structure and track geometry for necessary rectifications.
j. No train movement shall be allowed on the weld until its trimming is complete and
the weld has cooled sufficiently or 30 minutes has elapsed since the completion of
infill of molten steel into moulds, whichever is later. After weld has cooled until final
profile grinding is complete, the track shall be released for train operation with
speeds restriction of 15kmph with the presence of lookout man /patrolman.
k. Check flatness of rail top and side of rail head at gauge face (using 1meter straight
edge and filler gap scale) and execute final grinding of uneven spots, to attain
following tolerances:
• The dimensional and alignment tolerances shall be under:
Deviations from Straight on 1-m Straight Edge

Any deviation from straight after profile grinding shall not exceed the following
limits:
Vertical at Head (-) 0 to (+) 0.3 mm
Horizontal at Head (-) 0.5 to (+) 0.5 mm
No dip weld permitted for both tolerances.
Table 4.2.7.j: Limit of deviations from straight on 1-m Straight Edge

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• The alignment of the finished joint shall be measured with the rail at ambient
temperature. The vertical alignment of the weld shall be measured on the
running surface at the center-line of the weld relative to datum points on the rail
500mm either side of the weld. The horizontal head alignment shall be measured
similarly on gauge face.
• Flatness of The Joint
Surface flatness across the weld shall be measured using a 200mm straight
edge. The maximum gap between the straight edge and the profiled rail surface
shall be 0.15mm on the running surface and gauge face. Limit of the grinding
length from the joint shall be within 450mm.
• Maintaining Rail Head Profile
Apart from meeting the requirement of finishing tolerances, final grinding shall
ensure smooth profile of rail head (Top and both sides)
4.2.8 Replacement of Failed Welds
a. All failed welds shall be cut and removed including the heat affected zone, which is
not less than 100mm on each side of the weld, and the rails, wherever feasible, to
be re-welded by pulling the adjacent panel. Alternatively, plug rail of not less than 6
meters length is to be inserted accordingly (where failed weld and heat affected
zone are taken away). Where by activities stated in Clause 4.2.1. to 4.2.7. will be
executed accordingly.
4.2.9 Tests to Finish Weld
a. Prior commencement of routine Alumino Thermic welding work, samples of rail

joints shall be prepared in accordance with type of rail need to be joined i.e. Normal
to Normal, Normal to Head hardened and Head hardened to Head hardened which
are also subjected to type of rail. These samples shall be tested to meet the
requirements stated in Clause 4.1.4.
b. During routine Alumino Thermic welding work, samples of rail joint shall be randomly
produces when required for testing. These samples shall be tested to meet the
requirements stated in Clause 4.1.4.
c. All required tests or Quality Assurance and control procedures shall be in

accordance with Clause 7.0 of this MS.
d. All joints shall be ultrasonically tested as per approved method statement which will
be submitted separately.
e. Complete quality control inspection checklist will be fill in Alumino Thermit Welding
- Production Test Certificate. (refer to approved ITP Manual- checklist form)
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4.2.10 Weld Numbering System
a. The numbering system of joint welds in temporary track diversions (TTD) shall follow
TTD starting chainage. Odd number shall be used for left hand and even number
for right hand joints. For example, if weld starts at Ch. ‘X’ the numbering will be
X/AT/1/ indicates first weld in the left-hand side.
b. The numbering system of turnout joint welds at permanent line shall display Turnout
ID at the field side of the stock rail. For instance, if turnout ID stated as GEN01, the
running number will be GEN01/ N-H, H-H, H-N/ 001/ DDMMYY.
c. The replacement weld number will carry the prefix F. Example F/X/TY/1.
Replacement of one weld by two welds will carry both prefix and suffix as follows:
F/X/TY/1A and Turnout ID/ N-H, H-H, H-N/ 001A/ DDMMYY.
d. The weld numbers shall be painted at the web of the rail near the weld on the non-
gauge side. The painting of ATW & FBW Weld numbers to be clear & visible until
the defect liability period. The numbering system will have records of the acceptance
of the weld and re-weld details if carry out.
e. Register all completed welding in a Alumino Thermit Welding Weld Monitoring Data
Base form. (refer to approved ITP Manual- checklist form).
f. If a weld failed, the re-weld shall be given a unique number. This will ensure that
the weld is subjected to a retest. The results of retests of repair welds shall be
identified and recorded. A table showing each weld number with related PTC shall
be maintained, to facilitate easy retrieval of date
5.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENT
5.1 Health and Safety Requirement
5.1.1 All applicable statutory requirements/standards shall be adhered to at all time, including
but not limited to:
• Land Public Transport Act 2010

