Exhibit O - CFRC MWIs.pdf

State of Florida Department of Transportation

Exhibit “O”

CFRC MWI

Central Florida Rail Corridor (CFRC) Track Improvements

– Multiple Locations

Financial Projects Number(s): 412994-4-52-33, 412994-8- 82-54, 412994-8-82-55, 412994-8-82-56, 412994-8-82-47

DOT-RFP-25-5002-TIML

Type No. Name

MWI 301 Ballast Specifications

MWI 401 Timber Crosstie and Switch Tie Requirements

MWI 403 Requirements and Use of Nail Plates for Cross and Switch Ties

MWI 507 Use of Transistion Rails and Compromise Rails

MWI 703 Rail Anchoring Policy

MWI 708 Insulated Joint Installation Policy

MWI 801 CSX Welding Manual

MWI 901 Road Crossing Installation

MWI 1003 Uses and Installation of Geotextiles and Geogrids

MWI 1101 Continuous Welded Rail Projects

MWI 1103 Surfacing Policy

MWI 1109 Temporary Speed Restrictions

MWI 1125 Installation and Thermal Adjustment of CWR

MWI 1402 Bridge Walkways

MWI 1403 Inner Metal Guardrail on Bridges

MWI 1404 Bridge Approach Ties

MWI 2001 FRA Track Safety Standards

MWI 2107 Curve Superelevation Markings

TYP DWG 2216 16'-6" Double Switch Point Derail

TYP DWG 2217 No. 15 Turnout and Crossover with 26’-0” Curved Switch Points

TYP DWG 2218 No. 15 Offset and Layout Diagrams for 136RE rail

TYP DWG 2224 No. 10 Turnout and Crossover Railbound Manganese Frog for 136RE Rail Only

TYP DWG 2225 No. 10 Offset and Layout Diagrams Railbound Manganese Frog for 136RE Rail Only

TYP DWG 2228 Number 20 Turnout and Crossover, Railbound Manganese Frog for 136RE Rail Only

TYP DWG 2229 Number 20 Offset and Layout Diagrams, for 136RE Rail Only

TYP DWG 2307 Stock Rails for 16’-6" Switch Points with Floating Heel Block Assembly or 115RE, 122CB, 132RE, and 136RE Rail

TYP DWG 2317 Switch Machine and Special Switch Ties used by Train Control in Turnouts

TYP DWG 2321 26’- 0” Curved Split Switch Uniform Risers, Machine Operated for 136RE rail

TYP DWG 2322 Stock Rails for 136RE Rail 26’- 0” Curved Switch Points

TYP DWG 2323 Gage Plates for 26’-0” Curved Switch and 136RE Rail

TYP DWG 2324 Switch and Turnout Plates for 26’-0” Curved Switches with Uniform Risers for 136RE Rail

TYP DWG 2325 Adjustable Rocker Clip

TYP DWG 2326 Switch Rods for use with Rocker Clips

TYP DWG 2335 16'-6" Straight Split Switch Uniform Risers, Machine Operated for 136RE Rail Only

TYP DWG 2336 Gage Plates for 16’-6” Switch for 136RE Rail Only

TYP DWG 2337 Switch and Turnout Plates for 16’-6” Straight Switches with Uniform Risers for 136RE Rail Only

TYP DWG 2338 39’-0” Curved Split Switch, Uniform Risers, Machine Operated for 136RE Rail Only

TYP DWG 2339 Stock Rails for 39’-0” Switch Points for 136RE Rail Only

TYP DWG 2340 Gage plates for 39’-0” Switch for 136RE Rail Only

TYP DWG 2341 Switch and Turnout Plates for 39’-0” Curved Switches with Uniform Risers for 136RE Rail Only

TYP DWG 2400 Frogs, General Requirements and AREMA Clarifications

TYP DWG 2411 Hook Flange Guard Rails for 115RE, 122CB, 132RE, 136RE, 140RE, and 141lb Rail

TYP DWG 2412 Bolted Adjustable Guard Rails for 115RE, 122CB, 132RE, 136RE, 140RE, and 141RE Rail

TYP DWG 2413 Guard Rails, Usage and Location

TYP DWG 2415 Number 15 Railbound Bonded Heel Manganese Steel Frog for 132RE, 136RE, and 141lb Rail

TYP DWG 2422 No. 10 Railbound Bonded Heel Manganese Steel Frog for 136RE Rail Only

TYP DWG 2425 Frog Gage Plate

TYP DWG 2431 Frog Plates for No. 10 RBM Frog for 136RE Rail Only

TYP DWG 2435 No. 20 Railbound Managenese Frog, Bonded Heel, for 136RE Rail Only, with Plates

