Professional Documents
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Quality Assurance
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Acknowledgements
Table of Contents
Acronyms/Abbreviations .................................................................................................................. i
Executive Summary ........................................................................................................................ iii
1 Introduction ................................................................................................................................. 1
1.1 Purpose of this Report.................................................................................................................1
1.2 PNR South Description ................................................................................................................1
1.3 Inspections ..................................................................................................................................2
1.4 Report Structures ........................................................................................................................2
2 Hydrological Study........................................................................................................................ 4
2.1 Project Location...........................................................................................................................4
2.2 Climate.........................................................................................................................................5
2.3 Rainfall .........................................................................................................................................6
2.4 Tropical Cyclones and Typhoon Tracks .......................................................................................8
2.5 Bicol River Basin and Environs ....................................................................................................9
2.6 Flooding, Debris Flow & Local Drainage Problems ...................................................................11
2.7 Recommended Work ................................................................................................................18
3 Geotechnical Study ..................................................................................................................... 19
3.1 Project Location.........................................................................................................................19
3.2 Geological and Geotechnical Conditions ..................................................................................20
3.3 Seismicity and Geologic Hazards ...............................................................................................22
3.3.1 Seismic Hazards..................................................................................................................22
3.4 Liquefaction ...............................................................................................................................24
3.5 Settlement .................................................................................................................................27
3.6 Downslope Movement ..............................................................................................................28
3.7 Flooding .....................................................................................................................................28
3.8 Matrix of Geohazards ................................................................................................................35
3.9 Way Forward .............................................................................................................................36
4 Condition Assessments – Track ................................................................................................... 37
4.1 Standards...................................................................................................................................37
4.2 Condition Assessment ...............................................................................................................38
4.2.1 Rail ......................................................................................................................................39
4.2.2 Sleepers ..............................................................................................................................39
4.2.3 Ballast .................................................................................................................................40
TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
Acronyms/Abbreviations
AADT Annual Average Daily Traffic
BOO Build-Own-Operate
BOT Build-Operate-Transfer
FS Feasibility Study
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
TA Transaction Advisor
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
Executive Summary
This report presents our observations and findings of our condition assessments of fixed
infrastructure on the existing PNR South line including track & roadbed, bridges, stations and
depots. The objective of the rehabilitation plan is the restoration of the track structure to safe
use at the design speeds of 75 kph and maximum permissible axle loads of 15 tons. Although
the inspection and condition assessment covers the entire mainline south from Tutuban,
Manila to Legazpi (south terminus of the line), this report and associated rehabilitation plan will
cover only the portion from Calamba to Legazpi. The portion from Calamba northward will be
dealt with in a separate volume.
The Batangas Branch, which has been abandoned for about 70 years, is also dealt with
separately since, with the exception of much of the embankment, this line will require
complete reconstruction with new materials.
Track – Track is ballasted track system where parallel steel rails are laid upon cross ties
embedded in ballast (except on open-deck bridges)
o Rail weight is 32 and 37 kg/m rail of lengths varying in length between 10 and 60
meters. Overall, rail was found to be in good condition with newer 37 kg/m rail
in better shape than the older lighter rail (of 32 kg/m). We recommend
replacement of the remaining 32 kg/m rail from the track and replaced with 37
kg/m rail. The lighter rail should be saved for use in siding and depot tracks.
o Sleepers are mainly concrete but with wood sleepers on some curves and on
open-deck bridges. Concrete sleepers are in generally good condition though
many sleepers were observed to be missing. It appears they were largely
removed by PNR forces for use in areas of very poor tie condition, typically on
bridges. Wood ties on curves were observed to be in poor to fair condition.
Wood bridge ties were found to be in poor condition though there have been
recent programs to replace the sleepers. Unfortunately, it appears that some
poor quality sleepers have been used and they have not performed well. In
addition, we have seen many cases of concrete sleepers with wood sleepers on
bridges. We see that this was done in an act of desperation by track forces; but it
is an unsafe practice.
We recommend replacing all damaged and missing concrete sleepers with like
kind, and replacing all wood track sleepers with concrete sleepers using the
existing PNR sleeper patterns. We also recommend the removal of all concrete
sleepers, and deteriorated or damaged wood sleepers from open deck bridges,
and quality hardwood sleepers installed.
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
Bridges were found to have high degrees of corrosion largely due to lack of
maintenance, old age and inadequate protection from natural environment. Bridges
were classified in one of three categories, as follows:
o Full Replacement - when the retrofit cost approaches 70 % of a new bridge – 34
bridges
o Major Rehabilitation - replacement of span, re-plating, etc. – 72 bridges
o Repair - sand blasting, replacing bolts & nuts – 323 bridges
It is important to note that our observations and assessments were limited to what
could be seen from the on top and below the bridge. It is possible that deteriorated or
damaged sections of superstructures exist but are not visible from these vantage points.
As well, the structural integrity of substructures has not been assessed.
Stations and flag stops were observed to be insufficient for satisfactory and safe operation
along the whole line except for the stations within Manila division. Outside of the Manila
Division, most have been used residences (typically by illegal settlers), used as a storage area,
or a public area. There has been minimal maintenance by PNR. Requirements for stations and
flag stops will be further studied as part of our traffic and operational analysis. However, we
have included for rehabilitation and replacement of stations in the capital plan included in this
report.
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Three depots are maintained and used by PNR: Manila Depot, Naga Depot, and Calamba Line
Sheds. All three are operational but would require investment in structures, equipment and
access roads and tracks for maintenance of larger rolling stock fleets.
Our estimate of costs to rehabilitate the PNR South for the return of operations is PHP 28
billion. It is important to note that this does not include rolling stock which will be analyzed in
our operational analysis.
Figure 0-1 Capital Cost to Rehabilitate/Replace Fixed Infrastructure (million PhP)
The total estimated capital cost to restore the Batangas Branch for safe operation at a design
speed of 75 kph and for maximum axle loads of 15 tons is estimated at 8 B PhP, as summarized
below.
Figure 0-2: Total Capital for Batangas Branch (Million PhP)
Description Total
Fixed Costs 772
Track 3,347
Crossings 29
Bridges 1,925
Stations 116
Communications 255
Land Acquisition 1,280
Totals 7,724
The total cost to rehabilitate the south line and restore the Batangas Branch is PHP 36 billion.
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
This report provides a summary of our condition assessments from Manila to Legazpi, and
rehabilitation recommendations and cost estimates for the PNR South Line from Calamba to
Legazpi. Field investigations were undertaken by train and trolley car starting in May, 2013 and
concluding in November of the same year. At the same study geotechnical and hydrological
studies were being undertaken, and analysis was conducted to determine the most suitable
options for rehabilitation. Lastly, we prepared our recommendations for rehabilitation and
prepared costs estimates based on these recommendations. This is all addressed in this
document.
There are about 430 existing bridge structures along the mainline south as reported in the
“PNR List and Details of Bridges along Mainline South”. The existing structures have been
1
It is our understanding that 32 kg/m profile was originally installed and has been partially replaced with 37 kg/m
during rehabilitation works done by PNR.
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located according to Telegraphic Post (TP) stationing provided by PNR. The structures vary in
age, type and span.
