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Technical Note - TN 042: 2017

For queries regarding this document


standards@transport.nsw.gov.au
www.asa.transport.nsw.gov.au

Technical Note - TN 042: 2017


Issued date: 17 October 2017

Effective date: 17 October 2017

Subject: Changes to durability requirements arising from


the publication of T HR CI 12002 ST Durability
Requirements for Civil Infrastructure
This technical note is issued by the Asset Standards Authority (ASA) to notify that the durability
requirements for civil infrastructure contained in the following documents have been superseded.

• ESC 310 Underbridges

• ESC 340 Tunnels

• T HR CI 12030 ST Overbridges and Footbridges

• T HR CI 12040 ST Overhead Wiring Structures and Signal Gantries

• T HR CI 12060 ST Retaining Walls

• T HR CI 12065 ST Station Platforms

• T HR CI 12070 ST Miscellaneous Structures

• T HR CI 12072 ST Track Slabs

• T HR CI 12130 MA Track Drainage

• T HR CI 12130 ST Track Drainage

Durability requirements are now contained in T HR CI 12002 ST Durability Requirements for Civil
Infrastructure.

© State of NSW through Transport for NSW 2017 Page 1 of 2


Technical Note - TN 042: 2017

Authorisation:
Technical content Checked and Interdisciplinary Authorised for
prepared by approved by coordination release
checked by
Signature

Date
Name Richard Hitch Richard Hitch Jason R Gordon Jagath Peiris
Position Lead Civil Engineer Lead Civil Engineer Chief Engineer Director
Network Standards
and Services

© State of NSW through Transport for NSW 2017 Page 2 of 2


Technical Note - TN 082: 2016

For queries regarding this document


standards@transport.nsw.gov.au
www.asa.transport.nsw.gov.au

Technical Note - TN 082: 2016


Issued date: 21 December 2016

Subject: Revised reference to risk criteria


This technical note has been issued by the Asset Standards Authority (ASA) to notify the
following.

• The risk criteria to be used by the Authorised Engineering Organisations (AEOs) providing
engineering services to TfNSW are contained in T MU MD 20002 ST Risk Criteria for
Organisations Providing Engineering Services, version 1.0.

• 30-ST-164 TfNSW Enterprise Risk Management (TERM) Standard provides the risk criteria
to be used by TfNSW.

• All references to the TERM standard in this document, where applicable to AEOs, shall read
as T MU MD 20002 ST.

Authorisation:
Technical content Checked and Interdisciplinary Authorised for
prepared by approved by coordination release
checked by
Signature

Date
Name Richard Adams Andy Tankard Andy Tankard Graham Bradshaw
Position Manager Safety and Principal Manager Principal Manager Director
Risk Assurance SQER SQER Network Standards
and Services

© State of NSW through Transport for NSW Page 1 of 1


T HR CI 12040 ST

Standard

Overhead Wiring Structures and


Signal Gantries

Version 1.0
Issued date: 30 June 2016

Important Warning

This document is one of a set of standards developed solely and specifically for use on Transport Assets (as defined in the Asset
Standards Authority Charter). It is not suitable for any other purpose.

You must not use or adapt it or rely upon it in any way unless you are authorised in writing to do so by a relevant NSW Government
agency. If this document forms part of a contract with, or is a condition of approval by a NSW Government agency, use of the document
is subject to the terms of the contract or approval.

This document is uncontrolled when printed or downloaded. Users should exercise their own skill and care in the use of the document.

This document may not be current. Current standards may be accessed from the Asset Standards Authority website at
www.asa.transport.nsw.gov.au.

© State of NSW through Transport for NSW


T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

Standard governance
Owner: Lead Civil Engineer, Asset Standards Authority
Authoriser: Chief Engineer, Asset Standards Authority
Approver: Executive Director, Asset Standards Authority on behalf of the ASA Configuration Control
Board

Document history
Version Summary of changes
1.0 First issue

For queries regarding this document,


please email the ASA at
standards@transport.nsw.gov.au
or visit www.asa.transport.nsw.gov.au

© State of NSW through Transport for NSW


T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

Preface
The Asset Standards Authority (ASA) is an independent unit within Transport for NSW (TfNSW)
and is the network design and standards authority for defined NSW transport assets.

The ASA is responsible for developing engineering governance frameworks to support industry
delivery in the assurance of design, safety, integrity, construction, and commissioning of
transport assets for the whole asset life cycle. In order to achieve this, the ASA effectively
discharges obligations as the authority for various technical, process, and planning matters
across the asset life cycle.

The ASA collaborates with industry using stakeholder engagement activities to assist in
achieving its mission. These activities help align the ASA to broader government expectations
of making it clearer, simpler, and more attractive to do business within the NSW transport
industry, allowing the supply chain to deliver safe, efficient, and competent transport services.

The ASA develops, maintains, controls, and publishes a suite of standards and other
documentation for transport assets of TfNSW. Further, the ASA ensures that these standards
are performance-based to create opportunities for innovation and improve access to a broader
competitive supply chain.

This standard details the whole of life civil and structural requirements for overhead wiring
structures (OHWS) and signal gantries on the TfNSW heavy rail network.

This standard has been developed from RailCorp standard ESC 330 Overhead Wiring
Structures and Signal Gantries Version 2.4. This standard is approved by the ASA
Configuration Control Board and is a first issue.

