EEQA 770 Specification.pdf

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

EE&QA - 770

Materials and Workmanship Specification

ISSUED:

September 23, 2008

REVISIONS:

IR

SUBWAY OPERATIONS DIRECTORATE

EQUIPMENT ENGINEERING AND QUALITY ASSURANCE

Equipment Engineering and Quality Assurance Technical Specification

Specification:

EE&QA – 770

Materials and Workmanship

Page: i

Date: September 23, 2008

Revised:

Revision: IR

1.0 Materials & Workmanship

1.1 General Description

1.1.1 Reference Documents

1.2 Units of Measure

1.3 Storage of Material

1.4 Metals

1.4.1 Low-Alloy, High Tensile Strength, Structural Steel

1.4.2 Heat-Treated Alloy Steel

1.4.3 Stainless Steel

1.4.4 Steel Castings

1.4.5 Rivet Steel

1.4.6 Aluminum

1.4.7 Aluminum Extrusions

1.4.8 Aluminum Castings and Forgings

1.5 Non-Metals

1.5.1 Elastomers

1.5.2 Neoprene Foam

1.5.3 Fiberglass-Reinforced Plastic

1.5.4 Thermoplastic

1.5.5 Glass

1.5.5.1 Laminated Safety Glass

1.5.5.2 Tempered Safety Glass

1.5.6 Floor Covering

1.5.7 Marking Films & Graphics

1.6 Structural Panels

1.6.1 Honeycomb

1.6.2 Plywood & Plymetal

1.6.3 Panel Flatness

1.7 Fastening / Joining

1.7.1 Fastening to Structural Members

1.7.2 Threaded Fasteners

1.7.2.1 Fastener Materials

1.7.2.2 Locking Requirements

1.7.2.3 Plating & Treatment of Fasteners

1.7.2.4 Torque Marking/Indexing

1.7.2.5 Bolts and Nuts

1.7.2.6 Electrical and High Temperature Connections

1.7.3 Riveting

Page: ii

1.7.4 Welding

1.7.4.1 Welder Certification

1.7.4.2 Welding Procedures

1.7.4.3 Welding Electrodes

1.7.4.4 Weld Repairs

1.7.4.5 Welding Inspection and Examination

1.7.4.6 Heat Treatment

1.7.5 Brazing

1.7.6 Soldering

1.8 Piping, Tubing & Pressure Vessels

1.8.1 Piping and Tubing

1.8.2 Filters

1.8.3 Pressure Vessels

1.9 Bearings & Lubrication

1.10 Corrosion Control

1.10.1 Dissimilar Metal Treatment

1.11 Cured Materials

1.11.1 Paint & Primer

1.11.1.1 Carbody Exterior

1.11.1.2 Equipment Enclosures

1.11.1.3 Exposed Piping, Conduits and Wireways

1.11.1.4 Undercoating

1.11.1.5 Painting and Undercoating Restrictions

1.11.2 Powder Coating

1.11.3 Adhesives

1.11.4 Sealants & Caulking

1.12 Insulation

1.12.1 Acoustic Insulation

1.12.2 Thermal Insulation

1.13 Fabrics & Upholstery

1.13.1 Woven Fabric

1.14 Electrical

1.14.1 Wiring General Requirements

1.14.1.1 Conductors

1.14.1.2 Wire & Cable Insulation

1.14.1.3 High-Temperature Wire & Cable

1.14.1.4 Communications Wire & Cable

Page: iii

1.14.1.5 Application & Installation

1.14.1.6 Undercar and Roof Wiring Installation

1.14.2 Power Cables

1.14.3 Cable Connectors

1.14.3.1 Terminals

1.14.4 Conduit and Raceway Requirements

1.14.5 Cleating

1.14.6 Equipment Enclosures & Junction Boxes & Fittings

1.14.7 Wire Identification & Terminal Markings

1.14.8 Splicing and Taping

1.14.9 Circuit Protection

1.14.10 Grounding

1.14.11 Electrical Components

1.14.12 Relays and Contactors

1.14.13 Pushbutton Switches

1.14.14 Inductors

1.14.15 Transformers

1.14.16 Resistors

1.14.17 Capacitors

1.14.18 Motor Starters

1.14.19 Electronic Components

1.14.20 Printed Circuit Boards

1.14.21 Semiconductor/Integrated Circuits Requirements

1.15 Microprocessor-Based System Requirements

1.16 Software Requirements

1.17 Flammability, Smoke Emission & Toxicity

1.18 SUBMITTALS – CDR

1.0 Materials & Workmanship

The vehicles contain a variety of miscellaneous components including: labels, grommets, springs, gaskets, mounting hardware, captive screws, threaded fasteners, washers, lock washers, nuts, hangers, tape, tamper proof hardware, elastomeric components, seals, couplings, link pins and hook plates, vertical support rods/eye bolts, packing seals, springs, cotter pins, fuses, etc. Wherever such components are identified to be replaced, they shall be replaced in kind with new components.

1.1 General Description

Workmanship and Quality shall conform to the best manufacturing practices in all respects. All work shall be performed by properly trained, qualified personnel skilled in the tasks they will be performing. All work shall be performed using correct tooling and procedures.

All new materials and components used in the rebuild of the vehicle shall comply with the requirements of this section.

Surfaces exposed to passengers, crew, or maintenance personnel shall be kept smooth and free of burrs, sharp edges or corners, and dangerous protrusions. The vehicle rebuild shall avoid pinch points, tripping hazards, snagging points, water traps, and debris accumulation points.

Carbody structural parts that are permanently covered and concealed after assembly shall not be made of copper, copper bearing aluminum alloys, brass, bronze, silver, or nickel.

Foreign matter, such as shavings, chips, etc., shall be completely removed from all parts of the vehicle, its components, assemblies and subassemblies, whether hidden or exposed.

Materials for the rebuild of the vehicle shall be in accordance with the stated specification or cited standard, unless The Contractor obtains Massachusetts Bay Transportation Authority’s (MBTA), herein referred to as the Authority, approval for a substitution in writing. Alternate standards may be proposed, but must be supplied in English, with a narrative comparing both standards, and citing justification why the substitution is equivalent.