There are a total of 45 stations and 43 flag stops along the Mainline South. Most of the stations
and flag stops are not operational, except for stations between Tutuban and Binan.
The Mainline South is divided into the four divisions; Manila, Lucena, Hondagua and Naga
Divisions. In Appendix 1, we have included alignment drawings for the entire rail line from
Tutoban to Legazpi.
Figure 1-1 PNR South Divisions
Design speed (as well as maximum permissible speed) along the line is 75 kph and
permissible axle load is 15 tons.
1.3 Inspections
Inspections were undertaken by train and by trolley across the entire PNR South by many
members of the project team. Detailed inspections were undertaken jointly by bridge
engineers and track engineers by trolley on the following dates:
Naga Division: Legazpi Station to Lupi Station
- August 19 – 21, 2013; September 11 – 14, 2013 and September 18 – 21, 2013.
Hondugua Division: Lupi Station to Gumaca Station
- September 20 – 21, 2013 and October 07 – 11, 2013
Lucena Division: Gumaca Station to Pansol Flag Stop
- October 22 - 24 and November 12 - 15 2013
Manila Division: Pansol Flag Stop to Tutuban Station
- November 27 – 29, 2013.
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Appendices
Alignment Drawings – Appendix 1
Track Condition Assessment Reports – Appendix 2
Bridge Condition Assessment Reports – Appendix 3
Typical Drawings and Plans – Appendix 4
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This chapter deals with the hydrology study of the PNR mainline south from Manila to Legazpi.
The mainline south railway (Figure 1) starts from Manila and passes the plains of Laguna and
goes south to Lucena City. It then follows the coastal towns of Pagbilao, Agdangan and Unisan
which fronts Tayabas Bay. The railway crosses the mountainous terrain and emerges at Plaridel,
and passes through the coastal towns of Gumaca and Lopez which fronts Lamon Bay. It then
leads to mountainous terrain down to the Bicol River Basin and finally ends at Legazpi City.
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2.2 Climate
The climate of the Philippines is tropical and maritime. It is characterized by relatively high
temperature, high humidity and abundant rainfall. The Philippine climate is classified into four
types depending on the rainfall distribution and pattern. Rainfall intensities range from very
light to heavy. Precipitation is influenced by prevailing air streams, monsoons, tropical
cyclones, the Inter Tropical Convergence Zone (ITCZ), topography fronts, easterly waves and
local thunderstorms. The four climate types are described as follows:
Type I - Two pronounced seasons. Dry from November to April, wet during the rest of year
Type II - No dry season with a very pronounced rainfall from November to April and wet
during the rest of year
Type III - Seasons are not very pronounced, relatively dry from November to April, wet
during the rest of year
The south line railway is located along the south eastern part of Southern Tagalog region and
partly in the central of the Laguna-Quezon-Bicol region, henceforth it falls mostly under Type
IV, as indicated in figure 2-2.
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2.3 Rainfall
Based on the rainfall data of the PAGASA Synoptic stations, the normal annual rainfall is
presented in Figure 2-3. The north railway experienced rainfall in the amount of 2500 mm in the
northern region and about 2000 mm near the Manila Area. On the other hand, the south
railway is exposed to higher annual rainfall of about 3000 mm.
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Figure 2-4 exhibits the maximum 1-day rainfall for the 20 year return period. The south railway
maximum is about 300 mm.
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The mean annual number of tropical cyclones that pass through the Philippine Area of
Responsibility is about twenty (20). The north railway season has 11-20% typhoon occurrence
while the south railway has 21-30% typhoon occurrence, as per Figure 2-6.
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Likewise, the watersheds along the western slope of Mt. Mayon contribute also to the flooding
of the Bicol River Basin. For prolonged intense rainfall as result of monsoon rains or passage of
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typhoon within its vicinity, debris flow of the eruptive deposit of Mt. Mayon is remobilized or
migrated downstream.
The Bicol River Basin drains an area of 3,771 square kilometers in Southern Luzon. It embraces
the central portion of Camarines Sur, the northern portion of Albay, and a portion of
CamarinesNorte. The basin is oriented in a northwest-southeast direction and bounded on the
east by a chain of volcanoes (i.e. Mt. Isarog, Mt. Malinao, Mt. Masagara, Mt. Iriga and Mt.
Mayon) and on the west by highlands and low hills. The flat alluvial land in the Bicol Plain
occupies the area between the Eastern Bicol Cordillera and the Ragay Hills. The runoff which is
estimated annually at 5,100 million cubic meters, starts from the Mayon Volcano with an
elevation of 4,421m, and meanders in a generally northwestward direction. After being
regulated through lakes Bato, Buhi, and Baao, the stream flow reaches the mainstream of the
BicolRiver which owing to its very gentle slope, is affected by tides as far as upstream of Naga
City.
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The principal tributary of the BicolRiver is the Sipocot River. The Sipocot River cuts through
mountainous terrain and has a steeper slope. The Bicol River after joining the Sipocot River
widens to more than 1,000 meters across at the estuary before discharging into San Miguel
Bay.
The average annual rainfall varies from 2,000mm in the southeastern area to 3,600mm in the
northwestern section of the basin. Flood-producing rains in the basin from May to February
are mainly due to tropical cyclone passages, northeast monsoon and orographic effect.
Flooding from the sea in the alluvial plain near the mouth of the river is caused by storm surges
associated with the passage of slow-moving typhoons near or over San Miguel Bay particularly
during high tides.
Rainfall of Typhoon Reming had triggered large volume debris flow (lahar flow) which had
resulted into the flooding and sediment deposition in most of communities along the foot of
Mt. Mayon. The Bicol Provincial Disaster Coordinating Council reported 75 dead persons for
Legazpi, 141 dead persons for Daraga and 197 dead persons for Guinobatan.
The affected rivers are Yawa river which discharges to Albay Bay through Legazpi City and
Tagaytay river which drains towards Guinobatan and then into the Bicol River Basin.
Yawa River has a channel width of 50 to 70 meters before Typhoon Reming but it widens to
about 300 to 500 meters. The Yawa Bridge at Legazpi City was washed out during Typhoon
Reming. It was also estimated that the 50 year and 100 year flood is about 1250 m3/s and 1500
m3/s, respectively.
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Typhoon Reming of 2006 had brought significant damage to the municipalities of Guinobatan,
Daraga and Legazpi City. Typhoon Reming brought flood waters as well as debris flow from the
Mt. Mayon. The Yawa and Tagaytay Rivers which drains close to the Daraga–Guinobatan railway
alignment. In this case, there is high risk disaster risk as shown in the extent of lahar flow
damage as seen in Figure 2-11.
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
The most common problems related to bridge hydrology and hydraulics are bridge deck
overtopping or flood inundation, minimal vertical clearance and inadequate local surface
drainage facilities.
Overtopping of Bridges
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Typical flood event under ordinary rainfall is shown in Figure 2-13 for the San Ramon Bridge.
Floating debris is evidently trapped or had piled up at piers. Water way is also covered with
vegetation.
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
A total of forty (40) bridges are included in the bridge clustering. Typical pictures of affected
bridges are shown in Figure 2-14.