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

Table of contents
1. Introduction .............................................................................................................................................. 6
2. Purpose .................................................................................................................................................... 6
2.1. Scope ..................................................................................................................................................... 6
2.2. Application ............................................................................................................................................. 6
3. Reference documents ............................................................................................................................. 7
4. Terms and definitions ............................................................................................................................. 8
5. Safety requirements ................................................................................................................................ 9
6. Environment and sustainability ........................................................................................................... 10
7. Heritage .................................................................................................................................................. 11
8. Structure configuration requirements ................................................................................................. 11
9. Standard structures .............................................................................................................................. 12
10. Design criteria ........................................................................................................................................ 13
10.1. Design standards ............................................................................................................................. 13
10.2. Design life ........................................................................................................................................ 14
10.3. Design responsibility ........................................................................................................................ 14
11. OHWS – structural design actions....................................................................................................... 15
11.1. OHWS permanent actions ............................................................................................................... 15
11.2. OHWS imposed actions ................................................................................................................... 16
11.3. OHWS wind actions ......................................................................................................................... 16
11.4. OHWS deflection limits .................................................................................................................... 16
12. Signal gantry – structural design actions ........................................................................................... 17
12.1. Signal gantry permanent actions ..................................................................................................... 17
12.2. Signal gantry imposed actions ......................................................................................................... 17
12.3. Signal gantry wind actions ............................................................................................................... 17
12.4. Signal gantry deflection limits .......................................................................................................... 18
13. OHWS – anchor structures ................................................................................................................... 18
14. Footings.................................................................................................................................................. 19
14.1. Standard structure footings.............................................................................................................. 19
14.2. Standard guy footings ...................................................................................................................... 20
14.3. Site specific footings ........................................................................................................................ 21
15. Clearances.............................................................................................................................................. 22
16. Attaching to civil infrastructure ........................................................................................................... 22
16.1. Chemical anchors ............................................................................................................................ 23
17. Electrical earthing and bonding ........................................................................................................... 23
18. Galvanising ............................................................................................................................................ 23
19. Approved materials ............................................................................................................................... 23
20. Drawing standards ................................................................................................................................ 24

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

21. Existing structures ................................................................................................................................ 25


21.1. Assessment of existing OHWS for reuse ........................................................................................ 25
22. Construction .......................................................................................................................................... 26
23. Maintenance ........................................................................................................................................... 27
24. Decommissioning and disposal........................................................................................................... 27
Appendix A Standard OHWS and signal gantry drawings ................................................................. 29

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

1. Introduction
Electric trains on the TfNSW heavy rail network operate on 1500 V dc power. These trains
obtain their power for traction from overhead wiring (OHW) and associated equipment.
Overhead wiring structures (OHWSs) are provided to support the OHW electrical system.

Signal gantries are structures over tracks that support signal equipment at specific locations.

2. Purpose
This document specifies the design, refurbishment, construction, maintenance and
decommissioning and disposal requirements for OHWSs and signal gantries on the TfNSW
heavy rail network and supplements relevant Australian Standards by providing specific TfNSW
requirements. These specific requirements include loading, deflection limits, design life,
materials, documentation and standard drawings for the structures and the foundations.

2.1. Scope
This standard sets out the civil and structural requirements for the life cycle of TfNSW heavy rail
OHWSs and signal gantries from design through to decommissioning for the following:

• new OHWSs (including electrical feeder structures and anchor structures)

• new signal gantries

• refurbishment of existing OHWSs and signal gantries

• assessment of existing OHWSs for reuse

Aspects of safety, environmental, sustainability, heritage and configuration across the asset life
cycle are also included. This document does not cover requirements for other engineering
disciplines such as electrical and signals (including associated fittings and equipment).

This standard does not cover timber pole OHWSs.

2.2. Application
This standard is intended for use by competent personnel engaged in the provision of services
relating to rail infrastructure.

Compliance with the requirements in this standard will not, by itself, be sufficient to ensure that
satisfactory outcomes will be produced. Personnel providing services based on this standard
need to bring appropriate expertise to the matters under consideration.

In addition to the requirements of this standard, asset decisions take into account the life cycle
cost considerations specified in T MU AM 01001 ST Life Cycle Costing.

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

If, when using the standard, it is considered that the intent of stated requirements is not clear, a
clarification should be sought from the ASA.

This standard should be read in conjunction with TMC 331 Design of Overhead Wiring
Structures and Signal Gantries.

3. Reference documents
The following documents are cited in the text. For dated references, only the cited edition
applies. For undated references, the latest edition of the referenced document applies.

Australian standards

AS 1657 Fixed platforms, walkways, stairway and ladders – Design, construction and
installation

AS 2159 Piling – Design and installation

AS 3600 Concrete structures

AS 4100 Steel structures

AS/NZS 1170 Structural design actions

AS/NZS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles

Transport for NSW standards

30-ST-164 TfNSW Enterprise Risk Management (TERM) Standard (available on request from
ASA by requesting in writing to ASARisk@transport.nsw.gov.au)

EP 08 00 00 01 SP Overhead Wiring Standards for Electrification of New Routes

EP 12 10 00 13 SP 1500 V Traction System Earthing

EP 12 20 00 01 SP Bonding of Overhead Wiring Structures to Rail

ESC 100 Civil Technical Maintenance Plan

ESC 215 Transit Space

ESC 300 Structures System

ESC 302 Structures Defect Limits

ESC 310 Underbridges

ESC 340 Tunnels

SPC 301 Structures Construction

SPG 0705 Construction of Cable Routes and Signalling Civil Works

SPG 0706 Installation of Trackside Equipment

T HR CI 12030 ST Overbridges and Footbridges


© State of NSW through Transport for NSW Page 7 of 30
T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

T HR CI 12060 ST Retaining Walls

T HR CI 12065 ST Station Platforms

T HR CI 12075 ST Airspace Developments

T HR EL 08001 ST Safety Screens and Barriers for 1500 V OHW Equipment

T HR EL 08009 ST Designations of Overhead Wiring Conductor Systems

T HR EL 12002 GU Electrolysis from Stray DC Current

TMC 331 Design of Overhead Wiring Structures & Signal Gantries

T MU AM 01001 ST Life Cycle Costing

T MU AM 01003 ST Development of Technical Maintenance Plans

T MU HF 00001 ST Human Factors Integration - General Requirements

T MU MD 00006 ST Engineering Drawings and CAD Requirements

TS 20001 System Safety Standard for New or Altered Assets

Legislation

Heritage Act 1977

Work Health and Safety Act 2011

Other references

Office of Environment and Heritage January 2005, State Agency Heritage Guide – Management
of Heritage Assets by NSW Government Agencies, publication number HO05/01

NSW State Heritage Register

NSW Sustainable Design Guidelines

RailSafe website – railsafe.org.au

TfNSW Section 170 Heritage and Conservation Register

WorkCover NSW Safe design of structures code of practice

4. Terms and definitions


The following terms and definitions apply in this document:

AEO Authorised Engineering Organisation; means a legal entity (which may include a Transport
Agency as applicable) to whom the ASA has issued an ASA Authorisation

ASA Asset Standards Authority

CAD computer-aided design

Central Planroom the physical location where drawing information is stored and managed

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Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

loading diagram is design documentation produced by the OHW electrical design engineer
that contains OHW loading information for each OHWS location.