• KTMB General Rules and Regulations
• Local Government Act 1976 (Act 127)
• Occupational Safety & Health Act 1994 (Act 514)
• Factories and Machinery Act 1967 (Act 139)
• Construction Industry Development Board Act 1994 (Act 520)
• Approved (Project Health and Safety Plan, PHSP), which include Hazard
Identification Risk Assessment and Determination Control (HIRADC)
Page 15 of 20
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5.1.2 Training
TRAINING PERSONNEL
CIDB course All personnel
Contractor’s Safety Induction All personnel
KTMB 038 course All personnel working within ROW
KTMB 039 course Person In Charge of Work (PICOW)
KTMB 040 course Look out / Flagman
First Aid (basic) Supervisors, engineers and dedicated staff
Welding Competency (Level 1) Welders
Welding Competency (Level 2) Welding Supervisor
5.1.3 Apparel
• High visibility vest (orange colour)

• Safety helmet
• Safety boots
• Safety gloves
• Safety goggle
• Dusk masks
• Ear plug/ear muffs
• Welding helmet
• Fire/ flame resistance clothing and aprons
5.1.4 Permits, Isolation, Possession
• Isolation required
• Possession required
• Hot working permit
• Night time working
5.1.5 Risk Assessment
• The safety and health specific hazard, risk, potential significant impact, proposed
control measures, potential emergencies, related legal applicability and
responsible parties are tabulated in the Hazard Identification Risk Assessment and
Determination Control (HIRADC) as tabled in Appendix A.
5.1.6 Communication
• Safety and Environmental key personnel

• Site Engineers
• Mobile phone or radio shall be used for communication.
• Emergency contact numbers shall be displayed at prominent locations
Page 16 of 20
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00001 16/11/2021
5.1.7 Safety Briefing
• Prior to commencement of the works, a Kick off Meeting with Safety & Health will
be held to implement and audit the safety requirements at site.
• Regular safety & tool box briefings will be conducted for the workers on site to
ensure compliance to safety requirements.
• Wherever required, prior to commencement of the work described in this a Job
Safety Analysis will be conducted in accordance with the requirements of the
Project Safety and Health Plan.
5.1.8 Additional precautions while Line Site Working.
• Ensure that PICOW/Lookout man is appropriately assigned when doing LSW (Line
Side Works)
• All PICOW involved must attend the LSW briefing conducted by contractor.
• PWI/Track superintendent/ Site Supervisor/PICOW to check site condition before
commencement of work.
• All Plant and Machinery used on site must have prior visual inspection by HSE
Department with sticker intact.
• All operators are to update and conduct a pre-start check list of plant and
Machinery.
• To ensure close supervision of truck and vehicle movements at all times and when
working in close proximity to OCS masts.
• To ensure close supervision of all lifting and slewing operations at all times and
when working in close proximity to OCS masts, underneath the OCS and adjacent
to the life track.
• All Plant and Machinery on the formation will be supervised by 1 no. Lookout man.
The Lookout man will warn the operator as a train approached on the adjacent live
track and all activities will be stopped.
• To create safe working area delineators will be placed at 2.25 meter adjacent to
the life track.
5.2 Environmental Requirement
5.2.1 All applicable statutory requirements/standards shall be adhered to at all time, including
but not limited to:
• Environmental Quality Act 1974 (Act 127)

• Approved EMP
• Approved EMS Manual, which include EAI
• Approved ESCP
5.2.2 All personnel in this scope of work shall place the highest importance on protection of
the environmental and will become familiar and comply with all environmental laws and
regulations issued by the client, government, local authority or any other duly appointed
authority having jurisdiction over the work site. In this regard, the following steps among
others shall be taken within the works limits:
• No hazardous, unsafe, unhealthy or environmentally unsound condition or activity

shall be permitted on work site.
Page 17 of 20
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• The transportation of materials and plants shall be arranged so as to cause