TYP DWG 2505 Epoxy Bonded Insulated Joint for 132RE, 136RE, and 141RE Rail

TYP DWG 2506 Joint Bars for Standard Rail Sections

TYP DWG 2507 115RE, 122CB and 140RE Rail Sections

TYP DWG 2508 132RE, 136RE and 141RE Rail Sections

TYP DWG 2512 Main Track Spiking Patterns / Side Track Spiking Patterns

TYP DWG 2513 Turnout Spiking Patterns

TYP DWG 2514 Joint Area Spiking Patterns x

TYP DWG 2516 8” X 18” Tie Plate for 6” Base Rail Sections

TYP DWG 2527 Heavy Duty Road Crossing, Full Width Concrete on Wood Ties

TYP DWG 2536 Normal Duty Road Crossing, Timber and Asphalt Crossing

TYP DWG 2537 7 3/4” x 14 3/4” Tie Plate for 6” Base Rail Sections

TYP DWG 2540 7 3/4" x 14" Tie Plate for 5-1/2" Base Rail Sections

TYP DWG 2601 Roadbed Sections

TYP DWG 2602 Ballast Sections

TYP DWG 2604 Clearance Diagrams

TYP DWG 2605 Clearance Matrix

TYP DWG 2607 Bridge Approach Ties

TYP DWG 2609 Inner Guard Rail

TYP DWG 2613 Typical Layout at Highway Crossing with Active Warning Device

COMMON DWG 130005 6" Track Spike

COMMON DWG 130800 Rectangular Head Timber Coach Screw

COMMON DWG 135010 Bar Stock Anchor for 5-1/2" and 6" Base Rail

CFRC MAINTENANCE OF WAY INSTRUCTIONS - PHASE 2 SOUTH

Maintenance of Way

Welding Manual

ISSUED: December 9, 2013 REVISED: March 6, 2015

MWI 801-06

CFRC Welding Manual

Issued: 12/9/13 Revised: 3/6/15

PURPOSE: To establish uniform procedures for all welders performing work for the

Engineering Department on track appliances, buildings, bridges or other structures using the thermite, oxy-propane, or electric-arc methods of welding.

SAFETY: Observe all applicable Safety and Operating Rules and Regulations and Safe Job Procedures.

LOCATION:

All CFRC tracks and property.

ENVIRONMENTAL: Observe all applicable Federal, State and Local Environmental Rules and Regulations.

I. DISCUSSION

A. The Welding Manual is prepared and issued to you for your benefit. It is your duty to study and understand it and perform your work in accordance with these instructions.

B. This manual should always be considered jointly with the other Rules, Regulations, and

Instructions affecting the employees of the Engineering Department.

II. PROCEDURE

The Welding Manual follows:

3/6/15

Welding

Manual

Table of Contents

Section Title Page

Number

A Safety A-1

B Qualifications for CFRC Welders B-1

C Repair of Engine Burns C-1

D Repair of Rail Ends D-1

E Repair of Rail Ends for Glued Bonded Insulated Joints E-1

F Repair of Switch Points F-1

G Repair of Frogs and Railroad Crossings G-1

H Cutting Rail H-1

I Thermite Welding

General I-1

Hydraulic Rail Puller Procedures I-7

Orgo-Thermit 1”Gap with Single-Use Crucible

I-12

Boutet 1” Gap with CJ Crucible (One-Shot) I-20

Boutet 2 3/4” Gap with CJ Crucible (One-Shot) I-28

Grinding I-36

J Grinding Equipment J-1

K Miscellaneous Welding K-1

L Air Arc Metal Removal L-1

M In Track Electric Flash Butt Welding M-1

N Approved Rods N-1

O Other Welding Supplies O-1 ii

Table of Drawings

Drawings Title

A-1 Safety Pan for Thermite Welding A-2 Safety Pan for Thermite Welding-Bridge C-1 Engine Burn Measurement C-2 Arc Welding Engine Burns C-3 Lowering Engine Burn C-4 Raising Engine Burn D-1 Rail End Batter Measurement D-2 Slotting Joints

D-2A Slotting Joints with Rail Gap Greater than 1/8” D-3 Electric Arc Welding of Rail Ends D-4 Finish Grinding E-1 Electric Arc Welding of Insulated Joints F-1 Switch Point Details End View F-2 Switch Point Details Side View F-3 Stock Rail Undercutting for Samson Switch Points F-4 Stock Rail Recessing for Knife Blade Type Points F-5 Stock Rail Recessing for Knife Blade Type Points G-1 Frog Point Detail (Depressed Point) Cross Section G-2 Frog Point Detail (Depressed Point) Side View G-3 Re-establishing Ramp on Railroad Crossing

Diamonds G-4A Frog and Crossing Check Gauge G-4B Heavy Point Go/No Go Check Gauge G-5 Guard Rail Drawing G-6 Hook Flange Guard Rails Drawing G-7 Conformal Gauge for Checking Tread Wear G-8 Conformal Gauge for Weld Repair of Wing and Point G-9 Gauge to Check 5/8” Point Wear G-10 Conformal Gauge for Weld Repair of Wing and Point I-1 Vertical Alignment-Thermite joint I-2 Vertical Alignment-Boutet joint I-3 Vertical Alignment-Boutet 2 ¾” gap weld I-4 Thermite Weld Grinding Sketch

Table of Photos

Photos Title

A-1 Orientation of hot cut chisel A-2 Cutting point of chisel to strike at an angle A-3 Head of chisel must be hit squarely A-4 Chip protector is correctly sized

MWI 801-06

Page

A-12 A-13 C-3 C-4 C-5 C-5 D-1 D-2

D-4 D-5 E-2 F-3 F-4 F-4 F-5 F-5 G-6 G-6 G-7

G-8 G-9 G-9 G-15 G-16 G-19 G-20 I-14 I-21 I-30 I-37

Page

A-14 A-14 A-15 A-15 iii

G-1 Expected grooving caused by false flange of wheel G-13 G-2 Location of maintenance grinding to remove excess metal flow G-14 G-3 Example of Boltless Conformal Frog Gauges on a #20 Frog G-18 iv

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A. SAFETY

GENERAL

1. Safety is of the first importance in the discharge of duty.

2. The title Welder, as used in this Manual, is intended to include Welding Forman, Welder, Welder Helper, and those individuals specifically qualified by the Chief Engineer to operate a burning torch.

3. The Welder is responsible for compliance with this Welding Manual, and all other CFRC policies. If the meaning of a rule or policy is uncertain or any conflicts between rules or policies exist, it must be brought to the attention of the Chief Engineer for explanation and resolution.

4. Job Briefings that cover welding, cutting, and grinding activities must include a fire prevention and response plan. Before stepping off the ballast line, check area for plants that may cause an allergic reaction and have insect spray applied.

5. Welding, cutting, and grinding will be done only by or under the direct supervision of a qualified employee. There are several categories of welding used by the Engineering Department. Employees must not do or supervise work in any category that the Chief Engineer has not qualified them for.