OHW overhead wiring

OHWS overhead wiring structure provides support for the traction OHW and associated
electrical components. It can comprise portal, cantilever, mast, special tunnel structures and
other variations and can include associated electrical feeder and access structures

RIM rail infrastructure manager; in relation to rail infrastructure of a railway, means the person
who has effective control and management of the rail infrastructure, whether or not the person-

(a) owns the rail infrastructure, or

(b) has a statutory or contractual right to use the rail infrastructure or to control, or provide,
access to it

signal gantry a structure spanning tracks that provides support and access to signal
equipment. It can comprise portal and cantilever structures and other variations.

structure diagram civil design documentation that conveys the design intent and relevant
information to the construction phase of the project for each OHWS location. One or more
structure diagrams may be placed on a structure diagram drawing.

TfNSW Transport for NSW

Other terms and definitions associated with OHW and signal gantry design are provided in
TMC 331, AS 1170 Structural design actions and AS 4100 Steel structures.

5. Safety requirements
Safe design is mandated in the Work Health and Safety Act 2011 and shall be incorporated into
the design. Guidance on the safe design of structures can be found in the WorkCover NSW
Safe design of structures code of practice.

The AEO shall establish and implement a design process system that manages safety
assurance across the full life cycle of the infrastructure. The design process system shall be
developed in accordance with TS 20001 System Safety Standard for New or Altered Assets.

The design of OHWSs and signal gantries, including the refurbishment of existing structures,
shall take into account safety considerations for construction, operational, maintenance and
decommissioning workers and the potential users of the structure.

Weight tensioner arrangements are commonly installed to maintain constant tension in the
OHW. These weights can create an unsafe situation for infrastructure workers at locations such
as around flyovers, above elevated tracks or near to retaining walls and the like. When these
weight tensioners cannot be relocated, appropriate protection such as safety cages or barrier
fences shall be provided around the weight system to protect personnel.

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

The design of OHWSs and signal gantries shall also provide safe access for inspection and
maintenance activities where required. This can include items such as access steps, ladders,
landings, cages, walkways, kick plates, hand rails, fixing points, rescue points and other items.

Where there is a risk of unauthorised access to a structure, for example, structures located in
cuttings or dives, the structure shall be secured with an access prevention security grille in
accordance with the electrical and signal design requirements.

The associated electrical requirements are stated in T HR EL 08001 ST Safety Screens and
Barriers for 1500 V OHW Equipment.

General requirements for human factors integration are provided in T MU HF 00001 ST Human
Factors Integration - General Requirements.

Operators and rail workers can use the Railsafe website to obtain the latest safe working
information. The website has safe working information including the network rules and
procedures, network local appendices as well as contractor information, safe working policies,
safe tracks flyers, weekly notices and safe notices.

6. Environment and sustainability


The design of OHWSs and signal gantries, including the refurbishment of existing structures,
shall consider environmental impacts and sustainability opportunities across the full life cycle.
The design should conform to contemporary good practice in environmental and sustainability
consideration and implementation. Considerations specific to OHWSs and signal gantries
include the following:

• durability of material that will last for the expected or planned operational life as per the
asset management cycle

• components (including any other chemicals) for operations and maintenance use shall not
contain any substance of high toxicity if a substance of lower toxicity is available that could
be just as effective

• use of recycled and recyclable or low energy materials that meet operational requirements

• visual impact and amenity

• resilience to climate change

• ability and ease to maintain and ‘retrofit’ improvements over time

• disposal and reuse at lifecycle end

Environmental protection of the site works shall consider, assess and minimise environmental
impacts in accordance with the relevant rail infrastructure manager (RIM) procedures and
systems. The principles of NSW Sustainable Design Guidelines shall also be followed.

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

7. Heritage
Transport agencies are responsible for maintaining and appropriately managing heritage items
under their stewardship and control. The Heritage Act 1977 is designed to protect, maintain and
manage environmental heritage in NSW including items of archaeological significance. When
changes are proposed to items with heritage significance, the following applies:

• for those items listed on the NSW State Heritage Register the provisions of the Heritage
Act shall be met

• for items listed on a state agency Section 170 Heritage and Conservation Register, the
heritage management principles and relevant asset management guidelines that are
outlined in the State Agency Heritage Guide – Management of Heritage Assets shall be
followed

Advice from a professional heritage practitioner shall be obtained early in the project scoping
and design stage to determine heritage constraints and opportunities, to assess potential
heritage impacts and to guide the nature and extent of all proposed works.

Older style OHWSs and signal gantries shall be assessed for their heritage attributes and
values. Where such structures form part of a heritage precinct or are within the visual catchment
of a heritage item, any changes shall be undertaken in a manner that respects and maintains
the heritage significance. Older style OHWSs and signal gantries with heritage, aesthetic or
environmental values should be retained and appropriately maintained as required, wherever
possible. Where decommissioning of a structure within a heritage precinct is justifiable any
proposed replacement structures shall be designed to respond contextually to relate to
traditional models.

If archaeological evidence is discovered during investigation, construction or maintenance


works then works shall cease immediately. The RIM shall be informed and notification shall be
made in accordance with the relevant legislation.

8. Structure configuration requirements


Requirements for OHWSs and signal gantries to standardise structure arrangements, structural
detailing and to minimise maintenance shall be as follows:

• each structure shall be designed as a standalone, independent structure

• each structure shall be configured using smooth, clean faced elements without a
proliferation of small members, fittings and metal to metal interfaces

• the thickness of major steel structure components shall be not less than 8 mm

• steel structures and fittings shall be hot dipped galvanised as outlined in Section 18

• fillet welds shall be not less than 6 mm

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

• structures shall be detailed such that moisture and debris collection pockets are not formed
during the life of the structure

• the top surface level of footings and holding down bolts shall be clear of the track ballast,
cess and sub grade levels by not less than 150 mm

• footing hold down bolts shall be installed with appropriate nuts, lock nuts and washers
(guidance is outlined in TMC 331)

• structure footings shall not block or impede drainage systems and affected drainage
systems shall be corrected where applicable

• structure footings shall not be founded on cuttings where future cutting widening is likely to
occur

9. Standard structures
The TfNSW Central Planroom holds a set of standard drawings of OHWSs and signal gantries.
The standard drawings show standard fabrication and construction details. A list of these
standard drawings is contained in Appendix A.