minimum damage to existing road, vegetation and minimum inconvenience to the
public.
• Any rubbish, debris or materials shall not be left on any road, street, pavement or
footway and need to be cleared timely so as not to cause hindrance or obstruction
to vehicles or pedestrians.
• Every effort has to be taken to minimize the noise to the nearby residential area
especially when night shift is ongoing.
6.0 PLANT, MACHINERY AND EQUIPMENT
6.1 Quantities for one welding team shall be as below,
Nos Spare
Part No. Description
Required Required
E001 Adjustable Preheater Support 1 -
E002G Universal Rail Clamp 1 -
E003 Crucible Stand 1 -
E004 Crucible Cap 1 -
E004SP Crucible Cap W/Spatter Skirt 1 -
E006 Crucible Top 1 -
E006SP Crucible Top With Extension Ring 1 1
E010 Slag Pot 2 1
E012G Thimble Drift 1 -
E037 Gap Setting Gauge – 25Mm 1 -
E015 Hot Set Head 2 1
E016 Hot Set Handle 2 1
E017A Straight Edge With Cut Out 1 -
E018 Tommy Bar 1 -
E019 Wedge 18 -
E20 Rail Thermometer – Magnetic 1 -
E036 Oxy – Propane/Lpg Preheating Assembly 1 -
E022 Rail Protection Cover – Large 1 -
E023 Rail Protection Cover - Small 1 -
E027G Thimble Appplicator 1 -
E02B Crusible Adaptor Ring 1 -
E039 Tongs 1 -
E035-1U Mould Protectors 80A SKV-F 2P 1 1
Table 6.1: SKV - F Equipment Set
Page 18 of 20
CRCC-CREC-CCCC
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00001 16/11/2021
Nos Spare
Required Required
E104 Check Gauge 800 –Kpa (Oxygen) 2 2
E104-1 Check Gauge 250 – Kpa (Propane/Lpg) 2 2
E105 Comet 3 Handpiece 1 -
E106 13mm Dia Oxy – Propane/Lpg Mixer 1 1
E107 Comet 3 Cutting Attachment 1 -
E108 Tip Cleaners 1 -
E102O Oxy Hose 10mm Id x 20m Long C/W Fitting 1 -
Propane/Lpg Hose 10mm Id x 20m Long C/W
E102P 1 -
Fittings
E109 Hose Clips (Packet Of 5) 4 -
E110 Cutting Nozzle Type 44, Size 20 2 -
E115 Dual – Stage Oxy Regulator 1 1
E116 Lpg Regulator (Gascon Highflow) 1 1
E131 Flash Back Arrestor – Oxygen 1 1
E131-1 Flash Back Arrestor - Propane/Lpg 1 1
Edgn- O&F Ibeda Flash Back Arrestor Set (Oxy & Lpg) 1 1
Table 6.2: Boc Gas Equipment Set (For 1 Welding Team)
Nos Spare
Required Required
E141 Hydraulic Rail Shear C/W Handpump
And Shear Blades
E150 Rail Grinder
E155 Rail Saw
Torch Light
Timer (Stop Watch)
Feeler Gauge
Mirror
Light Weight Hood
Table 6.3: Auxiliary Equipment (For 1 Welding Team)
Me07 Grinding Wheels

E155-1 Rail Saw Cutting Disc
Table 6.4: Consumables
Page 19 of 20
CRCC-CREC-CCCC
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00001 16/11/2021
7.0 QUALITY ASSURANCE & CONTROL REQUIREMENT
a. Quality Assurance and Control procedure shall follow the procedure laid down in this method
statement with: -
• Project Quality Plan

• Inspection Test Plan
• Request for Inspection (RFI)
• Quality Control Inspection Checklist
8.0 OTHER RELATED DOCUMENTS
a. Construction drawings, including Location Plan & Detail Drawings (Refer to approved
construction drawings)
b. Permit to work forms (Refer to approved HS Plan)
c. Contractor’s Construction Railway Operations Procedure (CRO)
d. KTMB Permanent Way Manual
e. KTMB Rules and regulations
f. KTMB Red Book
g. FMA 1967
9.0 APPENDICES
A. Hazard Identification, Risk Assessment and Risk Control (HIRARC)