Figure 2-14: Bridges with Low Minimal Vertical Clearance
TAGAYTAY BRIDGE
KM 460.35 –KM
460.40
SAPANGPALAYBRIDGE
KM 441.30 – KM 441.35
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KM 475.70 – KM 475.860
KM 473.50 – KM 473.60
KM 471.90 – KM 472.00
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In case of clustered bridges with not enough vertical clearance, flood plain analysis should be
conducted. A detailed topographic survey is needed so as to define the physiographic
characteristic of the flood plain. A mathematical hydraulic modeling of the flood water over
spilling to nearby and neighboring tributaries will be represented. Likewise, a review and
updating of the river flood discharge should be undertaken. Any planned integrated area
development by local government unit or government agencies will be incorporated in the
modeling process.
It is also suggested to provide regular maintenance by clearing of the waterway that is fully
covered with vegetation. The carrying capacity of the waterway will increase as well as water
level on both sides of the railway will easily equalize.
In case of the simple local surface drainage inundation, if an outfall can be easily identified
providing an interceptor channel which will collect rainfall from high area will be an option to
reduce or eliminate surface drainage inundation. The rain water will then be conveyed to an
outfall. The interceptor may be part track improvement scheme considering the geotechnical
and structural stability of the railway.
For more complex surface runoff pattern, an urban drainage study should be conducted. The
scope of work includes defining the catchment area, estimation of flow, hydraulic sizing and
design of the interceptor channel or culvert. In addition, the outfall should be identified and
corresponding transmission conveyance should be designed.
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Three (3) general varieties of volcanic materials are recognized in the region:
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unconsolidated deposits are often layered volcanic deposits that resulted from the explosive to
gentle extrusion of fragmented materials from the numerous volcanoes found in and near the
study site. These deposits range in thickness from a few centimeters to tens of meters
depending on their proximity to the source. Most of these deposits are airfall tephra, i.e.
materials blown skyward by the explosive volcanic activities. The basaltic and andesitic lava
flows consist of both historic and pre-historic lava flow deposits and volcanic necks.
The historic lava flow deposits show less massive surfaces. The most extensive type of volcanic
deposits is the pyroclastic beds which are thinly bedded and horizontally stratified tephra
layers.
Bicol region, on the other hand, is characterized by Pre-Cretaceous metamorphics, which are
overlain by Quaternary volcanic and sedimentary rocks composed of interbedded greywacke,
cherts, tuffs, spilitic to andesitic lava flows, mudstones and cherty limestone’s of Cretaceous
age. Mt. Cadig, located near the northern stretch of the project site, is made up of serpentinize
dultramafics and is a thrusted body shoved against folded schists and Cretaceous (Geology and
Mineral Resources of the Philippines, Bureau of Mines and Geosciences, 1981).
Figure 3-2 presents the sedimentary, metamorphic and igneous rocks which are associated in
each segment of the Mainline South Network. (Ref: Mines and Geosciences Bureau Geology
Map).
Figure 3-2: Geologic Map of Luzon - Regions 4 to 5
M
a
i
n
li
n
e
S
o
u
(Upper Miocene – Pliocene) Largely marine clastics overlain by extensice, locally transgressive
t pyroclastics (chiefly
tuff, tuffites) and tuffaceous sedimentary rocks. h
(Pliocene-Piestocene) Marine and terrestrial sediments.Associated with extensive reef limestone; with
pyroclastics in western and southern central basin and in Bicol lowland.
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(Pliocene-Quaternary) Volcanic plain or volcanic piedomont deposits.Chiefly pyroclastics and/or debris at foot of
volcanoes.
(Recent) Alluvium, fluviatile, lacustrine, paludal and beach deposits; raised coral reefs, atolls, and beachrock.
(Ologocene-Miocene) Thick, extensive, transgressive mixed shelf marine deposits, largely wackes, shales and reef
limestone. Underlain by conglomerate and/or associated with paralic coal measures in places.
(Neogene) Largely intra-Miocene quartz diorite.Mostly batholiths and stocks, some laccoliths; also sills, dikes and
other minor bodies.Includes granodiorite and diorite porphyry facies and late Miocene dacite.
The country is a north-south strip of lithosphere built partly on abducted oceanic basement
rocks, and by portions of drifted continental crust from southern China. It is pictured as “a
wedge caught in between two opposite dipping trenches”. The north westward moving Pacific
Plate pushes the Philippine Sea Plate beneath the eastern side of the archipelago at the rate of
about 7 centimeters per year (PHIVOLCS, 1991). The oceanic parts of the slower moving
Eurasian Plate are being sub ducted along the western side of Luzon and Mindoro at the rate of
3 centimeters per year.
The archipelago is grouped into a mobile belt and a stable region. The former has high
seismicity while the latter is relatively free from frequent crustal movements. Luzon, the central
islands of Mindoro, Masbate, Panay, Negros, Cebu, Bohol, Leyte, Samar and other smaller
islands comprised the mobile belt while Palawan and Sulu Sea belonged to the stable regions.
The mobile belt is dissected by the left lateral Philippine Fault zone from eastern Mindanao
through north western Luzon. Recent geological and geophysical investigations revealed that
the tectonic history of the Philippine archipelago involved geological processes related to
convergent plate margins, island arcs, aphiolites, sedimentary basins and micro continental arc
collision. Luzon in particular, has sub direction zones in both the western and eastern sides.
Other locations of shorter sub direction zones indicated as trenches on the sea floor are found
off the coasts of Sulu, Cotobato, Negros and south western Palawan.
The Bicol region is sandwiched between the Philippine Fault and the Philippine Trench and cut
transversely by the Legazpi Lineament (Aurelio, 1992; Bureau of Mines, 1964; Daligdig and
Besana, 2000). It is therefore tectonically, seismically, and volcanically active.
The distribution of Active Faults and Trenches in the Philippines is shown in Figure 3 and the
map showing estimates of regional ground motion hazards in the Philippines is presented as
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
Figure 4. The expected peak ground acceleration with 10% probability of exceedance in 50
years for the project area (mainline north and south railways) is between 0.22g to 0.24g (USGS
and PHIVOLCS).
Figure 3-3: Distribution of Active Faults and Trenches in the Philippines
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3.4 Liquefaction
Soil liquefaction is a phenomenon that occurs mostly in medium to fine-grained sands wherein
a mass of soil loses a large percentage of its shear resistance when subjected to monotonic,
cyclic or shock loading, and flows in a manner resembling a liquid. Much of the damage on
substructures and foundation during earthquake is attributed to this phenomenon.
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3.5 Settlement
Considerable settlement may occur when constructing projects such as highway embankments,
bridge approaches, dikes, dams, large storage areas, tanks, or buildings on soft compressible
soil, due to the consolidation of soil under the superimposed load. Severe pavement damage
and structural failure can be a direct result of settlement and therefore it is critical that
potential settlements are estimated and appropriate mitigating measures are formulated.
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
Several factors are known to increase the likelihood of occurrence of landslides during heavy
rainfall. These include slope/gradient, water content of the soil and geology and materials
underlying the soil. Increase in any of the first three factors translates to increased probability
of slope failure while a decrease in vegetation cover also translates to increase probability of
occurrence of erosion.