The civil design engineer shall be satisfied that the standard structure selected satisfies the
current safety requirements, ultimate limit states and the serviceability limit states including for
strength, stability and serviceability.

The relevant standard structures shall be nominated on design drawings for new structures.

All standard drawings shall be read in conjunction with a structure diagram containing details for
a specific location. The civil design engineer shall perform the following tasks:

• undertake the design for each structure

• determine which standard structure type if any is suitable for the location under
consideration

• produce the structure diagram

• undertake design check or verification

A standard structure cannot be simply nominated for multiple locations over a particular OHW
run because the loading from the OHW can vary significantly depending on the wiring system in
use, distance between structures, number of wires being connected, the radius of the track and
out-of-running or anchor wire angles. All of these design loads, together with the wind loads
shall be considered when a standard structure type is selected.

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

A large range of structure sizes is available for use and the civil design engineer shall nominate
the most economical structure for the location under consideration. An order of preference
should be applied when selecting standard OHWS types as follows:

i. single mast PP type (most preferred)

ii. single mast HP type

iii. SHS portal

iv. cantilever mast

v. double channel portal

vi. double UB portal (least preferred)

For OHW anchor structures order of preference, refer to Section 13. Where structure types
other than a single mast or a SHS portal are nominated by the designer, the justification shall be
documented.

If existing standard structures are not suitable for a particular location, then a non-standard
structure can be used, provided approval from the Lead Civil Engineer, ASA is obtained.

10. Design criteria


OHWSs shall be designed to support the traction OHW for the nominated section of track. The
OHW electrical design engineer shall determine the appropriate OHW system in accordance
with the requirements documented by the Lead Electrical Engineer, ASA.

Design documentation shall identify standards for design, including loading, materials, design
life and wind speeds.

The design of OHWSs and signal gantries shall take into account the associated requirements
such as signal sighting, service routes, earthing and bonding, drainage and other rail
infrastructure.

10.1. Design standards


OHWSs and signal gantries shall be designed in accordance with this standard and to the
relevant Australian Standards including the following:

• AS/NZS 1170 Structural design actions

• AS 1657 Fixed platforms, walkways, stairway and ladders – Design, construction and
installation

• AS 2159 Piling - Design and installation

• AS 3600 Concrete structures

• AS 4100 Steel structures

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

The associated signal discipline requirements for signal gantries are provided in SPG 0705
Construction of Cable Routes and Signalling Civil Works and SPG 0706 Installation of
Trackside Equipment.

Guidance on the application of this standard is given in TMC 331.

Where conflict exists between the standards, the civil requirements of this document shall take
precedence.

10.2. Design life


New OHWSs and new signal gantries shall be designed for a serviceable working life of 100
years with minimum maintenance. Existing OHWSs and signal gantry minimum remaining
serviceable life requirements are contained in Section 21 and Section 21.1.

The design of OHWSs, signal gantries, associated structural components and anchor structures
shall determine any special requirements to protect the structure within the environment and to
provide durability to the structure. In particular, structures in proximity to a marine environment,
in a tunnel, in a dive or in a cutting require specific protection for long-term durability.

10.3. Design responsibility


Cooperation amongst all design disciplines is required to ensure all structural aspects and
loading are identified and determined.

The design of OHW systems is the joint responsibility of the OHW electrical design engineer
and the civil design engineer.

The design of signal gantries is the joint responsibility of the signal design engineer and the civil
design engineer.

The civil design engineer shall ensure that the OHWS or the signal gantry structure satisfies all
of the structural design action limit state requirements including strength, stability and
serviceability.

The civil design engineer shall be accountable for the following:

• OHWSs and signal gantries (for example, single masts, cantilever masts, portal structures,
anchor masts and associated footings)

• associated structural details such as drop verticals, guy footings, access ladders and
walkways, access prevention devices

• non-standard structural attachments to other structures such as overbridges, tunnels and


airspace developments

• non-standard structural fittings required by the OHW electrical design engineer or the
signal design engineer, such as special anchor plates

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

• interpreting the electrical loading diagram produced by the OHW electrical design engineer

• liaising with the OHW electrical design engineer

• liaising with the signal design engineer

• liaising with the track design engineer

• liaising with the geotechnical design engineer

OHWS positioning shall be determined by the OHW electrical design engineer and then agreed
with the signal design engineer and the civil design engineer. Signal gantry positioning shall be
determined by the signal design engineer and then agreed with the civil design engineer.

11. OHWS – structural design actions


The OHW electrical design engineer shall determine the loads associated with the traction
OHW system onto the OHWS and produce an electrical loading diagram for each structure.
These loads are described in EP 08 00 00 01 SP Overhead Wiring Standard for Electrification
of New Routes and include weight, radial, tension and wind loads from all OHW electrical
equipment.

Other loading aspects that shall be considered in the design include the following:

• maximum, minimum and intermediate load values that produce the worst effect on the
structure

• loading due to staged construction

• out of balance loads such as at fixed midpoint structures

• out of plane loads generated by longitudinal movement or displacement of the OHW

• broken OHW effects

Guidance for OHW loads and OHWS load cases is included in TMC 331.

11.1. OHWS permanent actions


Permanent actions (dead loads) for OHWSs shall be determined in accordance with
AS/NZS 1170. The following OHW loads shall be considered as permanent actions:

• static weight load

• radial load

• regulated tension

• fixed anchor tension

• weight stack load

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T HR CI 12040 ST
Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

11.2. OHWS imposed actions


Imposed actions (live loads) used in the design of OHWSs shall be a concentrated load of
1.1 kN applied to each wire run attached to the structure or a greater load value as determined
by the OHW electrical design engineer. This load represents the action of one person standing
on the wire run as a minimum.