6. Protective clothing, shoes, and gloves, which will give the full body protection, must be worn during all welding, cutting, and grinding operations.

a. Aluminum leggings must be worn for surface grinding with plate mounted or cup wheels. When combination leggings (welding leggings) are available, they may be used for all grinding, sawing, and torch cutting procedures. Aluminum or leather leggings must be used for other grinding work.

b. Clothing must be kept free of grease, oil, and other flammable materials. When performing these operations, employees must keep shirt sleeves rolled down and collar fastened. Caution must be exercised at all times to keep sparks or slag from being caught in cuffs, pockets, sleeves, under gloves, and out of shoes, eyes, and ears.

Frayed clothing must never be worn. Synthetic fabrics that are readily combustible must never be worn.

c. Welding gloves must be worn during any welding or grinding procedure.

7. Safety glasses must be worn at all times. Employees observing, working near, or performing any grinding, welding, or cutting operations must wear necessary approved face shields, helmets, goggles with approved lenses, and cover glasses.

8. When possible, welding and/or cutting should not be done near combustible material. Either the work or the combustible material should be moved to a safe place.

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9. The use of cutting or welding equipment to perform maintenance work on or in a structure without authorization by or without the knowledge of the person in charge of the structure is prohibited.

10. When welding or cutting close to wooden beams, partitions, flooring, or scaffolding, a guard of sheet metal or other non-combustible material should be used. Fire resistant guard curtains (not tarpaulins) should be large enough, tight, and weighted down to prevent sparks rolling underneath or through openings. Every precaution must be taken to provide suitable protection against flying sparks. Before work is started, all surfaces in the area should be carefully cleaned of any readily ignitable material, and combustible surfaces, such as floors, partitions, etc., should be wetted down before the operation is started, and constantly wetted while the work is going on.

11. An employee should be assigned as a “fire watch” to extinguish fires started by sparks, molten metal, or hot slag. A careful inspection of the area, where hot work has been performed, must be made before leaving the work area to detect and extinguish any live sparks or smoldering fires.

12. Suitable fire extinguishers, readily accessible, in ample numbers in close proximity of where the equipment is being used, to provide a quick response. Before beginning grinding, if a water hose is provided, off track area must be dampened with plain water and have hose at the ready for possible pop up fires. Beware of smoke and avoid being in line of smoke so as not to breathe it in. If available on the welding truck in use, the 12 volt pump sprayer must be kept in good working order. If the 12 volt pump sprayer is not available, the 5 gallon Indian pump water sprayer is the best substitute. Always spray from the ballast line when possible.

13. The use of cutting and/or welding equipment, in the performance of maintenance work in structures containing combustible materials, should be avoided. Where the use of welding or cutting equipment is permitted in these facilities, every precaution must be taken to minimize the risk of fire. The Roadmaster will be contacted to assign someone to patrol the area for several hours after the hot work ceases as a “fire watch.”

14. Welding equipment must be positioned so that flames and sparks do not fall on cylinders, hoses, electric welding cables, hydraulic hoses, and other equipment.

15. Welders working on bridges, scaffolds, platforms, and other such work areas higher than the surrounding ground will comply with FRA and other governmental regulations in the use of lifelines, safety belts, or other safeguards as protection against falling.

16. Welding or cutting must not be done from any platform suspended by rope subject to burning or damage by fire.

17. Welding or cutting in “confined spaces” may only be performed by employees qualified to enter confined spaces.

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a. Welding or cutting in a closed or confined space rapidly burns up breathable oxygen. Adequate ventilation must be provided when working in closed or confined spaces. Equipment must be tested for leaks prior to entering confined area. A person must be in position to see the Welder and near welding equipment to turn it off in case of emergency. Oxygen, propane, or other fuel tanks must not be taken into a confined space.

b. When the welder must enter a confined space through a small opening such as a manhole, a lifeline and safety belt are required. The welder is to adjust the lifeline and safety belt in such a manner that will allow the welder to be pulled from the confined area without having the welder's body jam in the opening.

c. One cannot enter a confined space without a trained rescue team. A life line and safety belt alone is not a suitable extraction plan.

18. Adequate ventilation must be provided when welding or cutting certain metals or using certain welding rods or fluxes as toxic fumes may be produced. Among the metals or items that may produce toxic fumes are beryllium, brass, bronze, cadmium, chromium, fluxes containing fluorides, galvanized iron, lead, lead based paint, manganese, mercury, and zinc.

It is mandatory when welding or grinding on manganese to use a power blower. If electricity is available, a power blower is recommended for any welding or grinding operation. If adequate ventilation cannot be provided, a suitable metal fume or HEPA filter respirator must be used.

19. When necessary to obstruct the track(s), the welder must first know that full protection is provided in accordance with Operating Rules.

20. The Welder is to report equipment defects or safety hazards to their Roadmaster. The equipment should not be used until it has been checked for safety. Only qualified personnel will make repairs to welding equipment.

21. Hands, whether gloved or otherwise, must not be used to brush slag or metal from material being welded or cut.

OXY-PROPANE WELDING AND CUTTING

1. Refer to propane as “propane” not “gas”. The word “gas” is a general term and confusion is dangerous.

2. Welding and cutting equipment must be kept clean, free of oil and grease, and in good condition. This equipment will be equipped with flash back arrestors and reverse flow check valves to ensure that the gasses mix at the torch. Exception: If using a Victor HD310C torch handle, add on reverse flow check valves must not be used, as they are built in this torch handle.

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3. Daily inspection must be made on all equipment. Leaky cylinders, hoses, or connections must not be used. Any odor must be traced and all precautions taken against sparks.