Factors that influence the occurrence of landslides during intense shaking include intensity of
shaking, duration of shaking, slope gradient, geology, degree of vegetation cover and amount
of rainfall, if the earthquake or volcanic activity coincides with a period of high rainfall.
Slope protection measures may include drainage improvement by providing ditches and chute
blocks, in order to mitigate saturation of the slope material. Slope benching (to modify the
slope’s geometry), planting of vegetative cover and construction of toe walls can also be
considered.
3.7 Flooding
Based on the completed maps for the entire province of Laguna, Quezon, Camarines Sur, and
Albay, the Mainline South railway along Calamba, Gumaca and Naga has low to moderate
susceptibility to landslide and flooding, while Legazpi City is generally not flood- prone. Figures
8 to 13 show the Landslide and Flood Susceptibility Map of provinces within the Southern
Tagalog and Bicol Region.
Susceptibility to tsunami inundation for earthquakes with magnitude of 8.2 generated by the
Manila trench is presented in Figure 3-8 and 3-9 for various provinces traversed by the mainline
south railway network.
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Figure 3-8: Landslide and Flood Susceptibility Map of Calamba Quadrangle, Batangas and Laguna Provinces
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44.1 Standards
Condition
Assessments – Track
The current track is composed of the following:
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Technical Regulatory Standards on Japanese Railways. As such for the sake of our analysis and
recommendations for moving forward, we propose that the following portions of the Japanese
Technical Regulatory Standards on Japanese Railways be used:
In order to assess the current condition of the MLS track, a joint inspection of the whole track
line was undertaken together with PNR division personnel. The condition assessment covered
the following:
Rail
Sleepers
Ballast& sub-ballast
Formation
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Detailed condition assessments are included in Appendix 2 - Assessment Report on Existing PNR
Railway, as follows:
4.2.1 Rail
Two (2) rail profiles are installed on the MLS; 37 kg/m and 32 kg/m. It is our understanding that
32 kg/m profile was originally installed and later replaced with 37 kg/m during rehabilitation
works done by PNR. However, the replacement of all 32 kg/m was not completed. Rail was
observed in 4 different lengths, as follows:
Overall, the condition of the rail itself is in good condition (largely on account of well-
constructed track; relatively light axle loads; and very little accumulated traffic). Most rail
defects and damage was due to improperly maintained joints. Overall condition of the lighter
32 kg/m rail was worse than the newer 37 kg/m rail.
4.2.2 Sleepers
Pre-cast sleepers are generally used on the main track while wooden sleepers are used on
bridges. Currently, PC sleepers are spaced at 714mm on tangent and 625mm on curve, while
wooden sleepers are spaced at 450 mm. In some sections uneven spacing of sleepers can be
seen and that the standard 1,400 pieces per linear meter of PC sleepers and 1,600 pieces of
wooden sleepers laid is not observed.
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Uneven spacing of sleepers was observed throughout and this was largely on account of
sleepers being cannibalized from the track for use elsewhere (most often on bridges). In
addition, significant numbers of broken PC sleepers were seen in the following sections where a
train derailment had occurred:
b. Two locations between Banga Caves and Ragay Station, 200m and 10m in length
respectively.
c. Between TP 6148 – TP 6149 right after Bayaao Bridge abutment, around 60m in length
The clips used to fasten the PC sleepers were observed to be missing in some sections and were
often seen to be placed alternately. Pilferage largely accounts for the loss; apparently at a rate
of 30,000 clips per year between Manila to Calamba in the past two years.
Most wood sleepers and fasteners were not observed to be in good condition. They were
typically observed with large cracks along the length of the wooden sleepers and missing
fasteners. New wood sleepers recently purchased from China appear to be softwood with
multiple cracks. Some cracks are quite big gaps visible throughout the ties end to end. Some of
these new wood ties were already installed (mainly on bridges) and some were stocked at PNR
Stations.
Bridges were observed to have both wood and concrete sleepers. The concrete ties have to be
removed and replaced with wooden ties.
4.2.3 Ballast
Generally the track ballast along MLS was found to be in less than good condition; and in some
sections, there was little or no ballast in place. Moreover, the presence of vegetation and water
on top of the track is evidence of poor ballast condition. The poor ballast is caused by the
quality of ballast used (mixed volcanic sand and soil instead of crushed rock especially within
Naga Division), poor maintenance and pilferage. It was observed that within the Manila
Division, the lack of track ballast has often led to damages to PC sleepers.
Embankments are not in its good condition due to lack of maintenance, drainage problems
caused by illegal settlements in right-of-way and from flood damage in areas of frequent
flooding.
4.2.4 Formation
Observations of failed or unstable formation were observed throughout but seen as being most
significant in Naga and Hondagua Divisions, and to a lesser degree Lucena Division. Sections
where there is an occurrence of landslides are located in areas that are prone to liquefaction
and settlement as identified in the Active Faults and Liquefaction Susceptibility Maps shown
and further discuss in the Geotechnical Report appended in this report. Track most prone to
flooding is that which traverses the central and flat alluvial land of the Bicol River Basin. This is
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
discussed in more detail in the Hydrology Report included in this report. The following figure
identifies the track sections with geotechnical and hydrological issues.
Figure 4-2: Track Sections with hydrological or geotechnical issues
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Alabang to Legazpi
There are 397 crossing between Alabang and Legazpi. Of these 214 are authorized and 183 are
unauthorized. Only 31 of the authorized are manned (at least officially) and none of the
unauthorized are manned.
Unauthorized crossings are ones that have been established without the formal consent of
PNR. They are often in areas of high encroachment, and very few have required signage or
gates and all are unmanned (officially).
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Visibility is defined as the distance a person can see an approaching train from a vehicle
approaching the crossing from various distances and orientations. Visibility has been assessed
as mainly fair or poor, as indicated in the following figure.
Figure 4-4: Visiability at Crossings - Alabang to Legazpi
Sightlines are most typically blocked by structures (and not vegetation) and most often, it is
illegal structures on railway right-of-way. Removing railway encroachment will significantly
improve overall crossing visibility.
The following figures present the crossings with crossing signs, listen signs and crossing
protection bars. As can be seen, very few crossings are equipped with complete signs and even
fewer with proper crossing protection bars.
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Unauthorized 2 2 4
Total 34 3 37
All 37 crossings have been evaluated as having good visibility, and but two have required
signage (though they may since been stolen or vandalized). Crossing barriers were found to be
fully installed and functioning at only 28% of crossings; whereas flashing lights and ringers were
fully installed at 75% (though at five crossing, there was no electricity at time of inspection).
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In addition, within the Manila Division, there are 7 cross-over’s within the double track section
of the Manila Division.
With the exception of the Manila Division, mainline turnouts were observed to be generally in
poor to fair condition, largely on account of muddied surface condition and missing or defective
components. On the Manila Division, mainline turnouts were found to be relatively new and in
good condition; though there were many missing bolts and nuts indicating insufficient
maintenance.