11.3. OHWS wind actions


Wind loading on the OHWS shall be determined in accordance with AS/NZS 1170.

The ultimate regional wind speed shall be determined using an appropriate average recurrence
interval using importance levels and design working life chosen from Table 1.

Table 1 - OHWS ultimate wind speed design inputs

OHWS condition and usage Importance Design working life


level (years)
New structure supporting OHW over tracks
2 100
carrying passengers
New structure supporting OHW over tracks not
carrying passengers (for example, stabling 1 100
sidings)
Existing structure (25 years or older) supporting
2 25
OHW over tracks carrying passengers
Existing structure (25 years or older) supporting
OHW over tracks not carrying passengers (for 1 25
example, stabling sidings)

The serviceability regional wind speed shall be determined using an average recurrence interval
of 25 years.

11.4. OHWS deflection limits


OHWSs shall satisfy all of the following conditions:

• lateral movement of the contact wire due to OHWS deflection shall not exceed 50 mm with
only serviceability condition wind loading applied on the OHWS and on the OHW and on
associated equipment (no permanent actions such as weight and radial loads, no imposed
actions or mast rake applied)

• OHWS deflection under static serviceability loading - permanent actions only, no imposed
or wind actions - shall not exceed the limits set out in Table 2 so that the aesthetic
appearance of the structure is acceptable

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Overhead Wiring Structures and Signal Gantries
Version 1.0
Issued date: 30 June 2016

Table 2 – OHWS static serviceability deflection limits

Structure or Maximum vertical deflection Maximum horizontal deflection


component type (in and out of plane)
Portals Span / 250 Height / 100
Single mast Not applicable Height / 100
Cantilever Length / 75 (+ve) upwards Height / 100
Length / 500 (-ve) downwards
Drop vertical Not applicable Length / 75

The limits set out in Table 2 shall be applied to the final deflected shape under the static
serviceability loading. Beneficial pre-set mast rake or bridge camber may be provided to satisfy
the above deflection limits. Each member shall be evaluated by considering it in isolation with
the displacement of the end points of the member and the mid-point for portal bridges being
compared to the vertical or horizontal axis.

12. Signal gantry – structural design actions


Signal gantries shall be designed to support signal equipment at the specific locations
nominated by the signal design engineer. Loads imposed on signal gantries from the signal
equipment shall be determined using the weight of the equipment and the size of components
and the position of placement as determined by the signal design engineer. Loads associated
with access items shall also be considered.

12.1. Signal gantry permanent actions


Permanent actions (dead loads) for use in designing signal gantries structure shall be in
accordance with AS/NZS 1170.

12.2. Signal gantry imposed actions


Imposed actions (live loads) for use in the design of signal gantries shall be in accordance with
AS/NZS 1170 and AS 1657.

12.3. Signal gantry wind actions


Wind loading on signal gantries shall be determined in accordance with AS/NZS 1170. The
ultimate regional wind speed shall be determined using an appropriate average recurrence
interval using importance levels and design working life chosen from Table 3.

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Version 1.0
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Table 3 - Signal gantry ultimate wind speed design inputs

Signal gantry condition and usage Importance level Design working life
(years)
New gantries supporting signals, cages and
2 100
maintenance personnel
Existing gantries (25 years or older)
supporting signals, cages and maintenance 2 25
personnel

The serviceability regional wind speed shall be determined using an average recurrence interval
of 25 years.

12.4. Signal gantry deflection limits


Deflection of signal gantries under full serviceability loading - permanent actions, imposed
actions and wind actions - shall be limited so that the aesthetic appearance of the structure is
acceptable. Deflection limits in Table 4 shall be used as a minimum.

Table 4 – Signal gantry full serviceability deflection limits

Structure type Maximum vertical deflection Maximum horizontal deflection


(in and out of plane)
Portals Span / 250 Height / 125
Cantilever Length / 125 (+ve) upwards
Height / 125
Length / 500 (-ve) downwards
Signal cage Length of cage / 75
Not applicable
(out of plane only)

The limits set out in Table 4 shall be applied to the final deflected shape under the full
serviceability loading. Beneficial pre-set mast rake or bridge camber may be provided to satisfy
the above deflection limits. Each member shall be evaluated by considering it in isolation, with
the displacement of the end points of the member and the mid-point for portal bridges being
compared to the vertical or horizontal axis.

13. OHWS – anchor structures


OHW is terminated at the ends of the wire runs by anchoring the wires in the along-track
direction to an anchor structure. An order of preference should be applied when selecting OHW
anchor structure types as follows:

i. guy footing from an OHWS mast (most preferred)

ii. free standing anchor mast or guy bracket onto hard rock cutting

iii. guy bracket into track side structures such as tunnel portals, tunnel walls or retaining walls

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iv. guy bracket into over track structures such as overbridges, footbridges, station concourses
and airspace developments (least preferred)

When determining the most appropriate anchor type the designers shall consider the whole of
life aspects of the OHW and the anchor structures. Where an anchor structure type other than a
guy footing is nominated by the civil design engineer, the justification shall be documented.

The two general types of OHW anchor configurations are as follows:

• fixed anchors

• moving anchors

The type of anchor configuration shall be determined by the AEO responsible for OHW
electrical design.

14. Footings
Footings shall be designed to resist the loads from the OHW system or signal gantry and the
structure and the design reactions resulting from the founding conditions. These founding
conditions include various foundation materials, ground profiles and other site specific
constraints.

Standard footings shall be used unless site constraints require a site specific footing design as
described in Section 14.3.

Standard structure footing and guy footing drawings are included in the list in Appendix A.
These drawings show footing construction details including a table containing footing depths for
typical foundation conditions. The footing depth shall be selected in accordance with the
standard drawing details based on geotechnical information or advice.

The appropriate depth for footings taking into account actual geotechnical conditions shall be
verified on-site by the geotechnical engineer prior to steel and concrete installation.
Requirements for any on-site geotechnical verification shall also be documented on the
structure diagram.

Piled footings are preferred for steeply sloping ground. Global stability of sloping ground shall
also be considered.