4. The use of SNOOP is the preferred method and the only approved liquid for locating leaks.

Where SNOOP is not available the following pressure loss method may be used to detect leaks:

a. Connect equipment.

b. Open cylinder valves, set pressures, and purge hoses.

c. Close torch and cylinder valves.

d. Watch gauges for approximately one minute.

e. If the pressure indicated by the gauges remains the same, there are no leaks.

f. If the gauge indicating tank pressure shows a drop, there is a leak between the cylinder and the regulator.

g. If the gauge indicating hose pressure shows a drop, there is a leak between the torch and the regulator.

h. If a leak is indicated, check the fittings and hose in the appropriate area.

5. Keep oil and grease away from cylinders, cylinder valves, and hoses. Grease and oxygen is a highly explosive mixture.

6. Open cylinder valves slowly.

7. Purge oxygen and propane lines and hoses before lighting the torch.

8. Cylinders must not be roughly handled and must never be handled with a magnet. Cylinders must be transported, stored, and used in a vertical position. A special cradle can be used to ensure proper cylinder positioning.

9. Never use a cylinder or its contents for other than their intended purpose.

10. Protect cylinder valves from bumps, falls, falling objects, heat, and the weather. Use cylinder safety caps when moving any cylinder.

11. It is a CFRC, OSHA, and DOT requirement that all compressed gas cylinders MUST have safety caps protecting the valves when they are transported over public roadways. The APPROVED protector cylinder valve caps will fulfill this requirement and the regulators may be left on the cylinders. Some state and local laws may vary so always follow the most restrictive laws. If the protective valve caps are not available, the solid safety cap must to be used. Propane cylinders must have a screw-in safety plug in the valve outlet when being transported unless the solid safety cap design does not provide adequate room to accommodate the safety plug.

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Description Protector Cylinder Valve Cap – Oxygen Protector Cylinder Valve Cap – Propane Safety Plug – Propane

12. Before moving the cylinders, purge the hoses by closing the cylinder valves, opening the torch valves to release pressure on the gauges, and release the regulator valve screw.

13. Gauges must be removed from the cylinder at the end of every work day.

14. Mark empty cylinders ‘empty’ or ‘M.T.’ with a removable material, such as chalk or crayon.

Do not place marking on top of numbers stamped into or stenciled onto cylinders.

15. Send empty cylinders back to supplier promptly. Never attempt to refill any cylinders.

16. Storage of cylinders.

a. Cylinders shall be kept away from radiators and other sources of heat.

b. Inside of buildings, cylinders shall be stored in a well protected, well ventilated, dry location, at least 20 feet from highly combustible materials. Cylinders should be stored in definitely assigned places away from elevators, stairs, or gangways.

Assigned storage places shall be located where cylinders will not be knocked over or damaged by passing or falling objects, or subject to tampering by unauthorized persons. Cylinders shall not be kept in unventilated enclosures such as lockers and cupboards.

c. Inside a building, cylinders except those in actual use or attached ready for use shall be limited to a total gas capacity of 2,000 cubic feet or 300 pounds of liquefied petroleum gas.

d. Oxygen cylinders in storage shall be separated from propane cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet or by a noncombustible barrier at least 5 feet high having a fire resistance rating of at least one-half hour.

e. In vehicles, if the cylinders are kept in a locker or cabinet, the locker or cabinet must be ventilated. Openings both top and bottom must be provided or the locker or cabinet fitted with a louvered door that will permit any oxygen or propane leaking from a cylinder to disperse freely.

17. Keep valves closed on empty cylinders.

18. Use only approved wrenches for opening cylinder valves not equipped with handles.

19. Never use oxygen for any purpose other than welding. Oxygen is not a substitute for compressed air and should never be used to blow off clothing.

20. Cylinders must be fitted with twin Grade “T” hoses for propane and oxygen with an inside diameter of ¼” or 3/8”. Hoses with an

A-5 inside diameter of 3/8” must be used to preheat the rail ends when making field welds with a length not to exceed 100’.

21. Flashback arrestors and reverse flow check valves

a. Hoses for propane and oxygen will be fitted with combination flashback arrestors and reverse flow check valves at the regulator end.

b. Hoses for propane and oxygen will be fitted with reverse flow check valves at the torch end, unless using a Victor HD310C torch handle. Note that the placement of additional external reverse flow check valves on the Victor HD310C torch handle can cause fuel starvation and a possible blowout of the mixer assembly.

c. Flashback arrestors and reverse flow check valves must be inspected in accordance with manufacturer’s instructions at least every six months unless required more often by the manufacturer.

i. In the absence of manufacturer’s instructions for testing flashback arrestors and reverse flow check vales, the following procedure must be followed.

ii. Turn off both regulator adjusting valves. Remove the reverse flow valves from the torch and the flashback arrestors from the regulators.

iii. Attach the reverse flow valves onto the regulators. Pay particular attention to attach the oxygen valve to the oxygen regulator and the propane valve to the propane regulator.

iv. Turn on each cylinder with the “T” handle until the pressure reaches 65 psi for oxygen and 15 psi for propane. If either valve allows their respective gases to flow, the valves are defective and must be immediately replaced before proceeding.

v. Remove the reverse flow valves from the regulators and attach only the hoses to the regulators.

vi. Attach the flashback arrestor to the torch end of the hose (with the torch not attached). Pay particular attention to attach the oxygen flashback arrestor to the oxygen hose and the fuel gas flashback arrestor to the fuel gas hose.

vii. Turn on each cylinder with the “T” handle until the pressure reaches 65 psi for oxygen and 15 psi for propane. If either flashback arrestor allows their respective gases to flow the flashback arrestor is defective and must be immediately replaced before proceeding.

d. Victor HD310C torch handles will be checked for reverse flow using the following procedure.

i. Turn off both regulator adjusting valves.

ii. Disconnect one hose from one of the regulators.

iii. Open all torch control valves.