All materials shall perform safely and satisfactorily within their operating environment and in accordance with their intended function.

Whenever a commercial material is not covered by a specification or standard, The Contractor shall identify the material by the commercial trademark, name, and address of the supplier. The Contractor shall submit a description, and the technical data specifications, of the material composition for approval The Contractor shall maintain records that trace all materials to their manufacturers, and shall verify compliance with quality standards specified or cited in these Provisions.

Page: 2

[CDR 001]

Single-source materials shall not be permitted unless approved by the Authority. Approval shall be determined on a case-by-case basis. Specification equivalency and benefit data for any substitution to a cited standard shall be submitted to the Authority for review and approval.

[CDR 002]

Unless specifically authorized by the Authority, the following materials shall not be used in the rebuild of the vehicle:

PVC

Asbestos Lead in brake shoes Urethane foam Chlorinated fluorocarbons that may cause environmental problems or handling hazards Materials that, in their normal installed state, emit products that are known to be toxic or irritants Materials that, in their normal installed state, emit products that are known to be toxic or irritative Beryllium

The Contractor shall keep on file Material Safety Data Sheets (MSDS) for all chemical materials (paints, solvents, adhesives, caulking, etc) used in the rebuild of the vehicle, and provide MSDS information as requested by the Authority for any additional material in question. A copy of each MSDS shall be submitted to the Authority for review. At the completion of the project The Contractor shall submit one set of all MSDS sheets for all chemical materials used in the rebuild of the vehicle.

[CDR 003]

All materials utilized in the rebuild of the vehicle shall be subject to the approval of the Authority. The Contractor shall keep a running list of all materials used in the vehicle in matrix format (matrix shall contain; material name, specification or material ID number, application, approval status, correspondence number, etc.). The Contractor shall submit this matrix along with material certifications and material property test reports to the Authority for review.

Page: 3

[CDR 004]

The Contractor shall submit for approval joining and fastening data, specifications, and standards for all types and methods of fastening and joining used.

[CDR 005]

All name and rating plates shall be restored and permanently attached using mechanical fasteners. Fasteners shall not compromise the integrity of the enclosure. Exceptions may be made for small components and circuit boards.

All materials added shall be new and of recent manufacture. Materials approaching obsolescence shall not be used. Material, which is found to be defective and subsequently repaired, cannot be used unless specific approval is granted by the Authority.

All materials in replaced components, or added components, shall be inherently corrosion resistant, or be suitably finished with a corrosion resistant finish to minimize corrosion and degradation of appearance or function.

1.1.1 Reference Documents

The references listed in Table 19-1 are provided for convenience and shall not be construed as a complete list of all applicable references or standards. It shall be the responsibility of The Contractor to implement all applicable standards.

Table 19-1 Reference Documents

Source/Section Title

49 CFR 223 Safety Glazing Standards--Locomotives, Passenger Cars and Cabooses

AA Aluminum Association Standards for Aluminum Mill Products

AAR Specifications for the Construction of New Passenger Equipment Cars

AAR Signal Manual, Vol. 2, Section 6 AAR 2518 As Incorporated in Standard S-400 (AAR Manual E) AAR M-201 Steel Castings AAR M-618 High Pressure Hoses AAR S-501 Wiring and Cable Specification AAR S-503 Wire and Insulating Materials

Page: 4

AATCC 99-2000 Dimensional Change of Woven or Knitted Textiles:

Relaxation, Consolidation, and Felting

ANSI B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

ANSI B18.1.2 Square and Hex Bolts and Screws Inch Series ANSI C37 Circuit Breakers ANSI Z26.1 Safety Code for Safety Glazing Materials for

Glazing Motor Vehicles Operating on Land Highways

ANSI Z98.1 Steady-State Thermal Transmission Properties Superceded by ASTM C177

APA PS1-95 National Institute of Standards and Technology ASME Pressure Vessel Code ASME B31.1 Power Piping ASNT, TC-1A American Society of Non-Destructive Testing ASTM A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and

Steel Products ASTM A242 Standard Specification for High-Strength Low-Alloy

Structural Steel ASTM A 269 Standard Specification for Seamless and Welded

Austenitic Stainless Steel Tubing for General Service

ASTM A27 Steel Castings, Carbon, for General Application ASTM A31 Steel Rivets and Bars for Rivets, Pressure Vessels ASTM A488 Standard Practice for Steel Castings, Welding, and

Qualifications of Procedures and Personnel ASTM A502 Steel Structural Rivets ASTM A514 Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

ASTM A588 Standard Specification for High-Strength Low-Alloy Structural Steel With 50 Ksi Minimum Yield Point to 4 “Thick

ASTM A606 Standard Specification for Steel, Sheet, and Strip, Page: 5

High-Strength, Low-Alloy, Hot-Rolled, and Cold- Rolled, With Improved Atmospheric Corrosion Resistance

ASTM A666 Standard Specification for Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar

ASTM A 822 Standard Specification for Seamless Cold-Drawn Carbon Steel Tubing for Hydraulic System Service

ASTM B88 Standard Specification for Seamless Copper Water Tube

ASTM B108 Aluminum-Alloy Permanent Mold Castings ASTM B247 Aluminum and Aluminum-Alloy Die Forgings, Hand Forgings, and Rolled Ring Forgings ASTM B26 Aluminum-Alloy Sand Castings ASTM B33 Specification for Tinned Soft or Annealed Copper

Wire for Electrical Purposes ASTM B280 Standard Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service ASTM B456 Standard Specification for Electrodeposited

Coatings of Copper Plus Nickel Plus Chromium and Nickel Plus Chromium

ASTM B633 Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

ASTM B85 Aluminum-Alloy Die Castings ASTM C177 Standard Test Method for Steady-State Heat Flux

Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus (Supersedes ANSI Z98.1)

ASTM C1036 Standard Specification for Flat Glass ASTM C1048 Standard Specification for Heat-Treated Flat Glass--

Kind HS, Kind FT Coated, and Uncoated Glass ASTM C1422 Standard Specification for Chemically Strengthened

Flat Glass ASTM C542 Specification for Lock-Strip Gaskets ASTM D256 Standard Test Methods for Determining the Izod