In all cases the civil design engineer shall determine and specify a structure footing design that
ensures allowable, serviceable and ultimate limit state foundation capacities are not exceeded.

14.1. Standard structure footings


The standard OHWS drawings have a corresponding standard footing drawing.

For guidance, standard structure type footings generally satisfy stability requirements provided
the maximum allowable loads given in Table 5 are not exceeded.

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Version 1.0
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Table 5 - Maximum allowable footing loads

Maximum Maximum Maximum


allowable allowable allowable
Structure type
horizontal force moment MZ moment MX
FX or FZ (kN) (kN.m) (kN.m)
PP2/HP2 mast 10 90 90
PP3/HP3 mast 10 140 140
200 SHS portal 20 80 80
250 SHS portal 20 120 120
300 SHS portal 30 180 180
250 SHS cantilever mast 25 150 150
300 SHS light cantilever mast 40 220 220
300 SHS cantilever mast 50 250 250
300 Double channel portal 30 150 100
380 Double channel portal 30 210 170
FSAM 310 UC 137 or smaller 45 320 320
FSAM 310 UC 158 60 400 400

The maximum allowable footing loads shown in Table 5 shall be compared to the sum of the
applied unfactored forces and moments acting in each relevant direction from the structure mast
at the underside of the footing pedestal level.

The adopted global axes directions for the forces and moments in Table 5 are as follows:

• X is horizontal, perpendicular to the track direction

• Z is horizontal, parallel to the track direction

A vertical axis Y requirement is not shown, however, if any significant forces, moments or
torsions act in this direction, the civil design engineer shall design a site specific footing
accordingly.

14.2. Standard guy footings


There are standard drawings for guy footings, guy piles and guy rock footings.

For guidance, the standard guy footing sizes generally satisfy stability requirements provided
the maximum allowable loads given in Table 6 are not exceeded. To ensure that excessive
overturning moment is not produced, the pedestal height shall be limited to a maximum of 1000
mm.

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Version 1.0
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Table 6 - Maximum allowable guy footing loads

Guy footing type Maximum allowable Maximum allowable


horizontal force (kN) vertical force (kN) upwards
G1 guy 40 40
G2 guy 56 56
G3 guy 66 66

The maximum allowable guy footing forces shown in Table 6 shall be compared to the sum of
the applied unfactored forces acting in each relevant direction from the guy wires at the top of a
1000mm height footing pedestal.

The standard guy footing sizes and respective capacities are suited to the range of conductors
and tensions used in existing regulated systems. TMC 331 Table 9 provides guidance for
conductor systems nominated in T HR EL 08009 ST Designations of Overhead Wiring
Conductor Systems and maximum total tensions that can be used with each standard guy
footing type. The civil design engineer shall determine and specify a guy footing size that
ensures footing capacities are not exceeded.

14.3. Site specific footings


Standard footings are preferred. For some structures, it is not possible to use a standard footing
design as the structure loads exceed the allowable loading range given in Table 5 or Table 6.
For some structure locations, the geotechnical parameters or foundation material or the
required footing size may not satisfy the ‘footing depth table’ shown on the standard drawings of
OHWSs and signal gantries.

Site constraints can include poor ground conditions and nearby infrastructure such as
subsurface drains, service trenches, electrical feeder cables, planned future excavations and
other footings and the like within the footing zone of influence.

The civil design engineer shall consider all site constraints and design the site specific footing
using an appropriate and recognised method of analysis and appropriate geotechnical
parameters. If a non-standard footing design is required, then the overall footing structure
including size, depth, diameter, material strengths, reinforcement and hold down bolts and the
like shall be determined. The TfNSW preference is for standard footing designs with depth
increased accordingly and for standard pedestal sizes.

Note: OHWS regular and pile footings are considered to resist applied forces and
moments through lateral bearing only. Applied vertical forces are usually
comparatively minor, so bearing capacity of the base is not usually a critical factor.

Spread footings shall not be used on new OHWSs and signal gantries due to the relatively high
applied moments and the vulnerability of spread footings to interference by nearby excavations
and other works during the life of the structure.

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A site specific footing design requires site specific geotechnical parameters so that a footing
depth can be determined. The geotechnical parameters used in the design shall be documented
on the structure diagram.

If geotechnical data is not available the design shall provide a range of depths for different
founding materials at each footing location. The appropriate depth for footings taking into
account actual geotechnical conditions shall be verified on-site by the geotechnical engineer
prior to steel and concrete installation. Requirements for any on-site geotechnical verification
shall be documented on the structure diagram.

At footing sites where continuing ground movements have been occurring or are predicted,
special designs that avoid portal structures or incorporate structures that accommodate
expected movements shall be considered. Design limits shall be documented on the structure
diagram.

Refer to Section 14 for other general footing requirements.

15. Clearances
As a minimum, horizontal and vertical clearances from the track to OHWSs and signal gantries
shall be in accordance with ESC 215 Transit Space.

Horizontal and vertical clearances from the track to an OHWS shall be determined at each
location to suit the requirements of the electrical design including signal sighting aspects of the
particular location and access to the structure.

Horizontal and vertical clearances from the track to a signal gantry shall be determined at each
location to suit the requirements of the signal design, including the signal cage position, signal
sighting aspects and access to the structure.

16. Attaching to civil infrastructure


OHW and OHWSs attached to other civil infrastructure shall not compromise the structures
integrity or design life and shall also comply with the relevant infrastructure standards.
Appropriate geotechnical investigations and material testing shall be undertaken to plan and
design suitable attachments for the whole of life of the infrastructure and to avoid water ingress
and associated corrosion and the like.

OHW should not be attached or anchored to a bridge and OHWSs should not be located on a
bridge structure unless this OHW arrangement is unavoidable. Unavoidable situations may
include a wide or long bridge or the OHW system layout constraints. Requirements for
overbridges and footbridges are contained in T HR CI 12030 ST Overbridges and Footbridges
and requirements for underbridges are contained in ESC 310 Underbridges. Requirements for
airspace developments are contained in T HR CI 12075 ST Airspace Developments.

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OHWS attachments to tunnel structures shall not compromise the structural integrity of the
tunnel (including the tunnel lining and drainage systems and associated parts). Requirements
for tunnels are contained in ESC 340 Tunnels.