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iv. Plug the tip end.

v. Turn on the regulator that is NOT DISCONNECTED until a 2 to 5 psi reading appears.

vi. Put the end of the hose that is DISCONNECTED from the regulator under water or cover the end of the hose with an approved leak detector solution such as SNOOP.

vii. Bubbles will appear if the check valve is leaking. There should be no more than two bubbles in 10 seconds.

viii. If the check valve leaks, reconnect the hose to the regulator and unplug the cutting tip. Flush for 3 to 5 seconds with 10 psi of propane or 30 psi of oxygen (depending on the valve being tested).

ix. Retest the check valve using steps i. thru vii. above. If there is still a leak, replace or repair the torch before proceeding.

x. Reconnect the hose that was disconnected for the first test. Repeat steps i.

through ix. with the other hose.

xi. After both check valves test good, purge both the oxygen and propane lines before lighting the torch. Test all hose connections for leaks.

22. Quick disconnect hose couplings are not to be used.

23. Repair hoses and connections only with crimp style welding hose repair kit and perform

Snoop test prior to use.

a. Never attempt to repair hoses with friction tape, or other types of tape or with wire.

b. Do not use Teflon tape or pipe dope on any of the system’s compression fittings. (eg.

Regulator to cylinder valve, flashback arrestors, reverse flow check valves, test gauges, hose connections, etc.)

24. Before cutting through sheet metal, plate, or other material, employees must be certain that no persons are in a position to be burned or injured from falling material.

25. Do not use wooden or flammable material to support work for welding and cutting.

26. Only approved vendors will perform other than routine adjustments and maintenance to regulators.

ELECTRIC ARC WELDING

Mandatory use of wire feeder.

Any welding repair to frogs, switch points, engine burns, rail ends, etc. that require more than a 30 minute repair (minor repair) will be done with a wire feeder, All welding teams, other than a dedicated thermite Welding Team, that have a wire feeder are required to use it. If a team does not have a wire feeder, or it is broke down, the Chief Engineer for that area is to be contacted and he will handle accordingly.

This instruction applies to sections:

C. Repair of Engine Burns

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D. Repair of Rail Ends E. Repair of Rail Ends for Glued Bonded Insulated Joints F. Repair of Switch Points G. Repair of Frogs and Railroad Crossings

1. Avoidance of electric shock is largely within the control of the Welder. Most welding voltages are not high enough to cause severe injury by electric shock; however, a mild shock from normal working voltages may cause involuntary muscular action that might cause a person to lose balance. Wet clothing reduces the resistance of cloth and increases the effect of a normally small shock. Notwithstanding, under certain conditions, the voltages produced by an electric welder can be dangerous to one's life.

2. Live metal parts of an electrode holder must not be allowed to touch bare skin or wet clothing.

3. An electrode holder must not be permitted to touch any metal that contacts the welding ground. This will cause a dead short circuit on the welding generator resulting in damage to the equipment.

4. The jaws of the electrode holder must be kept clean.

5. Welding Cables:

a. Cable capacity must be matched to the welding machine.

b. The normal length of cables connected to the welding machine is 50 feet. Shorter or longer lengths may be used with permission of the Chief Engineer.

c. On territories where track access is limited by terrain, an additional 50 feet of cable may be added using insulated cable connectors.

6. Always be sure that the cables are in good condition and all cable connections are tight.

7. Cable splices must be 10 feet or greater from the electrode holder.

8. Cable is to be uncoiled before welding. It should be strung out on the ground without crossing itself. Do not leave cable coiled up and hanging from a hook or coiled up one layer upon another while welding.

9. Do not coil or loop electrode cable around the body while welding.

10. All ground connections must be mechanically strong, close to the work, and of adequate size electrically. Never attach ground clamp to the rail base. Use of a magnetic ground clamp that attaches to the ball of the rail is recommended. (Item # 280.0859924.1)

11. Never operate a gasoline or diesel powered welder in a confined space or without adequate ventilation.

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12. Never strike an arc on, or touch an electrode against oxygen, propane, or other cylinders used for the storage of compressed gas.

13. Electrodes must be removed from holders when not in use. Electrode stubs should be disposed of into a metal container.

14. Other than routine maintenance, only qualified individuals or vendors will make repairs to welding machines.

15. Where practical, the work should be enclosed with a fire proof screen to protect the eyes of others from the glare of welding rays. Welders working along the line of road must take precautions to protect the public and others employees not involved in the welding process from glare.

16. When the use of a wire feeder is complete, both the 15 feet welding gun and the roll of wire must be removed from the feeder.

ELECTRIC ARC WELDING IN TRACK CIRCUIT TERRITORY

1. High amperage current (100 to 300 amperes) used for welder operation, which flows through a section of rail during the arc welding process, has a tendency to leak to earth and unbalance the track circuit.

2. Stray electrical current could damage sensitive signal equipment that is used for train operation and active grade crossing warning devices.

3. Unbalancing of the track circuit may affect the operation of track relays resulting in signal interruptions.

4. Sufficient stray current could flow through the track relay to hold it energized with the track circuit occupied if the return current of the welding outfit is allowed to flow through only a short section of rail.

5. Operation of the electric arc welder on bridge guard rails, or on non-bonded tracks, such as sidings or non-signaled running tracks, running parallel to or in close proximity to main tracks equipped with track circuits, will also affect the proper operation of the track circuit.

The following instructions must be followed when using electric arc welding equipment on any track or guard rail in track circuited territory.

6. Before proceeding with the use of an electric welder on tracks in track circuited territory, the

Signal Maintainer must be notified a sufficient time in advance to install circuit fuses to protect signal equipment.