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Sleepers
Replace all damaged and missing concrete sleepers with like kind, and replace all wood track
sleepers with concrete sleepers using the existing sleeper pattern of sleepers on 714mm
spacing or (1400 pcs per kilometers) on tangents, and 625mm or (1,600 pcs per kilometers)
on curves.
Install all pads, clips and insulators for 100% installation.
Remove all concrete sleepers, and deteriorated or damaged wood sleepers from open deck
bridges, and install quality hardwood ties at spacing of 500mm on tangents and 450mm on
curves. Ensure no less than 4 spikes per sleeper with 2 on each rail for every sleeper.
Formation
At locations, where the formation is showing evidence of failure, dismantle track and re-
construct roadbed as needed, and replace sub-ballast and ballast materials. This would most
often be at locations prone to flooding or subject to high levels of trespassing.
Where needed, remove materials and properly profile ditches to permit proper drainage of
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TECHNICAL REPORT – PNR SOUTH | NSRP South Line Project (DFS) CPCS Ref: 13039
the track structure, and movement of surface water away of the rail line.
Work with LGU’s (Local Government Units) to find ways to close (or combine) unauthorized
crossings, and where needed to change classification to Authorized Road Crossing.
Mainline Turnouts
Where needed for operational purposes (such as train meets, to access passenger platforms, or
to reach depots or turning tracks), mainline turnouts should either be
Repaired by replacing worn or damaged components, installing proper drainage and surface,
and replacing worn or defecting sleepers, or
Replaced with new 37 kg/m no. 12 turnouts on hardwood ties (if condition does not warrant
repair).
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55.1 Standards
Condition
Assessments- Bridges
Currently there are no standards specifically for the design of railway structures being applied
and implemented in the Philippines. As such, the design of railway structures must conform to
the minimum requirements of the National Structural Code of the Philippines, Volume II
Bridges. Other codes to be utilized include but are not limited to the following:
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Non-compliance with the latest code does not necessarily mean the existing substructure is
unsafe or susceptible to collapse. The structure could be structurally safe from earthquake
depending on type of structure and mass loading applied. The structural integrity of the
substructure must be verified during the detailed engineering work.
It is important to note the limits of our inspections and assessments. Observed damage and
deterioration were limited to that for which that could be seen from the top and below the
bridge. It is possible that deteriorated or damaged sections of superstructures exist but are not
visible from these vantage points. As well, the structural integrity of substructures has not been
assessed. The extent of damage to be repaired shall require confirmation to be made on site.
The follow table presents a presents a summary of bridge condition along MLS.
Figure 5.1: Summary of bridge condition along MLS:
Naga 107 9 14 84
Hondagua 90 5 22 63
Manila 67 8 8 51
Generally most bridge members are found to be severely corroded due to lack of maintenance,
old age, inadequate protection from natural environment and consistent moisture that
attributed to unsafe hydraulic clearance from waterways. Likewise, most base plates and end
plates of girders are noted to be embedded with earth, covered with full grown shrubs and
have collected wet debris resulting to continuous deterioration and weakening of supports.
Slope protection generally appeared to be in good condition except on some bridge abutments
wherein scouring is evident. Some bridge location exhibit heavy siltation and constriction of
channel due to poor maintenance of waterways, on these locations the required clearance
from the soffit is unlikely met.
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Nine (9) bridges for replacement are noted in Naga Division, as follows:
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Erosion of embankment on approaches is noted and in some bridges there are reports that
embankment have been washed out during heavy rains.
Five (5) bridges are recommended for total replacement, as per the following figure.
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There are twelve (12) bridges recommended for total replacement, as per the following figure.
Figure 5.4: Bridges to be replaced on Lucena Division
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Out of 67 bridges there are 8 bridges recommended for full replacement as per the following
figure.
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6 Condition
Assessments -Stations
There are a total of 48 stations and 64 flag stops along the Mainline South. Most of the stations
and flag stops are not operational, except for stations between Tutuban and Binan. This line is
operational with daily trips from Tutuban – Muntinlupa starting from 5am up to 8pm, plus two
(2) trips daily from Tutuban – Binan; one in the morning and one in the afternoon.
Except for the stations within Manila division, most of the stations and flag stops were
observed to be insufficient for satisfactory and safe operation. Most of them are either turned
into a residential structure by illegal settlers, a storage area (where located within a public
market), and others which were never maintained since PNR operation ceased.
Requirements for stations and flag stops will be further studied as part of our traffic and
operational analysis. Station and Flag stop conditions are shown in the tables below.
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77.1 General
Condition Assessment
- Depots
Depots play a very important role in the operations of a railway system. The facilities,
equipment and basic/special tools within the Depot are vital instruments in the performance of
the required level of maintenance work not only for the maintenance of the rolling stock fleet
but also for the fixed facilities as well, such as the stations, tracks, bridges, buildings and other
areas necessary for effective the day to day railway operations.
Stabling tracks
Circulation tracks and shunting tracks
Overhauling shed (heavy maintenance and repairs))
Preventive maintenance shed (daily inspection, light maintenance and repairs)
Equipment/component repair, test and rehabilitation shops
Support shop for repairs or workshops
Cleaning Facilities (train washing plant, interior cleaning area, undercar blow down facility)
Waste water or sewage treatment facility
Water supply and fire-fighting facilities
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Manila Depot
Naga Depot, and
Calamba Line Sheds.
Stabling and shunting areas for DMU’s, locomotives, passenger cars, baggage cars, EMU’s
(converted to locomotive hauled passenger cars)
Stabling of track maintenance equipment
Stabling of re-railment equipment (rail mounted cranes) and equipment cars
Stabling of freight cars (flat wagons and box cars)
Preventive maintenance of DMU’s (minor and major maintenance), but currently only
corrective maintenance/emergency repairs are being done due to insufficient maintenance
budget.
Preventive maintenance of locomotives (minor maintenance), passenger cars and baggage
cars, but at the moment only corrective maintenance/emergency repairs are being done due
to insufficient maintenance budget.
Maintenance Crew office
Fuel Depot (overhead fuel tank and fuel tank cars)
The Manila (Tayuman) depot has two (2) shed for rolling stock maintenance. One shed is
purposely for the maintenance (minor and major) and repair of the six four- car train DMU’s ,
but currently only corrective maintenance/emergency repairs are being done due to
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insufficient maintenance budget. There are four maintenance tracks inside the shed and two
maintenance tracks outside and adjacent to the shed. To carry out the maintenance works, the
shed is equipped with 4 mobile lifting jacks, scissor lift table, fork lift and compressed air
system equipment.
The other maintenance shed have five maintenance tracks and used for the minor maintenance
and repair of the locomotives, but again for the moment only corrective maintenance and
emergency repairs are done on these maintenance tracks.
Figure 7-1: Manila Depot, Tutuban
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maintenance and emergency repair for the past years of operation and is still continuously
being undertaken up to now.
Though this is not a good engineering maintenance practice, PNR has no choice but to resort to
this action just to cope up with the day to day operational requirements. However, this practice
has a detrimental effect on the condition of the railway system and in fact this can be proven by
the continuing reduction on the number of operational rolling stocks over the past years due to
numerous breakdowns on the major equipment and components because of the non-
implementation of the timely preventive maintenance.