Requirements for retaining walls are contained in T HR CI 12060 ST Retaining Walls and
requirements for station platforms are contained in T HR CI 12065 ST Station Platforms.

16.1. Chemical anchors


Proven stainless steel chemical anchors may be used to attach OHW and OHWSs to concrete
and masonry components of suitable retaining walls, tunnels, bridges and other structures. As
the load carrying capacity for these types of anchor is usually based on concrete strength,
account shall be taken of the age and condition of the concrete or masonry structures into which
these anchors shall be installed (for example, fractured concrete or brickwork) in order that the
manufacturers’ specifications and installation instructions are met.

The design documentation shall specify the relevant design parameters, on-site load testing,
electrical insulation and installation criteria.

17. Electrical earthing and bonding


The design of OHWSs and signal gantries shall provide for earthing and bonding of metallic
components in order to mitigate touch potential hazards and corrosion of steel. Earthing and
bonding requirements for OHWS are provided in EP 12 20 00 01 SP Bonding of Overhead
Wiring Structures to Rail, T HR EL 12002 GU Electrolysis from Stray DC Current,
EP 12 10 00 13 SP 1500 V Traction System Earthing and shall comply with the requirements of
the Lead Electrical Engineer, ASA.

18. Galvanising
OHWSs and signal gantries shall be hot-dip galvanized in accordance with AS/NZS 4680 Hot-
dip galvanized (zinc) coatings on ferrous articles, unless approval is given by the Lead Civil
Engineer, ASA to use alternative coatings (for example, coatings to meet heritage
requirements). Holes required in structural steelwork should be drilled before galvanising.

19. Approved materials


Approved construction materials for main structural elements are steel and concrete. Timber
materials shall not be used as structural elements for OHWSs and signal gantries.

If any products specified in the design documentation can reasonably be deemed to be new or
infrequently used, these shall be identified by the AEO and referred to the Lead Civil Engineer,
ASA for approval. The AEO shall ensure that the manufacturer, constructor and maintainer of
the product understands any special requirements or practices relating to the product prior to

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the release of the design documentation. The special requirements shall be included in the
documentation such as design drawings and technical maintenance plans.

20. Drawing standards


Construction drawings shall comply with TfNSW standard procedures and formats, and shall
detail the design criteria and all information that is relevant to ensuring that the new structure
can be constructed and maintained in accordance with the design. Engineering drawing and
computer-aided design (CAD) requirements are specified in T MU MD 00006 ST Engineering
Drawings and CAD Requirements. Detailed OHWS and signal gantry design documentation
requirements and guidance are provided in TMC 331.

The structure diagrams shall include the following:

• structure name (OHWS location number)

• structure type and size

• footing set out coordinates

• cross section showing:

o bridge or boom length (L where applicable)

o horizontal location of mast

o structure or mast heights (H or HL or HR where applicable)

o vertical location of footing pedestals

o track centres and track names

o drop vertical lengths, types and position

o anchor heights and anchor plate notation (where applicable)

o guy footings (where applicable)

o bridge splice (where applicable)

o access prevention grille (where applicable)

o features of adjacent terrain, such as earthwork profile (ground line) and cess drains

o features of adjacent structures, such as troughing, retaining walls, overbridges and


other obstructions such as fences

o electrical clearances, such as at high voltage aerials and touch potential issues (where
applicable)

• notes and references

• special details (where applicable)

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• geotechnical parameters (where applicable)

• on-site geotechnical engineering verification requirements (where applicable)

• construction hazards and risks in the form of safety notes

Work as executed structure diagram drawings shall provide as constructed details such as
footing type, footing depth and geotechnical parameters.

21. Existing structures


Where existing OHWSs or signal gantries are required to be repaired, any repairs to the
structure shall satisfy the structural design action requirements specified in this standard. Whole
of life cost considerations should be taken into account to determine whether to repair or
replace structures.

21.1. Assessment of existing OHWS for reuse


When an existing OHW system is upgraded to a system with greater electrical capacity or an
existing wiring system is modified resulting in an increase in structure loading, a structural and
remaining serviceable life assessment of the OHWS shall be undertaken.

Situations in which a structural assessment is required include the following:

• wire adjustments

• conversion to independent registration

• conversion from fixed wiring to regulated wiring

• modifications to existing regulated wiring

• upgrading of existing wiring system

Existing structures that are to be reused shall have a minimum remaining serviceable life of 25
years if the structure is greater than 25 years old or 50 years if the structure is less than 25
years old. Structures shall be assessed in accordance with the requirements of this standard.

The structures shall comply with the strength and stability limit state requirements.

Some of the deflection limits have been relaxed for serviceability limit state requirements.

Deflection of an existing OHWS under static serviceability loading – permanent actions only, no
imposed or wind actions – shall not exceed the limits set out in Table 7 so that the aesthetic
appearance of the structure is acceptable.

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Version 1.0
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Table 7 - Existing structures (for reuse) static serviceability deflection limits

Structure or Maximum vertical deflection Maximum horizontal deflection


component type (in and out of plane)
Portals Span / 250 Height / 75
Single mast Not applicable Height / 75
Cantilever Length / 75 (+ve) Upwards Height / 75
Length / 300 (-ve) Downwards
Drop verticals Not applicable Length / 35

The limits set out in Table 7 shall be applied to the final deflected shape under the static
serviceability loading. Beneficial pre-set mast rake or bridge camber may be provided to satisfy
the above deflection limits. Each member shall be evaluated by considering it in isolation with
the displacement of the end points of the member and the mid-point for portal bridges being
compared to the vertical or horizontal axis.

Lateral movement of the contact wire due to an OHWS deflection shall not exceed 50 mm with
only serviceability condition wind loading applied on the OHWS and on the OHW and on
associated equipment (no permanent actions such as weight and radial loads, no imposed
actions or mast rake applied). This serviceability deflection limit state is not relaxed for OHWSs
nominated for reuse.

22. Construction
The design documentation shall identify standards for construction, including construction
methods, processes and materials.