Pendulum Impact Resistance of Plastics

Page: 6

ASTM D2583 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor

ASTM D1055 Flexible Cellular Materials, Latex Foam ASTM D1056 Flexible Cellular Materials - Sponge or Expanded

Rubber ASTM D1149 Standard Test Method for Rubber Deterioration-

Surface Ozone Cracking in a Chamber ASTM D1683 Test Method for Failure in Sewn Seam of Woven

Fabrics ASTM D2047 Standard Test Method for Static Coefficient of

Friction of Polish-Coated Floor Surfaces as Measured by the James Machine

ASTM D2240 Standard Test Method for Rubber Property— Durometer Hardness

ASTM D2262 Test Method for Tearing Strength of Woven Fabrics by the Tongue (Single Rip) Method (Constant-Rate-of-Traverse Tensile Testing Machine)

ASTM D2724 Standard Test Methods for Bonded, Fused, and Laminated Apparel Fabrics

ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape Test

ASTM D3512 Standard Test Method for Pilling Resistance and Other Related Surface Changes of Textile Fabrics:

Random Tumble Pilling Tester

ASTM D3574 Standard Test Methods for Flexible Cellular Materials—Slab, Bonded, and Molded Urethane Foams

ASTM D3597 Standard Specification for Woven Upholstery Fabrics-Plain, Tufted, or Flocked

ASTM D3675 Standard Test Methods for Surface Flammability of Flexible Cellular Materials Using a Radiant Heat Energy Source

ASTM D3775 Standard Test Method for Fabric Count of Woven Fabric

ASTM D3776 Standard Test Methods for Mass Per Unit Area

Page: 7

(Weight) of Fabric ASTM D3884 Standard Guide for Abrasion Resistance of Textile

Fabrics (Rotary Platform, Double-Head Method) ASTM D395 Standard Test Methods for Rubber Property-

Compression Set ASTM D4034 Standard Test Method for Resistance to Yarn

Slippage at the Sewn Seam in Woven Upholstery Fabrics

ASTM D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers-Tension

ASTM D470 Standard Test Methods for Crosslinked Insulations and Jackets for Wire and Cable

ASTM D471 Standard Test Method for Rubber Property-Effect of Liquids

ASTM D5034 Standard Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test)

ASTM D523 Standard Test Methods for Specular Gloss ASTM D573 Standard Test Method for Rubber-Deterioration in an Air Oven ASTM D618 Standard Practice for Conditioning Plastics for

Testing ASTM D624 Standard Test Method for Tear Strength of

Conventional Vulcanized Rubber and Thermoplastic Elastomers

ASTM D638 Standard Test Method for Tensile Properties of Plastics

ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics

ASTM D746 Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

ASTM D785 Standard Test Method for Rockwell Hardness of Plastics and Electrical Insulating Materials

ASTM D790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical

Page: 8

Insulating Materials ASTM D792 Standard Test Methods for Density and Specific

Gravity (Relative Density) of Plastics by Displacement

ASTM E 1354 Standard Test Method for Heat and Visible Smoke Release Rates for Materials and Products Using An Oxygen Consumption Calorimeter

ASTM E 1537 Standard Test Method for Fire Testing of Upholstered Furniture

ASTM E 1590 Standard Test Method for Fire Testing of Mattresses ASTM E 424 Standard Test Methods for Solar Energy

Transmittance and Reflectance (Terrestrial) of Sheet Materials

ASTM E119 Standard Test Methods for Fire Tests of Building Construction and Materials

ASTM E162 Standard Test Methods for Surface Flammability of Materials Using a Radiant Heat Energy Source

ASTM E648 Standard Test Methods for Critical Radiant Flux of Floor-Covering Systems Using a Radiant Heat Energy Source

ASTM E662 Standard Test Methods for Specific Optical Density of Smoke Generated by Sold Materials

ASTM F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F1344 Standard Specification for Rubber Floor Tile AWS A5.0 Filler Metal Procurement Guidelines AWS C1.1 Welding Resistance - Recommended Practices AWS D15.1 Railroad Welding Specification - Cars and

Locomotives.

AWS HDBK Brazing and Welding Handbook AWS-D1.1 Structural Welding Code - Steel AWS-D1.2 Structural Welding Code - Aluminum AWS-D1.3 Structural Welding Code - Sheet Steel CFFA-1A Abrasion Resistance CFFA-2 Accelerated Light Aging

Page: 9

CFFA-3A Adhesion of Coating to Fabric CFFA-4 Blocking CFFA-6A Cold Crack Resistance CFFA-7 Crocking Resistance CFFA-15 Stretch and Set CFFA-16C Tearing Strength CFFA-17 Tensile Strength and Elongation CFFA-700 Dimensions of Coated Fabric DIN 267 Fasteners – Technical Specifications FAR 25.853 Air Worthiness Standards: Transport Category

Airplanes, Fire Protection, Compartment Interiors FED-STD-191 Textile Test Methods IEC 249 (60249) Base Materials for Printed Circuits IEC 326-3 (60326-3) Design and Use of Printed Circuit Boards IEC 60077 Rules for Electric Traction Equipment IEC 61133 Electric Traction and Rolling Stock and Test

Methods for Electric and Thermal/Electric Rolling Stock on Completion of Construction and Before Entry Into Service

IEEE 1016 Recommended Practice for Software Design Descriptions

IEEE 383 Type Test for Class 1E Electric Cables, Field Splices, and Connections

IEEE 730 Software Quality Assurance Planning ISO 3506 Mechanical Properties Of Corrosion Resistant

Stainless-Steel Fasteners ISO 898 Mechanical Properties Of Fasteners Made Of

Carbon Steel and Alloy Steel ISO 4042 Threaded Components - Electroplated Coatings MIL-C-7438 Core Material, Aluminum, for Sandwich

Construction MIL-DTL-5015H Connectors, Electric, Circular Threaded, AN Type, General Specification For MIL-HDBK-349 Manufacture and Inspection of Adhesive Bonded, Aluminum Honeycomb Sandwich Assemblies for

Page: 10

Aircraft MIL-HDBK-691B Adhesive Bonding MIL-P-8053 Plywood, Metal-Faced (Cancelled but used for reference) MIL-PRF-6106 Relays, Electromagnetic, Including Established