The Depot has not been spared of the same problem wherein the maintenance facilities and
equipment were not properly maintained due to budgetary constraints. With such a problem, it
cannot be expected from PNR to provide an efficient and safe railway system due to the fact
that the Depot which is supposed to provide the first line maintenance for the railway system
(especially the rolling stock) has so many inadequacies within.
For the return of reliable and efficient long-distance rail services, it will be necessary to
rehabilitate the existing depots. In this section, we highlight major areas requiring
rehabilitation, repair or replacement for each of the facilities.
Others
a) Installation of Dried Sand Room Facility
b) Construction of Yard House (for Yard supervisor/Switchmen)
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d. Fire-fighting system
e. Water supply system
f. Compressed air system
Yard
a. Replacement of tracks
b. Rehabilitation of track beds
c. Construction of Yard House (for Yard supervisor/Switchmen)
Other
a) Installation of waste water treatment facility
Line Sheds
a) Roofs, roof framing, columns (steel), walls, floors
b) Lightings and power outlets
c) Fire-fighting system
d) Water supply system
e) Compressed air system
The above mentioned items needs immediate rehabilitation in order to provide a condition of
safe and reliable railway service for the existing and more so if additional or new rolling stocks
are procured and route extensions introduced to complement the existing PNR service. To be
coupled with this also is effective organization/personnel to handle all the daily operation and
maintenance requirements and activities.
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8 Condition Assessment
– Communications,
Control & Signalling
8.1 General
Railway operations often rely on signalling systems to, among other things, maintain a safe
separation distance between running trains. The minimum distance between trains must be
sufficient for a train to come to a complete stop, with a suitable safety margin with the train
ahead. The signalling system facilitates the movement of trains at maximum operating speed
allowed without compromising safety. It allows the train to operate the trains at scheduled
time table and assigned headway in an efficient and safe manner. The signalling system also
protect specific paths or routes at junctions or level crossings, crossovers, sharp curves and at
approaches to terminal or end stations using automation to reduce or remove the possibility of
human error which is usually responsible for a big percentage of rail transit incidents.
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requires reliable communications between the trains (and maintenance foreman) and the
dispatcher. It also requires the dispatcher to have a basic computer system to track the
locations of trains and foremen (based on the information on their locations they provide).
Lastly, it requires a formalized protocol for granting track access. Typically this involves verbal
instructions by the dispatcher with an exact repeat by the train conductor or maintenance
foreman. Conditions can be attached to the authorization. This type of system is used
throughout the world on lightly used lines and is called many names such as track warrant
system or occupancy control system. To work most effectively, a communication system needs
to be in place so that the dispatcher can communicate with trains and maintenance foreman
(and between trains and foreman) across the entire territory.
A more rudimentary system that does not require a reliable communication system is one
where local station masters or operators grant permission for trains to depart their station and
move to the next one. The operator can only grant authority to depart it station and can only
do this after verifying with the station operator that no trains have been or will be granted
access to the track. Track maintenance can be undertaken only when station masters at both
ends of the section of track have granted permission and have blocked entrance of trains into
the section. How authority is granted by stations masters to trains differs across the world. In
some cases, where there are communications, the train can be granted permission verbally and
will not need to stop at the station. Some railways require a written permission from the
station master or a physical token which requires them at the station. The system goes by a
variety of names including direct train control, token or tokenless systems and other names.
This is the system that is used on the PNR South.
On the PNR South, trains depart the stations after the station master/personnel has given or
handed the line clear certificate or departure or pass slip to the driver. Blocking or separation
of running trains is carried out between stations and regulated or controlled by the station
master/personnel on each station by communicating with each other either thru the telephone
system or the VHF radio communication system to coordinate the arrival and departures of
train on their respective station .In the depot and line sheds, train movements (arrival,
departure, shunting, and stabling) is controlled and managed by the Yard Master giving orders
to switchmen to manually operate or set the relevant switches or points during train
movements.
8.2.1 Signalling
The PNR does not have a signalling system or any infrastructure that would be of any use to any
system that could be installed in the future. Stations with sidings have no interlocking devices
either and the points or track switches movements are manually operated with the use of a
switch handle or lever.
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8.2.2 Communications
The backbones of communications at PNR are VHF radios and land and mobile telephones.
Communications with the VHF system is localized as there are no repeater stations. The system
is augmented with use of land and mobile phones.
In the immediate term, it would be prudent to continue with the existing system whereby
station masters grant access to adjacent stations. It would be wise to equip locomotives,
station masters and crossing guards with reliable VHF radios especially for locations that mobile
service is not strong. Where mobile service is reliable and strong, this may pose the best
communication mode for the immediate future. A review of current train control and
communication practices should be undertaken and more formalized practices and procedures
introduced.
In due course as traffic grows, a modern system of train control will be required. A GPS/GSM-
based signaling and train control system would be very suitable to the PNR South, as it has
minimal wayside infrastructure and can be implemented incrementally as traffic grows. Such
systems do not have physical signals at station layouts and use radio, backbone transmission
facilities, the GSM mobile phone network to replicate a physical signaling system working on
the same principles as centralized Train Control. Train signals are communicated to units
located within locomotives. The system can be modified to assist in the control of fuel thefts,
continuously monitor train positions and plan efficient meets.
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increase, capacity can be added by increasing the number of passing loops and equipping
turnouts for remote control by central dispatchers. Another option for increasing capacity
would be lengthening passing loops so longer trains can be run.
In our operations study, we will undertake operations analysis and assess projected traffic
levels against capacity under various investment and operating scenarios. It is at this time, we
will advise on the appropriate investment in communications, control & signalling system as
well as the number and lengths of passing loops.
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9 Track Rehabilitation –
Cost Estimates
This chapter describes the methodology used to generate quantities and unit costs used to
estimate rehabilitation cost for track work. The basis for the quantity estimates are:
Unit cost development is discussed in section 9.4 and cost estimates are included in section 9.5
The cost information herein is a planning level order of magnitude cost estimate developed to
provide a budgetary cost for evaluating the viability of the rehabilitation of the PNR South line.
In the following 5 figures, we provide the characteristics of track sections. They will be used to
estimate quantities for rehabilitation.