7. The location of insulated joints must be ascertained before any work is undertaken. If there is a question as to the limits of any track circuit, a signal employee must identify the limits

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8. Electric arc welders (generators) must be properly insulated, and insulation kept in good condition.

a. All electrical equipment must be grounded at the source, and all connections must be clean and tight.

b. The ground clamp must be clean, fit well, and make full contact without any current resistance. Use of a magnetic ground clamp is recommended.

9. Do not disturb the ground clamp while welding. Welders equipped with mechanical ground bars must not be moved during welding, nor stopped with the ground spanning an insulated joint.

10. Care must be exercised to see that the ground plates are never allowed to touch the opposite rail of the track on which welding is performed as this will cause serious damage to signal apparatus.

11. The welding electrode and ground plates must never be dropped in the ballast or be permitted to come in contact with the ground while the generator is running. When the welder is not in operation, they should be carefully laid on the end of a tie.

12. At points where the wires are run under or over the rails of any track, additional protection of the insulation must be provided by sliding a short section of rubber hose or placing an insulating mat between the wire and rail.

13. When performing electric arc welding operations on or about bridge structures, the use of guard rails or bridge members for completing the "Hot" side of the circuit between generator and welding electrode must be avoided. An insulated cable conductor must be used for this purpose. When welding guard rails or bridge members, extreme care must be taken to prevent tools, tie plates, or other metallic objects from making contact between main track rails and the member on which welding is performed.

14. Equipment such as grinders, slotters, push cars, and hi-rail vehicles must be properly insulated to prevent shorting the track circuit.

15. In track circuit territory, multiple operator welding systems where two or more welding circuits are connected electrically to the same source must not be operated.

16. No more than two single arc-welding machines may be operated within the limits of any track circuit. This applies to territory having one or multiple tracks.

17. Automatic and semi-automatic wire feed systems must be fully insulated from the unit frame.

18. For the welding of conventional insulated joints, joint bars shall be applied on only one joint at a time. (When the insulated joint is on the closure rail, the installation of

A-10 joint bars may short the track circuit.)

19. Protect bond wires during preheating, post heating, welding heat, surface grinding, and cross slotting.

20. The polarity switch must be in the “OFF” position while traveling or when removing the welding machine from the track. Some welding machines do not have a polarity switch with an “OFF” position. These welding units must be turned off while traveling or when removing the machine from the track.

THERMITE WELDING

1. Daily inspection must be made of all equipment to ensure that the equipment is kept clean and in good condition.

2. All equipment and personnel, not directly involved in making the weld, will be moved to a safe distance of 20 feet (30 feet if snow on the track) during the weld reaction and pour, as well as during the grinding operations. In particular, equipment will be far enough from the work to ensure that it is not showered with sparks from these operations.

3. The slag basin shall have 3/4” of dry sand placed in the bottom of the basin during the preheat process.

4. At any time the ballast or surface under a field weld is wet, a safety pan will be placed directly under the weld. The safety pan is a metal container approximately 8” x 18” x 6” with 3” of dry sand in the bottom as illustrated in Sketch A-1.

5. When a weld must be made on an open deck bridge: A safety pan will be placed directly under the weld. The safety pan is a metal container approximately 10” x 26” x 6” with 3” of dry sand in the bottom as illustrated in Sketch A-2.

6. A full face shield, welding gloves and long sleeves are required when handling hot slag basins and during the tear down process of a poured weld. This face shield and welding gloves are required during the shearing process.

7. Do not move the slag basins until five minutes (six minutes for wide gap welds) have passed since the pour. After five minutes, move the slag basin fifteen to twenty feet (eight to ten ties) and place on level ballast. After twenty additional minutes have passed, empty slag basin in designated location.

8. Never throw hot metal or slag into water, snow, or ice because an explosion may occur.

9. The contents in the slag basin(s) and safety pans should be dumped only after they have completely solidified, and in a dry place where it will not cause a fire or personal injury.

A-11

Sketch A-1

10. One method for removing weld risers is the weld riser removal tool. Insert the tool vertically with the large opening over the riser and the notch toward the weld. Pull the end of the tool smoothly to the desired angle in accordance with the welding procedure. When breaking of a riser, completely insert the tool onto the riser and use the tool defensively due to the snapping effect. After breaking off a riser, the riser may be handled with the tool and placed in the disposal area.

11. If using a hammer to remove the weld risers, a full face shield and welding leggings must be worn. Always stand on the opposite side of the rail from the riser that is being struck. A hot cut chisel can be used to gently remove the sand mold from around the base of the risers to allow for cooling. The risers should not be removed until approximately 25 minutes after the end of the pour. Be sure to clear the “red zone” before striking the risers and use only light taps with the hammer.

A-12

Sketch A-2

HAND TOOLS

Using Hot Cut Chisel:

1. Hot cut chisel may be used for clean up of sand mold debris around base risers and side of weld areas, but will not be struck doing this clean up task. Employee must stand on opposite side of rail to be cleaned and with light downward strokes, remove sand away from risers. When done cleaning on first side, step over the rail to clean other side of rail.

All required PPE is stated below.

2. In case of emergency, such as weld shear failure, the hot cut chisel will be used to cut risers from side of ball and clean up top of ball after torching off head. This will be done only after the hot cut chisel has been inspected as explained below.

3. Hot cut chisel handle will be inspected for cracks, the chip protector will be removed, and head of hot cut chisel will be inspected for cracks, overflow, or missing pieces.

4. The tool will be ground if not found in compliance and if pieces are missing, the hot cut chisel will be removed from service.

5. After the head of the hot cut chisel has been inspected and corrected, the chip protector will be put back in place.

A-13

3/6/15

6. The cutting edge of the hot cut chisel is to be properly sharpened using the procedure outlined in MWI 1702.

Chip Protector – 3 lbs. Hot Cut Chisel Chip Protector – 5 lbs. Hot Cut Chisel

Note: When using a hot cut chisel to cut away excess metal from the sides of the railhead, the following procedure must be followed:

1. Head of the hot cut chisel must be turned to a perpendicular angle between 10 to 15 degrees away from vertical in relation to the ball of rail. See photo A-1.