B. Environmental Log Report
C. Manufacturer’s Recommendation Values
Page 20 of 20
APPENDIX C :-
MANUFACTURER’S RECOMMENDATION VALUES
WELD DATA SHEET
54E1 SKV-F
© 2020 Thermit Australia Pty Ltd | TEC_2021.01.27 Weld Data Sheet 54E1 SkV-F Oxygen and Propane
GAS PRESSURES
PREHEAT TORCH MOULD CROWN
WELDING RAIL TIME GAP SIZE HEIGHT OXYGEN PROPANE REMOVAL GAP
PROCESS SIZE [MINUTES] [MM] [MM] [KPA] [KPA] [MINUTES] [MM] TORCH TYPE
3 Rows
SkV-F 54E1 5.5-6.0 24-26 40 350 100 5 1.5 - 2
(32 holes)
Disclaimer: Welding information on this sheet should only be used when using THERMIT AUSTRALIA materials and
equipment exclusively. Parameters are to be reviewed as soon as possible.
Thermit Australia Pty Ltd, 170 Somersby Falls Rd, Somersby NSW 2250, Australia
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
www.goldschmidt.com
WE ARE GOLDSCHMIDT
……………………………………………………………
THERMIT AUSTRALIA PTY LTD
is part of the Goldschmidt Group.
ASIA COMMUNICATION & ELECTRONIC SDN BHD
PROJECT: EDTP GEMAS JOHOR BAHRU
Subject: Recommendation of Portion Grade
To Whom it may concern.
Prior to the beginning of flame cutting and welding work, the steel grade shall
be determined according to the rolling mark.
If different welding grades are welded to each other, the THERMIT portion shall
be used according to the steel grade with the lower hardness.
Therefore, when A R260 rail and R350HT rail welded together, Z90 portion is
recommended.
Kind Regards
Danny Austine
Technical Services Manager

Method Statement For ATW of Rail Joints Rev F - Approved ICC 06122021

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Method Statement For ATW of Rail Joints Rev F - Approved ICC 06122021

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GOVERNMENT OF MALAYSIA

DESIGN, CONSTRUCTION, SUPPLY, INSTALLATION, COMPLETION,

METHOD STATEMENT FOR

OWNER INDEPENDENT CHECKING

DESIGN AND BUILD MALAYSIA ENGINEERING

CRCC CREC CCCC GCU Consultants Sdn. Bhd.

Doc No. CRJGR-SIPY-MsT-TWK-So. 0-inK-Am- Date :

Revision Date Revision Information

o 01/03/18 New submission.

A 01/06/18 Revised as per commented by KLC (Ref No. : KLC/5055/CCCC/colaC/L037)

C 25/06/20 Revised as per commented by KLC

APPROVED Z APPROVED WITH COMMENTS . REJECTED, .

Reviewed by UTHAYAKUMAR Signature xi, VIA V\,. Date 06,122,

Verified by IR. LOH JOHN KEE Signature Date 06.12,21

IPIease tick the appropriate box)

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

3.0 SCOPE OF WORKS

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

4.0 WORK METHODOLOGY/SEQUENCING

4.2 Welding Process

4.2.1 Preparation of the rail ends to be welded

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

g. No welding shall be undertaken if rain is anticipated. In case of rain after welding

h. In cases where routine Alumino Thermic Welding needs to be carried-out on

4.2.2 Ensuring appropriate gap and rail end alignments

c. Upon completion of the above (as stated in Clause 4.2.2.):

• Execute confirmation of spacing between both rails end using measuring

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

• Ensure setting of above rails joint is withstanding firmly for subsequent

• Remove dust, if any, by air blowing

4.2.3 Fixing of moulds

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

Diagram 4.2.2b: Finishing Tolerance of a Welded Joint

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

4.2.4 Preparation and Loading of Crucible

d. Execute mixing of Alumino Thermic portions thoroughly in a non-metallic, inert and

4.2.5 Preheating the rail ends to attain the designed temperature

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

• A stopwatch shall be used for controlling the preheating time.

• Preheating time and temperature shall be defined accordingly based on type of

• Preheating time recommended by Alumino Thermic product’s manufacture for a

Rail Sections Time Required (Minutes)

• Temperature of rail’s head at the end of preheating time shall be affirmed by

4.2.6 Ignition of Thermit Portion

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

• Type Z90 portion is to be used at joints between both R260 Rails.

• Type Z110 portion is to be used at joints between both R350HT Rails

• The lowest of portion or Type Z90 portion is to be used at combination joints

Sample of portion types are shown in Figure 4.2.6.f below.

4.2.7 Removal of Moulds and Accessories

Doc No. CRJGR-SIPY-MST-TWK-S0.0-TWK-ATW- Date :

• The dimensional and alignment tolerances shall be under:

Deviations from Straight on 1-m Straight Edge

Vertical at Head (-) 0 to (+) 0.3 mm

Horizontal at Head (-) 0.5 to (+) 0.5 mm

No dip weld permitted for both tolerances.