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Legazpi - Travesia - Ligao - Polangui - Iriga– Pili Pili - Naga Naga - Pamplona Libmanan - Sipocot -
Travesia Ligao Polangui Iriga Pamplona - Libmanan Sipocot Lupi
Starting point (km) 479.00 455.70 445.40 437.05 411.95 389.90 377.60 365.15 353.30 340.45
End point (km) 455.70 445.40 437.05 411.95 389.90 377.60 365.15 353.30 340.45 330.50
Total distance (m) 23,300 10,300 8,350 25,100 22,050 12,300 12,450 11,850 12,850 9,950
Total curve distance (m) 7,390 4,450 700 3,700 1,250 1,550 1,550 1,950 2,800 6,700
Total tangent distance (m) 15,910 5,850 7,650 21,400 20,800 10,750 10,900 9,900 10,050 3,250
Total bridge distance (m) 401 149 160 170 191 176 555 526 113 463
Loop track ( Second ) 400 400 400 400 400 400 400 400 400 400
Lupi to Ragay - GRS GRS - Delgallego - Tagkawayan - AlonerosCalua Caluag- Hondagua- Lopez-
Ragay Delgallego Tagkawayan Aloneros g Hondagua Lopez Gumaca
Starting point (km) 330.50 312.40 297.70 286.90 278.40 255.05 243.50 237.25 229.80
End point (km) 312.40 297.70 286.90 278.40 255.05 243.50 237.25 229.80 210.60
Total distance (m) 18,100 14,700 10,800 8,500 23,350 11,550 6,250 7,450 19,200
Total curve distance (m) 5,302 2,849 3,119 4,454 9,461 3,910 1,828 1,848 4,964
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Total tangent distance (m) 12,798 11,851 7,681 4,046 13,889 7,640 4,423 5,602 14,236
Total bridge distance (m) 471 299 235 136 605 163 100 101 171
Reversing track 0 0 0 0 0 0 0 0 0
Loop track ( Second ) 400 400 400 400 400 400 400 400 400
End point (km) 199.74 187.65 179.65 171.95 165.65 156.05 143.60
Total distance (m) 10,262 12,088 7,996 7,704 6,300 9,600 12,450
Total curve distance (m) 4,637 5,372 2,604 2,133 1,848 3,307 3,096
Total tangent distance (m) 5,625 6,716 5,392 5,571 4,452 6,293 9,355
Reversing track 0 0 0 0 0 0 0
Loop track ( Second ) 400 400 400 400 400 400 400
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End point (km) 133.10 124.70 119.63 111.95 98.56 88.73 64.91 60.00
Total distance (m) 10,500 8,400 5,070 7,680 13,387 9,833 23,824 4,906
Total curve distance (m) 3,590 1,130 108 0 770 0 6,384 1,632
Total tangent distance (m) 6,910 7,270 4,963 7,680 12,618 9,833 17,441 3,274
Total bridge distance (m) 106 226 240 164 173 172 430 54
Reversing track 0 0 0 0 0 0 0 0
Loop track ( Second ) 400 400 400 400 400 400 400 400
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Total tangent distance (m) 6,028 13,650 3,700 6,690 3,462 22,426
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Mainline
12. Nuts and Bolts on Rail Joints 120 m. rail 100 100 100 60-100
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Station Tracks
3. Rail Replacement/Additional 80 80 80 80
8. Nuts and Bolts on Rail Joints 120 m. rail length 100 100 100 100
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Station Tracks
15. Replace defective turnouts and
turnouts accessories sets 20 18 30 14
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Cost estimates are expressed in Philippine Pesos (Php) with the following provisions;
The following assumptions were used as basis for unit cost derivation.
Regular working hours is eight (8) hours per day of six (6) working days per week
Project implementation plan shall be followed. Any failure to follow the plan may have a
material impact on project costs.
All taxes such as VAT and additional local taxes were included in the cost estimate
Local construction labor rates includes applicable premium contributions and taxes
The following items were excluded from the cost estimates;
Escalation beyond the estimate base date, including escalation due to local market
conditions
All impacts of foreign currency exchange rate variation. Forex used 1USD = Php43.74
Allowances for any changes to the scope of the project
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Any cost incurred to accelerate the work or to get the work back on schedule if it falls behind
schedule
Project application and approval costs
Figure 9-4 Unit Costs (PhP/unit) - Track work on Mainline and Station Tracks
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Station Tracks
15. Replace defective turnouts and
turnouts acecesories sets 3,055,731 3,058,418 3,058,418 3,061,081
22. Provide new fish plates pcs 1,196 1,292 1,292 1,387
23. Provide new ballast materials cu.m 7,586 7,638 7,638 7,716
24. Provide new sub-ballast materials cu.m 6,990 7,062 7,042 7,093
25. Clearing of track embankment slopes ha 24,888.0 25,177.0 25,177.0 25,649
26. Filling Materials cu.m 429 201 202 229
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- - - - -
Station Tracks
- - - - -
15. Replace defective
turnouts and
turnouts 61,114,620 55,051,524 91,752,540 42,855,134 250,773,818
accessories
16. Replace defective
and missing rail
with new 37kg rail 54,815,712 20,197,440 33,662,400 11,817,120 120,492,672
(20meters)
17. Replace wooden
ties with concrete
70,239,891 25,272,414 43,265,640 15,199,170 153,977,115
ties
18. Replace defective
and missing rail
11,147,136 4,479,516 7,465,860 2,836,088 25,928,600
clip
19. Replace defective
and missing
3,514,368 1,452,816 2,421,360 947,324 8,335,868
rubber pad
20. Replace defective
side post insulator
7,248,384 3,067,056 5,111,760 2,000,560 17,427,760
and rail insulator
21. Replace defective
and missing nuts
and bolts on the 49,776 23,004 38,340 11,544 122,664
fish plates
22. Provide new fish
plates 130,231 51,680 86,133 32,363 300,408
23. Provide new
ballast materials 92,928,500 34,371,000 57,285,000 20,254,500 204,839,000
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10 Bridge
Rehabilitation and
Replacement - Cost
Estimates
This chapter describes the methodology used to generate quantities and unit costs used to
estimate rehabilitation and replacement costs for bridges across all divisions. The basis for the
quantity estimates are:
The cost information herein is a planning level order of magnitude cost estimate developed to
provide a budgetary cost for evaluating the viability of the rehabilitation of the PNR South line.
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Minor rehabilitation works are applied to bridges in good to fair condition and consist of
localized repair works such as sand blasting and repainting of steel members, replacement of
bolts and nuts, welding works, etc. Repair works such as replacement of span, replacement of
substructure, re-plating, etc. are considered as major rehabilitation. Quantities for the
rehabilitation of bridges are summarized by division and presented in Figure 10.1 below.
Figure 10-1: Quantities of Bridge Reabilitation (both minor & major)
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Where the retrofit cost of a bridge approaches 60 to 70 percent of a new bridge, we have
recommended bridge replacement. The quantities of the work items for the construction of the
replacement bridges are summarized in Figure 10.2 below.