2. Cutting point of chisel must not strike risers squarely rather at an angle. See photo A-2.

3. Head of chisel must be hit squarely. See photo A-3.

4. Chip protector is correctly sized. See photo A-4.

Photo A-1 Photo A-2

Photo A-3 Photo A-4

A-14

Required PPE:

If the hot cut chisel does have to be used due to weld shear failure, the following PPE will be worn by both holder and striker:

• Hardhat,

• Safety Glasses,

• Face Shield with chin guard,

• Welder’s Gloves and,

• Leather/Metal Metatarsal Leggings

1. Handles must be maintained tight on all hammers, sledges, mauls, chisels, etc.

2. Ensure everyone is standing clear of the red zone before swinging any wide arching sledge or maul.

3. All burrs, chips, and battered metal must be ground off all hand hammer driven tools, such as sledges, spike mauls, hot cut chisels, wedges, drift pins, etc.

The use of a dead blow hammer is required when striking alignment wedges to crown rail ends for welding.

4. When striking and struck tools are repaired, they must be ground to an approved contour, checked with an approved template and fitted with a chip protector. See MWI 1702 for more information on repairing hand tools.

A-15

10/12/12

CUTTING RAIL AND TRACK BOLTS AT DERAILMENT SITES

1. Do not use welding or cutting equipment at the scene of a derailment until the person in charge of re-railing operations advises that it is safe to do so. Material leaking from damaged cars may be explosive or highly flammable and the use of open flames must be controlled.

2. Twisted and bent rails may shift to a new position with little or no warning when cut. Before making the cut, all personnel not involved in making the cut shall be clear of the Red Zone.

Use heavy equipment to stabilize the rail before cutting and during the entire cut. The torch must be at least 36 inches or longer. The welder must be positioned in order to not become caught between the rail and other objects if the rail does shift.

3. Joint bars on twisted and bent rails may be propelled a considerable distance when the bolts are cut. A chain loosely wrapped several times around the joint will restrain the joint bars when the bolts are cut. If the bolts are under pressure, they may also fly when cut. If in doubt, cut the rail first and then remove the joint bars.

A-16

B. QUALIFICATIONS FOR CFRC ENGINEERING DEPARTMENT

WELDERS

GENERAL:

1. All Welders performing work for the Engineering Department on track appliances, buildings, bridges, or other structures using the Thermite, Oxy-propane, or Electric-arc methods of welding must be qualified by a Welding Instructor or Manager–Welding.

2. The qualification test will consist of actual welding and grinding, as well as a written or oral examination on safety precautions and welding procedures. The test will be specified by the Chief Engineer.

3. The Chief Engineer will maintain a record of each person who qualifies as Welder. The record will indicate:

a. The welding category(s) in which an individual is qualified,

b. The date each qualification was granted,

c. Qualification as a Welder, and

d. The person who qualified the individual

4. No person will perform any welding without being qualified. Exception: Persons in training to become Welders may perform work specified by a Welding Instructor or Manager– Welding under the direct supervision of a qualified Welder.

5. It is understood that when an employee accepts the position of Welder Helper, they will progress toward becoming qualified as a Welder.

QUALIFICATIONS CATEGORIES:

1. Welding work performed for the Engineering Department will be divided into the following categories:

a. Structural; Electric-Arc Method

b. Track Appliance; Electric-Arc Method; Using Electrodes

1) Repair engine burns

2) Repair battered rail ends, regular and insulated joints

3) Repair switch points

4) Repair frogs and crossings

c. Track Appliance; Electric-Arc Method; Using Wire Feed

1) Repair engine burns

2) Repair battered rail ends, regular and insulated joints

3) Repair switch points

4) Repair frogs and crossings

d. Field Welding of Rail Ends; Thermite Method B-1

1) 1” Gap Welds

a) Boutet

b) Orgo-Thermit

2) 2 ¾” Gap Welds

a) Boutet

b) Orgo-Thermit

e. Rail piling; Electric-Arc Method Welding

f. Air arc metal removal

g. In track electric flash-butt welding of joints

h. Slice

i. Basic cutting with burning torch

ACCEPTABLE TRAINING INCLUDES:

1. Work under a qualified CFRC Welder.

2. Class room training directed by a Welding Instructor or Manager–Welding.

3. Commercial Trade School

AWARDING OF WELDER POSITIONS:

1. To be awarded a bid position of welder, a person must qualify under these rules prior to the expiration of qualification time as called for in the appropriate Labor Agreement.

QUALIFICATION REQUIREMENTS:

KNOWLEDGE AND UNDERSTANDING RAILROAD RULES

1. A person must obtain a copy of the Engineering Department Welding Manual and must demonstrate to a Welding Instructor or Chief Engineer a general knowledge of its contents.

2. A person must obtain a copy of the CFRC MofW Field Manual and demonstrate to the Chief

Engineer, or designee, a general knowledge of the rules.

3. A person must obtain a copy of the CFRC Operating Rules and must be examined and qualified as required by these rules.

B-2

5. A person must obtain a copy of the FRA Track Safety Standards and become qualified in accordance with §213.7.

6. A person must submit a welding report on Maximo at the completion of each work day.

QUALIFICATION REQUIREMENTS: DEMONSTRATION OF WELDING SKILLS

1. The qualification will be based on actual work performed under the personal observation of a

Welding Instructor or Chief Engineer for all track appliances and structural welding.

Qualification for bridge welding will also comply with American Welding Society Bridge Welding Code (AWS D1.5).

2. Certain welding procedures require that test samples, made in accordance with American

Welding Society specifications, be prepared for qualification. Test material will be mild steel plate (ASTM A36 structural steel or equal) 3/8” to 1” thick. A test sample will qualify a person only for the welding process used to make the test sample.