Reliability Types MIL-STD-889 Dissimilar Metals MIL-W-22759/6B Wire, Electrical, Fluoropolymer-Insulated, Abrasion

Resistant, Extruded TFE, Nickel-Coated, Copper Conductor, 600-Volt

MIL-W-81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkine-Imide Polymer, or Polyarylene Insulated, Copper or Copper Alloy

MIL-W-81381 Wire, Electric, Polyamide-Insulated, Copper or Copper Alloy

NEC National Electric Code (NFPA 70) NEMA AB1 Molded Case Circuit Breakers NEMA LD 3 High Pressure Decorative Laminates NEMA LI1 Industrial Laminated Thermosetting Products NEMA WC 70 (ICEA S-95-658) - Standard for Nonshielded Power

Cables Rated 2000 Volts or Less for Use in the Distribution of Electrical Energy

NEMA WC 71 (ICEA S-96-659) - Standard for Nonshielded Power Cables Rated 2001-5000 Volts for Use in the Distribution of Electrical Energy

NFPA 130 Standard for Fixed Guideway Transit Systems NFPA 70 National Electrical Code SAE AMS W 6858 Welding, Resistance: Spot and Seam SAE J403 Chemical Compositions of SAE Carbon Steels SAE J429 Mechanical and Material Requirements for

Externally Threaded Fasteners SAE J673 Automotive Safety Glass SAE J995 Mechanical and Material Requirements for Steel

Nuts SAE J1199 Mechanical and Material Requirements for Metric

Page: 11

Externally Threaded Fasteners

UMTA-DC-06-0152-

83-1

A Corrosion Control Manual for Rail Rapid Transit

Unless a revision is specifically stated, the cited references for this Contract shall be of the latest revision available at the date of Contract award.

1.2 Units of Measure

Rebuild components shall utilize the same standards as the parent, or original item. The mounting of all carbody and truck equipment shall use the English standard of measurement.

1.3 Storage of Material

All components removed from the vehicle during the rebuild process shall be stored such that they are able to be positively identified to the vehicle and location within the vehicle from which they have been removed. All components and materials shall be adequately protected to ensure that no damage occurs during storage.

All stored material subject to corrosion shall be adequately protected by waterproof covers, coatings, or packaging to prevent damage.

Equipment covers, cable entrances, and openings shall be suitably closed to prevent ingress of water or dirt.

All dated material shall have the expiration date clearly marked. Expired material shall not be used.

Material or components, which require maintenance during storage, shall be properly maintained as per the component(s) manufacturer's instructions. The Contractor shall document such maintenance, and provide these records as requested by the Authority.

Rejected or damaged material shall be clearly marked, dispositioned, and stored separately from all other material.

Page: 12

1.4 Metals

1.4.1 Low-Alloy, High Tensile Strength, Structural Steel

Low-Alloy, High Tensile (LAHT) steel for the carbody shall comply with the applicable American Standard for Testing and Materials (ASTM) standard, ASTM A242 or ASTM A588 for structural shapes, plates, and bars.

LAHT hot-rolled and cold-rolled steel sheets and steel strips, with improved atmospheric corrosion resistance, shall comply with ASTM A606.

1.4.2 Heat-Treated Alloy Steel

Heat-treated alloy steel suitable for welding and other structural purposes shall comply with ASTM A514, Grade F.

1.4.3 Stainless Steel

Austenitic, stainless steel sheets, strips, plates, and flat bars shall comply with ASTM A666, except that the carbon content shall not exceed 0.03%.

Stainless steel shall be American Iron and Steel Institute (AISI) type 201, 301, 301L 302, 304, 304L, 316, 316L or 347. 301L, 304L or 316L will be used wherever stainless steel is fused (welding or resistance). Other stainless steels conforming to ASTM A 666 are acceptable for non-welded applications.

Stainless steel used in structural applications shall conform to paragraph “f” of Section 2, of Association of American Railroads (AAR) Specifications for the Construction of New Passenger Equipment Cars.

1.4.4 Steel Castings

Steel castings shall be selected for the composition, heat treatment, and design best suited for the intended service.

Weld repairs of castings shall be allowed only by the approval of the Authority, provided that repairs are performed in accordance with an approved written procedure, and by certified welders, qualified to ASTM A488.

High strength castings shall be tested, inspected, and accepted in accordance with

AAR M-201.

General-purpose steel castings shall comply with ASTM A27, either Grade 65-35 or

Page: 13

Grade 70-36.

Low alloy nickel castings shall comply with AAR M-201.

1.4.5 Rivet Steel

Rivet steel shall comply with ASTM A31, ASTM A502, or ANSI B18.1.2. Exposed rivets shall be concentric to the shank and free from rings, pits, burrs, and deformities.

If rivet holes need to be enlarged to remove corrosion or damage, then such holes shall be reamed round to the size required such that the next larger rivet may be driven accurately. Rivets exposed to view shall be Austenitic stainless steel or aluminum, as appropriate to the material being joined.

1.4.6 Aluminum

Aluminum alloy mill products shall be identified by designations prescribed by the Aluminum Association (AA) and shall comply with the requirements contained in the AA publication, "Aluminum Standards and Data."

Aluminum alloy surfaces shall not make direct metal-to-metal contact with dissimilar metals, (copper, brass, bronze, silver, nickel, lead tin, ferrous metal, etc. or alloys of these materials) except for electrical connections where appropriate joint compounds shall be used, and will be subject to approval.

The forming of aluminum parts, their joining by bolting, riveting, or welding, and protection of contact surfaces shall comply with Aluminum Company of America (ALCOA) specification, “Covering Use of Aluminum in Passenger Carrying Railroad Vehicles”.

1.4.7 Aluminum Extrusions

Extrusions, sheets, and plates shall comply with AA standards for Aluminum Mill Products, contained in Aluminum Standards and Data.

1.4.8 Aluminum Castings and Forgings

Forgings shall comply with ASTM B247 or AA standards for Aluminum Mill Products, alloy, and temper 6061-T6.

Castings shall comply with ASTM B26, ASTM B85, ASTM B108, or AA standards for Aluminum Mill Products alloy and temper 356-T6, 364-T5, or 356-T6 respectively, and shall be free from blowholes, cracks, shrinkage, and other defects.