Figure 10-2: Quantities for Bridge Replacement
Waterway
Clearing of Waterways sq.m 4,696 2,461 3,297 101
Dredging of waterways cu.m 16,924 2,140 3,915 6,543
Gabions cu.m 406 211 2,272 636
Grouted Riprap (300mm thk) cu.m 245 137 63 24
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Substructure
Structural Concrete (f'c = 28 Mpa) cu.m 13,270 13,494 13,494 13,718
Reinforcing Steel (Fy = 414 Mpa) kg 86 87 87 88
Bored Pile - 800mm diameter (f'c - 35Mpa) lm 47,566 64,332
Waterway
Clearing of Waterways sq.m 63 64 64 66
Dredging of waterways cu.m 1,093 1,104 1,104 1,116
Gabions cu.m 4,083 2,017 2,017 2,017
Grouted Riprap (300mm thk) cu.m 3,030 3,212 3,212 3,390
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Substructure
Structural Concrete (f'c = 28 3,014,281 1,590,943 1,175,327 3,207,268 8,987,819
Mpa)
Reinforcing Steel (Fy = 414 Mpa) 2,984,544 1,512,408 1,137,351 3,089,328 8,723,631
Bored Pile - 800mm diameter 4,566,336 5,661,216 10,227,552
(f'c - 35Mpa)
Removal of existing concrete 2,583,820 2,904,583 2,112,424 2,157,144 9,757,971
structure (Piers)
Precast RC Pile 400x400mm (f'c 10,309,236 6,540,266 3,925,734 6,020,980 26,796,216
= 28 MPa)
Structural Excavation (incl. 320,410 320,410
removal of structure)
Waterway
Clearing of Waterways 295,848 157,478 210,982 6,692 671,001
Dredging of waterways 18,497,440 2,362,284 4,322,160 7,301,486 32,483,370
Gabions 1,657,698 424,780 4,582,624 1,282,812 7,947,914
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11 Station
Rehabilitation Cost
Estimates
11.1 Rehabilitation Requirements
Inventory and assessment of the stations and flagstops are discussed in Chapter 6. Stations and
flagstops within Manila Division from Tutuban to Lucena are in good condition, with some
recently rehabilitated by PNR. They do not require further works. Elsewhere, stations and
flagstops which are in fair condition (with buildings still intact) will be rehabilitated. While
stations and flagstops in deteriorated state, lack essential features or are non-existent will be
reconstructed. Conditions of stations and flagstops in the four divisions are categorized in the
following figures.
Figure 11-1: Station Condition
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DIVISION
DIVISION
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12 Depots -
Estimated Capital
Costs of Rehabilitation
Lump sum costs are derived to cover the amount needed to rehabilitate the facilities of the
depot to make it functional. The rehabilitation works as summarized in the following
presentation. The costs do not include fixed costs such as mobilization, engineering design,
works supervision, and site facilities. These are dealt with in chapter 10.
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13 Calamba to
Batangas Branch Line
This is a single-track line which leaves the south main line at Km 60.5 and extends 56.4 km to
Batangas City (seaport located on Batangas Bay), passing through the following main population
centers:
• Makiling - Km 7.4
• Tanauan - Km 15.3
• Malvar - Km 19.8
• Lipa Km - Km 31.1
• San Jose - Km 41.3
• Batangas - Km 56.3
The line was severely damaged during the Second World War and has been abandoned for about
70 years. Little remains of the line. The track has been removed at most locations. Bridges have
been destroyed or converted to road use. No station buildings remain. There is significant
encroachment along the entire length of the line, especially in the main population centers, where
there are many instances of permanent buildings constructed across the former right-of-way.
There are five areas identified that the PNR alignment is encroached with communities with high
volumes of population. Houses and permanent structures were built over the PNR right of way.
The areas identified are as follows:
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39+354 - 40+380
47+875 - 49+381
There are no major river crossing found on the alignment, however it crosses on two major
highways, two crossings on SLEX at station 2+820 and station 10+446; and at Star Tollways at
station 33+191. The line crosses low volcanic mountains and reached an elevation of 337 m
between Malvar and Lipa.
There is an 18 km long branch line from Malvar to San Pablo City (also abandoned). There is also a
5.8 km abandoned line from Batangas to Bauan, another port location on Batangas Bay.
To re-establish the Batangas Branch it will be necessary to carry out significant land acquisition. At
some of the larger population centers it may be better to bypass these locations rather than incur
the delays and cost of trying to re-establish the original alignment. This will be addressed in the
detailed design phase and should have little impact on overall costs. The former alignment is still
very much in evidence, and at most locations can be restored for railway use. The existing
embankments can be restored and new track installed. All bridge superstructures will require
replacement, however it is expected that most abutments and foundations can be restored. It will
be necessary to construct new passenger stations. Train control will be accomplished through
radio communication. A new radio system will be installed, likely using cellular technology and
repeater units.
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VARIABLE COST
DESCRIPTION UNIT QTY UNIT COST AMOUNT
Track (Mainline) Km 56 57,589,230 3,224,996,902
Side Track/Pocket Track l.m 2,000 60,880 121,760,426
Kilometer Post ea 56 3,613 202,328
Construction of Guard Post at level Crossings
lot 160 184,128 29,460,480
Construction of Stations lot 8 14,515,200 116,121,600
Construction of Bridges l.m 3,600 534,800 1,925,280,000
Signals, Electrification & Communication lot 1 254,648,334 254,648,334
Land Acquisition & Resettlement lot 1 1,279,784,667 1,279,784,667
Total 6,952,254,738
TOTAL COST
COST
Variable Cost 6.95
Fixed Cost 0.77
Total Cost 7.72
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BILL OF QUANTITIES
NARROW GUAGE (75 kph)
Item No. ITEM DESCRIPTION Qty Unit Unit Cost Amount
D CONSTRUCTION OF RAILWAY
D.1 Mainline
D.1.1 Sub-Ballast 44,515 cu.m 7,064 314,450,428
D.1.2 Ballast 105,990 cu.m 7,661 811,991,688
D.1.3 Installation of Concrete ties and pandrol 86,441 sets 5,843 505,074,763
D.1.4 Installation of Fishplates complete with nuts and bolts 1,941 sets 1,423 2,762,043
D.1.5 37 kg Rail (20m) 5,849 pcs 71,764 419,747,636
D.1.6 Clearing and Slope Stabilization 171 ha. 33,604 5,746,284
D.1.7 Embankment from Common Borrow 853,644 cu.m 1,365 1,165,224,060
E CONSTRUCTION OF BRIDGES
E.1 Construction of Bridges
E.1.1 Type 1 - Flat Slab 75 l.m 403,200 30,240,000
E.1.2 Type 2 - Reinforced Concrete Deck Girder 1,525 l.m 537,600 819,840,000
E.1.3 Type 3 - Prestressed Concrete Girder 2,000 l.m 537,600 1,075,200,000
G OTHER
G.1 Signals, Electrification & Communication 1 lot 254,648,334 254,648,334
G.2 Land Acquisition & Resettlement 1 lot 1,279,784,667 1,279,784,667
Sub Total of Part G 1,534,433,002
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14 Total Cost of
South Line
Rehabilitation
14.1 Fixed Costs
In the figure that follows, we present the fixed cost to undertake all work (track, bridges,
stations, crossings) on each of the divisions.
Figure 4-1: Fixed Costs for each Division (PhP)
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It is important to note that this excludes rolling stock which will be addressed in the operations
report. In this analysis, we will look at downstream expansion of depot facilities as the rolling
stock fleet increases to meet traffic demands, as well management systems and will be
required that will be required for sustained operations. The total estimated capital cost to
restore the Batangas Branch for safe operation at a design speed of 75 kph and for maximum
axle loads of 15 tons is 8 B PhP, as summarized below.
Figure 14-3: Total Capital for Batangas Branch (Million PhP)
Description Total
Fixed Costs 772
Track 3,347
Crossings 29
Bridges 1,925
Stations 116
Communications 255
Land Acquisition 1,280
Totals 7,724
The total cost to rehabilitate the south line and restore the Batangas Branch is 36 B PhP. Please
see Appendix 4 for typical drawings, as follows:
Bridges (4.1)
Track (4.2)
Stations (4.3)
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