OHWSs and signal gantries shall be constructed in accordance with SPC 301 Structures
Construction, AS 4100, AS 3600 and all project specific requirements as nominated by the civil
design engineer. This may include relevant references for material testing, testing of welds,
fabrication, excavation, erection and tolerances and the like. The design documentation shall
include all requirements and references necessary for completeness of the technical
specifications.

The design of OHWSs and signal gantries shall take into account construction constraints and
restrictions such as the following:

• live operating conditions

• track possession

• on-site geotechnical engineering verification

• staged construction

• trial assembly prior to track possession

• deep cuttings and steep embankments

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• other rail infrastructure

• future modifications to the rail corridor

23. Maintenance
The design of OHWSs and signal gantries shall provide ease of access and visibility to
components for inspection and maintenance tasks.

The design AEO shall carefully select components, materials and finishes that will minimise
maintenance during the life of the structure particularly due to the close proximity of these types
of structures to operating tracks.

OHWS and signal gantry design and detailing shall consider future replacement of OHW and
signal equipment which minimises impact to railway operations.

Maintenance requirements shall be specified in the design documentation for structures in the
form of a technical maintenance plan. The requirements shall include examination tasks and
frequencies, damage limits and repair standards. In most cases ESC 100 Civil Technical
Maintenance Plan and ESC 302 Structures Defect Limits shall apply. However site specific
maintenance requirements shall also be appropriately documented.

The requirements and high-level processes for the development of technical maintenance plans
are detailed in T MU AM 01003 ST Development of Technical Maintenance Plans.

24. Decommissioning and disposal


Decommissioning is the final process of withdrawing an asset from active service on the
network.

Disposal is the process of removing an asset from the network. For example demolition of an
OHWS or signal gantry followed by removal and recycling.

The decommissioning or disposal of an asset is the final stage of the asset life cycle. Proper
planning of this part of the life cycle is an integral part of the strategic life cycle process.

The process to be undertaken for the disposal of an OHWS or signal gantry shall be as follows:

• A report shall be produced to confirm that the asset is surplus to the requirements of the
rail network or it is life expired.

• The report shall identify the benefits including financial and costs arising from the proposed
decommissioning or disposal.

• The report shall confirm stakeholder engagement regarding the proposed action. Such
engagement shall include, but not be limited to the RIM, heritage, council and
environmental body consultation.

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• The means of decommissioning or disposal shall be a risk based decision carried out in
accordance with the TfNSW safety management system. Refer to 30-ST-164 TfNSW
Enterprise Risk Management (TERM) Standard for requirements regarding the mitigation
of risk SFAIRP.

• The report shall include a decommissioning or disposal plan for implementation.

Following decommissioning or disposal, the asset database shall be updated to reflect network
changes.

Ninety-five per cent of construction and demolition waste by weight of the decommissioned
asset should be diverted from landfill.

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Version 1.0
Issued date: 30 June 2016

Appendix A Standard OHWS and signal gantry


drawings
The controlled latest versions of the drawings listed in Table 8 are held in the TfNSW Central
Planroom. Access to the Central Planroom is provided to a contracted AEO by the TfNSW
representative for the contract. Only authorised access is provided to the information stored in
the Central Planroom. It is the responsibility of the contract manager to either provide the
required information to the contractor or to authorise the contractor to have access to the
Central Planroom. Uncontrolled drawings listed in Table 8 are available from the ASA website.

Table 8 - Standard OHWS & signal gantry drawings

Drawing No. Old Drawing OHWS or signal gantry drawing title


No.
CV0373001 PP2 Mast And PP3 Mast Steelwork And Footings
CV0373002 HP2 Mast And HP3 Mast Steelwork
CV0373003 HP2 Mast And HP3 Mast Footings
CV0373004 200 SHS Portal Steelwork
CV0373005 200 SHS Portal Footings
CV0373006 250 SHS Portal Steelwork
CV0373007 250 SHS Portal Footings
CV0373008 300 SHS Portal Steelwork
CV0373009 300 SHS Portal Footings
CV0373010 250 SHS Cantilever Mast Steelwork
CV0373011 250 SHS Cantilever Mast Footings
CV0373012 300 SHS Light Cantilever Mast Steelwork
CV0373013 300 SHS Light Cantilever Mast Footings
CV0373014 300 SHS Cantilever Mast Steelwork
CV0373015 300 SHS Cantilever Mast Footings
CV0373016 300 Double Channel Portal Steelwork
CV0373017 300 Double Channel Portal Footings
CV0373026 Guy Footings
CV0373027 Guy Pile And Guy Rock Footings
CV0373028 DS Drop Vertical And DSW Drop Vertical Steelwork
CV0373029 DT Drop Vertical And DTW Drop Vertical Steelwork
CV0373030 Free Standing Anchor Masts Steelwork And Footings
CV0373044 Repair For Exposed Mast Footings
CV0373046 Cutting Bridge Support Replacement Type 1 And Type 2
CV0145207 E1-437 380 Double Channel Portal – Steelwork
CV0152601 E1-438 380 Double Channel Portal – Footings

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Version 1.0
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Drawing No. Old Drawing OHWS or signal gantry drawing title


No.
CV0145208 E1-448 300 Double Channel Signal Or Feeder Structure – Steelwork
CV0152611 E1-449 300 Double Channel Signal Or Feeder Structure – Footings
CV0152612 E1-450 Double Channel Feeder & Signal Structure – Walkway And Balustrade
Steelwork
CV0142997 E1-451 Double Channel Feeder & Signal Structure – Ladder And Cage Steelwork
CV0152613 E1-452 Signal Cage Steelwork
CV0152614 E1-453 Ladder Landing Footing
CV0152615 E1-454 410 Double UB Portal – Steelwork
CV0152616 E1-455 Access Prevention Grill Steelwork
CV0152617 E1-456 460 Double UB Portal – Steelwork
CV0047941 Cantilever Signal Structure – Steelwork
CV0055980 250 SHS Double Cantilever Mast – Steelwork
CV0142949 Footing In Retaining Wall
CV0144833 Boxed Free Standing Anchor Mast – Mast And Footing Details
CV0465528 Guy Bracket On Rock Face
CV0364937 Double Channel Feeder & Signal Structure – Balustrade Gate At Signal
Cage Steelwork

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