Page: 14

1.5 Non-Metals

Material specifications (Technical Data & Specification Sheets) for all non-metal materials used in the vehicle shall be submitted to the Authority for review and approval.

All non-metals shall comply with the requirements in Section 1.17, Flammability, Smoke Emission & Toxicity.

[CDR 004]

1.5.1 Elastomers

Elastomeric parts may include door and window seals, glazing strips, truck bumpers/snubbers, structural and compressible gaskets, and mounting pads.

All elastomeric parts shall be composed from suitable elastomers compounded and cured to perform satisfactorily under the intended application and the environmental conditions in which the vehicle may be operated.

Elastomeric parts shall be suitably sized for the intended application such that the fit is correct (i.e., no gaps, bulges, stress tears, etc.). Gaskets or sealing extrusions shall not bulge, kink, or spread when installed. Seams in joined, extruded gaskets shall be oriented to minimize the possibility of leakage.

Elastomeric parts used for interior decorative trim shall be colored to harmonize with adjacent surfaces. All colors shall be as approved.

Metal parts to which elastomeric materials are cured shall be made of SAE J403 hot-rolled steel or equal, suitably cleaned for bonding. Elastomeric materials shall be tested to verify compliance with performance requirements as given below. The Contractor shall submit certificates stating compliance with the requirements of the standards.

[CDR 006]

In addition to the tests indicated below, elastomers must pass the combustibility requirements as specified in the Flammability, Smoke Emission & Toxicity section of this specification.

Table 19 -2

Physical Property Test Method Test Value

Hardness ASTM D2240 45 to 75, Durometer A Tensile Strength ASTM D412 1500 psi

Page: 15

Physical Property Test Method Test Value

Ultimate Elongation ASTM D412 300%, min Ozone Resistance ASTM D1149, Type A, 7

Days, Ozone concentration 100ppm, 104°F

No cracks under 7x magnification

Oil Aging Resistance ASTM D471, Test oil/fuel shall be representative of application, 72 hours, 158°F

+30% maximum change in volume

Permanent-Set Resistance ASTM D395, Method a or B 25% Maximum Set Tear Resistance ASTM D624, Method B 300 lb/in Brittleness Temperature ASTM D746 Brittleness temperature no greater than -40F Heat Aging Resistance ASTM D573, 72 hours, 158°F -30% change in elongation

-15% change in tensile strength -5 to +15 change in hardness

1.5.2 Neoprene Foam

Neoprene foam (flexible cellular rubber products) shall be high-resiliency foam latex.

Base elastomers of latex shall be polymerized chloroprene (polychloroprene) and shall contain no reclaimed rubber. The structure of the foam shall consist of a network of closed cells of uniform character. The foam shall have a high resistance to flexing, tearing, and wetting. The Contractor shall provide the physical and performance characteristics of all neoprene foam used in the vehicle.

[CDR 007]

The dimensions of flexible cellular rubber products shall comply with ASTM D1055.

Foam gaskets shall also comply with ASTM D1056, Class B.

1.5.3 Fiberglass-Reinforced Plastic

Fiberglass-Reinforced Plastic (FRP) shall be polymeric-reinforced laminated material, composed of a gel-coated surface, fiberglass reinforcement, and a polyester, acrylic, phenolic, or approved equal resin.

FRP shall be able to withstand, without any physical degradation or deformation, the

Page: 16 stresses encountered in the environment where it is to be used. Fiberglass components shall be molded, stored, and mounted, in their final, designed, shape, and shall not be mounted in a deformed/stressed condition.

FRP shall be resistant to acids, mild alkalis, and cleaning solutions normally used in rail transit service.

Fiberglass reinforcement shall be mat, fabric, woven roving, continuous roving, chopped spun roving, or swirl mat, as required to meet physical and process requirements. Glass content by weight shall be 30% minimum. Gel coats shall be resistant to scuffing, fire, weather, perspiration, and cleaning agents and shall be pigmented to match approved colors. Gel coat must contain Ultraviolet (UV) inhibitors/stabilizers.

Gel coat additives, fillers, monomers, catalysts, activators, inhibitors, pigments, or flame proofing materials shall be added to resin mixes to obtain finished products with required characteristics. Mineral filler shall not exceed 28% of finished weight for preformed matched die molding process.

FRP shall be manufactured by one of the following methods:

Method 1: Open molding, hand lay-up, or spray lay-up (Chopper Gun)

Method 2: Matched die molding, RTM, Vacuum bag, or preform

Production techniques shall ensure that the fiberglass reinforcement is distributed throughout the final product in such a manner as to preclude resin-rich or resin-starved sections.

Open-molded parts shall be gel coated.

Surfaces shall be uniform, smooth, and free of porosity and crazing.

The Contractor shall submit for approval certificates verifying that reinforced plastic materials comply with the minimum requirements specified below. Pre-test conditioning of test specimens shall conform to ASTM D618.

[CDR 008]

Page: 17

Table 19-3

Mechanical Property Test Method Method #1 Method #2

Tensile Strength ASTM D638 13,000 psi 18,000 psi Compressive Strength ASTM D695 22,000 psi 32,000 psi Flexural Strength ASTM D790 21,000 psi 28,000 psi Impact ASTM D256 10 ft-lbs/ in of notch 13 ft-lbs/ in of notch Hardness ASTM D2583 45 Barcol 45 Barcol Heat None 175°F Continuous - Thickness None 0.125 in, minimum 0.125 in, minimum Gel Coat Thickness None 0.014” or 14 mils, ± 2 mils.

N/A

1.5.4 Thermoplastic

Thermoforming plastic material (commonly available in the form of a PVC-Acrylic material) may be used, subject to Authority approval, in the low-smoke toxicity versions commonly available for transit applications.