3. Test samples may be required in the flat and vertical positions for track appliance. For structural welding, the person will be required to have vertical and overhead weld samples.

4. The Welding Instructor or Chief Engineer may require qualified Welders in structural or track appliance to make additional test samples if steel plates ¾” thick or greater, or high strength steel are required. Test samples will be made with the welding process and the type and thickness of steel to be used. The Welding Instructor or Chief Engineer will specify the welding positions.

5. The Welding Instructor or Chief Engineer may require qualified Welders who have not performed welding for the Railroad for a period of one (1) year or longer to make test samples in one or more positions to demonstrate that they have retained their welding skills.

6. The Welding Instructor or Chief Engineer will provide materials for the test samples and see that the samples are tested in accordance with American Welding Society's Specification for Compliance (Structural D1.1, Bridge D1.5), maintain records of results, and maintain a list of qualified Welders by welding categories.

7. The Welding Instructor or Chief Engineer will observe the person requesting qualification under actual work conditions to verify the welder’s work habits and methods are consistent with safe welding practices. Proper welding procedure is a requirement for qualification.

8. The Welding Instructor or Chief Engineer will examine welds for durability made by a person requesting qualification after they have been subjected to service for a period of time;

however, the period of time must not exceed the time referred to in Labor Agreements.

Durable welds are a requirement for qualification.

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9. Persons that have successfully completed a commercial trade school course in welding which required the preparation and examination of test welds in accordance with American Welding Society's Specification may be relieved by a Welding Instructor or Chief Engineer from making similar test samples for the Railroad, provided the following conditions are met:

a. The person desiring to be qualified has a written statement from the instructor of the course stating the welds met proper requirements.

b. A copy of the laboratory examination of the test samples showing they met American

Welding Society's specifications.

c. Not over one (1) year has passed since the samples were made and tested.

B-4

C. REPAIR OF ENGINE BURNS.

GENERAL

1. Engine burns in carbon steel rails will be repaired through the use of the electric-arc welding process with the mandatory use of either heating blocks or a Teleweld heater.

2. Engine burns in alloy rail will not be repaired. For description of alloy rail, see page H-2.

3. Engine burns should be repaired as soon as practicable. The impact of wheels on the defect will increase the metal flow, secondary batter, and thermal cracking.

4. The size and number of engine burns, that may be repaired in a given rail, depend upon the weight and condition of rail to be repaired and the availability of replacement rails.

Generally, defects, which will be deeper than 3/8” after grinding, should not be repaired (See Sketch C-1). Also, engine burns requiring a weld longer than 10” should not be repaired.

5. Engine burns will not be repaired:

In a rail with shelly spots in the burn area.

In a switch point.

In a stock rail.

In the guardrail area of a turnout.

Within three (3) feet of a plant or thermite weld.

6. When repairs are necessary in cold weather, the heated area must be protected to prevent rapid cooling, as follows.

Rail Weather Conditions

Temperature

Clear Wind, light rain, or snow

Air Cool Apply Weld Cooling Cover

40°F or greater Weld Cooling Cover is not immediately after shearing.

Leave cover in place until weld is required cooled below 800°F (about 35 minutes).

Between 40°F Prior to installation of molds, preheat railhead and base to 100°F (hand and 0°F hot) for a distance of 3 feet on both sides of the weld gap.

Complete weld and unmold normally.

Apply Weld Cooling Cover immediately after shearing.

Leave cover in place until weld is cooled below 800°F (about 35 minutes).

0°F and less Welding is not recommended

7. The Signal Maintainer will be notified in advance whenever welding is to be performed in track circuit territory.

C-1

8. See Section "A", Safety, for instructions for electric arc welding in track circuit territory.

PROCEDURE FOR REPAIRING ENGINE BURNS:

1. Check to see if rail can be repaired with a weld less than 10” long.

2. Before welding, three (3) ties on each side of the repair area will be inspected to determine if the rail can expand during the repair. Nip spikes and remove rail anchors if necessary.

3. Shim rail with a crown of 1/8” at the center of the engine burn using a 36” straight edge. See sketch in Section “I”, Thermite Welding.

4. Mark the limits of the repair. The repair limits should be marked at an angle across the railhead so that the length of repair on the gage side will be approximately one inch (1”) longer than on the field side on each side of the repair.

5. Grind out all damaged metal down to sound, clean parent metal. The removal shall not be accomplished through the use of a torch. Special care must be used to remove enough metal to eliminate all shatter cracks.

6. If during the repair work, it is found that the rail requires removal of more than 3/8 inch in depth of damaged metal by grinding; it will be repaired, protected by joint bars, and removed from track as soon as possible.

7. Preheating

a. Orgo-Thermit Heating Blocks - Before welding, the heating blocks are to be secured on each side of the rail in the web area and ignited. After the rail is heated to 800°F, carefully examine the rail for cracks. Cracks will appear as dark hair lines in the heated area. If cracks are present, further grinding is required. Heating blocks must remain in place until the repair has been completed.

1) Heat block for 90# to 119# rail

2) Heat block for 122# to 140# rail

3) Heat block are not currently available for 141# rail or greater

C-2

Sketch C-1

b. Other Heating Devices – An approved heater must be used to heat the rail to 800°F. The temperature will be verified using a Tempilstick or digital thermometer. Position the heater so that the pre-heated area includes the repair and four inches (4”) to both sides of the repair. One approved heater is the Teleweld Single Propane heater.

8. Repair of the engine burn must start immediately after the ground out area has been inspected for cracks and must continue without stopping until all weld material has been deposited.

9. Approved welding rods and wires for the electric-arc process are listed on page N-2.

10. Welding of engine burns should start on the gage side (not gage corner) and proceed to the field…