Thermoplastic materials shall comply the Flammability, Smoke Emission & Toxicity section of this specification, and with the following requirements:

Table 19-4

Physical Property Test Method Performance Requirement Value

Specific Gravity ASTM D792 1.20 to 1.36 Hardness, Rockwell ASTM D785 90 to 100, R-Scale Tensile Strength ASTM D638 5,500 psi (38 MN/m2) minimum at 73°F (23°C) Flexural Modulus ASTM D790 320,000 psi (2206 MN/ m2) minimum elasticity at 73°F (23°C) Flexural Strength ASTM D790 10,000 psi (68,947.6 kPa) minimum @ 73°F

(23°C) Impact Strength (@ 73°F notched IZOD)

ASTM D256 6.6 foot pounds per inch of notch minimum.

Heat Shrinkage None 15% maximum, 10 minutes @ 380°F (193°C) Thickness None 3/32” (2.38 mm) minimum

Page: 18

1.5.5 Glass

Test reports to verify glazing material compliance per the criteria specified in this section shall be provided.

[CDR 009]

1.5.5.1 Laminated Safety Glass

Laminated safety glass shall be used exclusively and shall conform to the following general, manufacturing, and finish requirements:

a) Float glass quality shall conform to ASTM C 1036, Type 1, Class 1, quality Q3.

b) If tempered glass is used in the laminate, it shall be fully tempered in accordance with ASTM C 1422, surface compression level 3, case depth level B.

c) Edges shall be seamed and ground smooth per SAE J673, Edge no. 4, and sealed with aluminum tape or equivalent.

d) Any overlap of one sheet of glass with respect to the other at an edge shall not exceed 0.031 “(0.8 mm)

e) The thickness tolerance of the individual sheets as supplied shall be held within 0.020” (0.5 mm)

f) The dimensional tolerance for the cut size dimensions of rectangular shapes, including squareness will be according to ASTM C 1036 Table 1, but not to exceed 0.040” (1.0mm). For other shapes, the cut size shall not exceed 1/16” (1.6mm) of the dimension specified. Unspecified corners shall have a 1/16” (1.6mm) radius.

g) Masking, if used, shall be applied between the laminated layers of the glass.

h) Tinted assemblies shall use a tinted polyvinyl-butyral (PVB) layer with clear glass laminate.

i) Manufacturers stamp shall be positioned in lower right hand corner as viewed from inside the vehicle.

Window glazing shall be bonded with an approved type of plasticized PVB resin in the form of a membrane 1.1 mm (0.045”) ±10% thick, which shall not be degraded by UV or visible light or temperatures that can be obtained by solar heating

Laminated safety glass shall also conform to the requirements of the applicable classification, as follows:

Page: 19

Group I glass shall:

• Be clear laminated safety glass used for forward facing glazing, e.g., windshields.

• Be coated, if required, to have maximum solar transmittance of 68% according to ASTM E 424, Method A.

• Meet the requirements of 49 CFR, Part 223, FRA Type I rating, having a minimum thickness of 9/16” (14 mm).

• Be certified to comply with the requirements of ANSI Z26.1, Table 1, Item 1.

Group II glass shall:

• Be clear laminated safety glass used for operator side windows.

• Be coated, if required, to have maximum solar transmittance of 68% according to ASTM E 424, Method A.

• Be certified to comply with the requirements of ANSI Z26.1, Table 1, Item 2.

• Meet the requirements of 49 CFR, Part 223, FRA Type II rating, having minimum thickness of 3/8” (10 mm).

Group III glass shall:

• Be tinted laminated safety glass used for passenger side, and door windows.

• Be coated, if required, to have maximum solar transmittance of 34% according to ASTM E 424, Method A.

• Be certified to comply with the requirements of ANSI Z26.1, Table 1, Item 3.

• Tinted with a visible light transmission of 28% ±2%.

• Have a minimum thickness of 1/4” (6.4 mm).

1.5.5.2 Tempered Safety Glass

Tempered safety glass that may be used for internal glazing and partitions, shall be manufactured to ASTM C1048, Kind FT, Condition A, Type 1 clear, Class 1 clear, Quality q3. (or Class 3, tinted, light reducing).

Page: 20

1.5.6 Floor Covering

The floor covering shall be replaced in kind. The floor covering material shall contain 20% (nominal, by weight of compound) Butadiene Styrene rubber, shall be non-staining, non-discoloring and non-oil extended, and contain additives to preclude damage or discoloring to UV light.

Only high-quality hard clay shall be used as filler. No limestone shall be used in the compound.

The rubber flooring shall be fully homogeneous throughout.

At 68°F (20° C), the rubber flooring shall bend 180 degrees around a ½” (13mm) diameter mandrel without breaking, cracking, crazing, or showing any change in color.

The rubber flooring material shall comply with ASTM F1344, table 1, with tile size adjusted for maximum sheet coverage, Class 1, B, and also comply with the Flammability, Smoke Emission & Toxicity section of this specification.

The coefficient of friction of the floor rubber shall not be less than 0.60 when tested to

ASTM D 2047.

The Contractor shall submit color/material samples for approval.

[CDR 010]

Prior to the installation of the floor covering, any depressions, voids, or cracks in the sub-floor shall be filled and the sub-floor shall be leveled and smoothed with an Authority approved leveling compound.

The floor covering shall be permanently secured to the sub-floor with an approved adhesive and as recommended by the flooring manufacturer. The bottom side of the flooring shall be sanded and then securely bonded to the sub-floor panels. The floor covering and adhesive shall be resistant to cleaning solutions and solvents normally encountered in rail transit service.

There shall be no tears or cracks allowed in the installed floor lining, non-penetrating defects such as blisters, lumps, craters, and deformations shall be no greater than 0.030” (0.76mm) in height difference from the nominal, surrounding rubber thickness, and shall occur no more than the following:

• Defect diameter ≥ 1” – Not permitted.

• 1” > Defect diameter > 1/4” – 1 each every 6 feet allowed, but must be repaired.

Page: 21

• Defect diameter ≤ 1/4” – 3 per 12”x12” square area allowed, with no others closer than 3 feet.

1.5.7 Marking Films & Graphics

All graphic materials shall be transportation grade materials. Signage graphics shall have an opaque background with clear, vandal resistant overlayment such as polyvinyl fluoride or polycarbonate. Printed graphics shall be either reverse printed on the back of the clear overlayment, or printed on opaque background and covered by the clear overlayment. The Authority shall approve all materials, graphic construction, and fixing method.

Application techniques shall be in accordance with manufacturer's recommendations.

Physical Properties of Graphic Material

• Lettering or striping film shall be sufficiently opaque so that, when applied, the film shall completely hide any contrasting background and shall be readily legible.

• There shall be an initial 60-degree gloss value of 40 when tested in accordance with ASTM D523.

• Films shall retain adhesive properties after one week of continuous exposure to a temperature of 66°C (150°F).

• Films shall be able to conform to moderate contours of the vehicle's interior and exterior surfaces at locations where applied.

• Overall thickness of processed film shall be between 0.004” and 0.008” (0.10 mm and 0.20 mm), multiple layer graphics may be up to 0.020” total thickness (excluding mounting adhesive thickness).

• Films shall withstand immersion in either distilled water or SAE No. 20 motor oil for 24 hours at temperatures of from 70°F to 90°F (21°C to 32°C) without any appreciable degradation in adhesion, color, or general appearance.

• Marking films shall withstand effects of detergents and brushes used in washing procedures for removal of graffiti.

• Films shall use a removable grade adhesive that upon removal does not require use of solvents, or secondary operations to remove adhesive or graphic residue.

• Square or rectangular graphics shall have rounded corners of suitable

Page: 22 radius to prevent the lifting or curling of corners.

Graphic material used for vehicle striping shall be 3M 690 Plus (Flexible Reflective Sheeting) or Authority approved equivalent.

1.6 Structural Panels

Sandwich panels include, but are not limited to, plymetal, honeycomb, or lumber-core panels, with metal or other approved facing material.

Melamine, high pressure laminates used in the construction of the vehicle shall be two-ply laminated and shall consist of a hard plastic film facing permanently bonded to base sheet.

Contact adhesives shall not be used to bond the melamine to the base.

The final laminate assembly shall comply with NEMA LD-3, General Purpose Type, and comply with the Flammability, Smoke Emission & Toxicity section of this specification.

1.6.1 Honeycomb

When finished, continuous edge reinforcement shall be incorporated if needed to facilitate transfer of stresses and to seal edges against moisture penetration and other damage. Where mechanical fasteners are used, threaded inserts shall be bonded into the panel.

The term “honeycomb panels” as used in these Provisions, refers to honeycomb material bonded to melamine or metal.

Honeycomb-core panels shall comply with applicable requirements of MIL-C-7438G, and MIL-HDBK-349, unless otherwise specified.

Bonding between the base material and the cover shall be sufficient to develop the full strength of the honeycomb material. The Contractor shall demonstrate by test and analysis, that the honeycomb panel design selected for a particular application, is adequate for the intended purpose.

1.6.2 Plywood & Plymetal

All plywood shall comply with National Institute of Standards and Technology (NIST), APA PS1-95, Exterior Grade B-B, High Density Overlay. Floor panels shall be a minimum of 5/8” (16mm) thickness.

Plymetal panels for floor construction shall be faced on both sides and at all edges

Page: 23 with stainless steel (wrapped). All plymetal panels shall have the metal seams bonded together.

All exposed edges of the panels, drilled holes, fastener heads, openings, or cutouts within the panels shall be waterproofed and sealed with an approved epoxy paint/coating as soon as possible after fabrication, and prior to installation.

Each plywood panel shall be formed from one piece. Jointed panels shall not be allowed.

Plymetal panels shall also meet the following test criteria:

Table 19-5

Minimum Metal to Wood Test* Minimum Value

Dry Shear 250 lbf/in.2 (1.72N/mm2) to 80% wood failure Boil shear, 3 hrs boil, tested at 68°F

150 lbf/ in.2 (1.03N/mm2) to 80% wood failure

Wet shear, 48 hrs. soak, 68°F 150 lbf/ in.2 (1.03N/mm2) to 80% wood failure Creep, under static load for 48 hrs, 68°F

250 lbf/in.2 (1.72N/mm2) to 80% wood failure

* The plymetal test reference refers to inactive standard MIL-P-8053.

1.6.3 Panel Flatness

The overall flatness shall not exceed a maximum deviation of 0.015" per lineal foot, with a maximum of 0.125” deviation of any point on the panel measured from a reference plane taken from any three corners. The overall deviation of the panel thickness shall not exceed 0.031" (1/32").

1.7 Fastening / Joining

Unless otherwise specified, screws, rivets, mounting bolts, or similar items shall be replaced in kind. The use of exposed fasteners on the vehicle interior shall be minimized.

Interior fasteners shall be countersunk where possible, or low profile heads shall be used where countersinking is not possible. Interior fasteners shall not protrude enough to become a tripping or snagging hazard.

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1.7.1 Fastening to Structural Members

Fastening to structural members shall be done only on the low stress portion of the member and shall not be located within 3/4” (17mm) from the open edge of the structural member.

The Contractor shall ensure that any fastening or joining to structural members does not result in moisture accumulation within any structural member. To this end, fastenings to hollow, closed section structural members shall not be accomplished using drilled holes in the structural member.

1.7.2 Threaded Fasteners

The number of different sizes and styles of fasteners used shall be minimized. A single standard, e.g., Metric (DIN/ISO) or US (ANSI/SAE/IFI)(preferred), shall be adopted for the fasteners used. Fasteners shall be properly marked per the system adopted. All threaded fasteners shall comply with ANSI B1.1 class 2 requirements, unless otherwise specified or approved. All structural threaded fasteners shall have rolled threads.

Self-tapping or thread forming screws may be used with Authority approval only, on a case-by-case basis.

Use of threaded inserts or special or non-standard fasteners shall require Authority approval.

At least 1 1/2 threads shall be visible beyond all nuts. Bolts smaller than 0.25” [6 mm] shall not project more than 1 1/2 thread plus 0.25” [6 mm]. Bolts 0.25” [6 mm] or larger shall not project by more than eight (8) threads.

Fasteners exposed to public view shall be treated as follows:

• On the vehicle interior, all exposed fasteners shall be stainless steel (Grade 316), with flat or oval heads, properly countersunk.

• On the vehicle exterior, all exposed fasteners shall be stainless steel.

• Exposed screws shall be “Pin in Head” Torx tamper-resistant type and approved by the Authority.

Fasteners not exposed to passengers on the vehicle interior shall be of stainless steel (Grade 316).

Fasteners and fastener components used on the vehicle underfloor or roof areas shall be stainless steel (Grade 316) except in cases where high strength fasteners such as

Page: 25

SAE grade 8 or metric Property Class 12.9 are required. Underfloor fasteners ½” diameter or larger may be plated steel of the same grade they replace. The Contractor shall provide a list of all threaded fasteners, fastener classification, material, finish, and location used, for Authority approval.

[CDR 011]

1.7.2.1 Fastener Materials

Fastener component materials (screws, nuts, washers, etc.) shall be properly selected for the application and shall not be mixed within an assembly. All fasteners shall be stainless steel, or unless otherwise specified, steel finished with protective coating such as passivation, dichromate, or zinc plating, depending on the specific application.

Threaded aluminum fasteners shall not be used, except in tapped holes in solid aluminum structures, and are subject to approval.

Stainless steel nuts and bolts shall be used for stainless-to-stainless joints. Anti-seize compounds shall be used on all stainless steel fasteners threaded into stainless steel, or using stainless steel nuts.

US Standard

Threaded fasteners shall conform to current SAE J429 standards for externally threaded fasteners and SAE J995 standards for internally threaded fasteners. Steel fasteners ¼” diameter and above shall be SAE Grade 5 minimum.

Stainless steel fasteners shall be manufactured from austenitic stainless steel alloys, according to ASTM F 593, with a nominal tensile strength of 100 ksi. All fasteners shall be clean and free of manufacturing scale.

Non-structural screws, such as Phillips or slotted head screws smaller than ¼” diameter, may be SAE Grade 2 minimum.

Metric

Carbon steel Metric threaded fasteners shall conform to SAE J1199, or the current equivalent, specified, DIN or ISO standards. Carbon steel fasteners 6mm diameter and above shall be Property Class 8.8 minimum for external threads, Property Class 8 minimum for nuts, per ISO 898/1 and ISO 898/2.

Stainless steel fasteners shall be manufactured from A2 or A4 grade, austenitic stainless steel with a minimum Property Class of 70 per ISO 3506-1979, with a

Page: 26 minimum nominal tensile strength of 700 MPa.

Non-structural screws, such as Phillips or slotted head screws smaller than 6mm diameter, may be Property Class 4.8 minimum for steel, Property Class 50 for stainless steel. Manufacturing tolerances shall be according to DIN 267, Part 2, “m” (medium class)

1.7.2.2 Locking Requirements

All threaded fasteners shall be self-locking or provided with locking devices. Locking devices shall be lock wire, lock washers, torque patch, or prevailing torque type locknuts as appropriate for the application or service. Lock wire, if used, shall be aircraft grade stainless steel.

Prevailing torque locknuts shall be of the nylon collar insert type. Previously installed and removed locknuts shall not be re-used. High temperature applications may use metallic distorted thread locknuts upon Authority approval.

Unless specifically approved by the Authority, bolts for use with locknuts shall not be drilled for cotter pins or in heat related applications.

All locknuts shall comply with the Industrial Fasteners Institute requirements regarding locking ability.

When oversized or slotted holes are provided for installation tolerance allowance, flat washers, of suitable size to cover oversized holes, or slots shall be used in all locations adjacent to the hole. In this case, at least one hole shall be of close tolerance to ensure accurate positioning of component. If slotted holes are provided as a means of adjusting a piece of equipment, a secure method of fixing the adjustment shall be provided, such as adjustment screws, ribbed or toothed adjustment washers, drilled holes and pins, etc.

1.7.2.3 Plating & Treatment of Fasteners

All steel fasteners shall be zinc plated with the highest protective service condition available per thread configuration. Stainless steel fasteners shall be passivated.

Chrome plated, steel fasteners used for interior, cosmetic applications shall be chrome plated per ASTM B 456, class SC-3. If stripping and re-plating of fasteners is required to meet the aforementioned criteria, documentation must be made available to verify that all applicable post plating treatments and standards have been met. The Authority may require batch testing of stripped and re-plated fasteners to ensure there is no hydrogen embrittlement.

Page: 27

US Standard

After manufacturing, steel fasteners shall be electroplated, zinc with a yellow chromate conversion per ASTM B633, Type II - Yellow (please refer to table for thickness).

Metric

After manufacturing, steel fasteners shall be electroplated, zinc with a yellow chromate conversion per ISO 4042, (please refer to table for thickness).

Table 19-6

Plating Thickness for Steel Fasteners, Zinc, Yellow Chromate Conversion

Bolt size Metric

DIN 267

US

ASTM B633

Thickness (Micro meter / inch)

Dia, up to #8 (M3) A1L - 3µm / .00012" Dia. >#8 (M3) to 5/16" (M8) A2C or

A2L SC1 5µm / .00020"

Dia. >5/16" (M8) to 7/8" (M22) A3C SC2 8µm / .00031" Dia. >7/8" (M22) to 1-1/8" (M33) A4C SC3 13µm / .00051" Dia. >1-1/8" (M33) and greater A5C - 15µm / .00059"

Hydrogen Embrittlement

Fasteners or fastener components with hardness greater than or equal to 320 HV (32 HRC) are susceptible to hydrogen embrittlement when pickled and/or electroplated.

This may cause these fasteners to fail at relatively low loads even if stress relief annealing (baking) is performed after plating. Examples of hardened fasteners are steel bolts - US Grade 8 (Metric Property Class 10.9), hardened steel washers, spring washers, etc. These types of fasteners shall be mechanically plated to avoid hydrogen embrittlement.

1.7.2.4 Torque Marking/Indexing

The Contractor shall ensure the proper application of all threaded fasteners.

Torque marks or stripes extending from the secured hardware to the surrounding surface shall be applied to all safety related hardware, including truck, door, and brake equipment bolts.

Page: 28

Tightening indication may be required on other non-safety related hardware upon the Authorities' request.

1.7.2.5 Bolts and Nuts

All threaded fasteners falling into this category used in this project shall require a submittal of Certifications of Compliance (C of C) with each shipment of hardware to the end user. The C of C shall be traceable to a manufacturer.

1.7.2.6 Electrical and High Temperature…