Attach_7_Spec_34_11_00.pdf

SECTION 34 11 00

RAILROAD TRACK AND ACCESSORIES

04/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN RAILWAY ENGINEERING AND MAINTENANCE-OF-WAY ASSOCIATION

(AREMA)

AREMA Eng Man (2012) Manual for Railway Engineering

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2011) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

AMERICAN WOOD PROTECTION ASSOCIATION (AWPA)

AWPA C6 (1999) Crossties and Switch Ties - Preservative Treatment by Pressure Processes

AWPA M2 (2011) Standard for Inspection of Treated Wood Products

AWPA M6 (2013) Brands Used on Preservative Treated Materials

AWPA P2 (2009) Standard for Creosote Solutions

ASTM INTERNATIONAL (ASTM)

ASTM A242/A242M (2013) Standard Specification for High-Strength Low-Alloy Structural Steel

ASTM A992/A992M (2011) Standard Specification for Structural Steel Shapes

ASTM C117 (2013) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C127 (2012) Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM C131 (2006) Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C142/C142M (2010) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C535 (2012) Standard Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C88 (2013) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM D1241 (2007) Materials for Soil-Aggregate Subbase, Base, and Surface Courses

ASTM D1310 (2001; R 2007) Flash Point and Fire Point of Liquids by Tag Open-Cup Apparatus

ASTM D1556 (2007) Density and Unit Weight of Soil in Place by the Sand-Cone Method

ASTM D1557 (2012) Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3) (2700 kN-m/m3)

ASTM D2171/D2171M (2010) Viscosity of Asphalts by Vacuum Capillary Viscometer

ASTM D3740 (2012a) Minimum Requirements for Agencies Engaged in the Testing and/or Inspection of Soil and Rock as Used in Engineering Design and Construction

ASTM D3776/D3776M (2009a; R 2013) Standard Test Method for Mass Per Unit Area (Weight) of Fabric

ASTM D402 (2008) Distillation of Cut-Back Asphaltic (Bituminous) Products

ASTM D4791 (2010) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D75/D75M (2009) Standard Practice for Sampling

Aggregates

ASTM E11 (2013) Wire Cloth and Sieves for Testing Purposes

U.S. FEDERAL HIGHWAY ADMINISTRATION (FHWA)

MUTCD (2009) Manual on Uniform Traffic Control Devices

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

The following shall be submitted in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

As-Built Drawings; G

SD-03 Product Data

Wood Ties; G New Jointed Rail; G Joint Bars; G Compromise Joint Bars; G Miscellaneous Track Materials; G Traffic Maintenance and Detour Plans; G, Electric Arc Welding; G Materials and Samples; G

SD-04 Samples

Ballast Subballast

SD-06 Test Reports

Sampling and Testing; G Wood Ties; G Ultrasonic Test; G

SD-07 Certificates

Wood Ties; G Ballast; G Subballast; G Materials and Samples; G

1.3 QUALITY ASSURANCE

1.3.1 Track Construction

Perform track construction under the direction of qualified and competent supervisory personnel experienced in railroad construction.

1.3.2 Welding

Perform welding under the direct supervision of an experienced welding supervisor or foreman.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Materials and Samples

Submit a complete schedule of the materials proposed for installation within 60 days of receipt of notice to proceed, and before installation of the materials; the schedule shall include a list of equipment proposed for the work. The Contracting Officer will notify the Contractor of the materials approved or disapproved. Disapproved materials that have already been delivered to the project site, shall be promptly segregated from the approved materials and removed from the premises. If materials are disapproved, acceptable replacement materials shall be provided at no additional cost to the Government. Submit performance data for components or products proposed as an equivalent to those specified. The Contracting Officer's written approval is required for any such equivalent type component or product proposed to be used. Initial approval by the Contracting Officer will not prevent the removal and replacement of materials that are materially defective or materials not meeting this specification that are discovered during construction and/or routine quality control/quality assurance operations. Submit manufacturer's certificates of conformance for the following materials:

a. Rail.

b. Tie plates.

c. Track bolts, nuts, and spring washers.

d. Joint bars.

e. Rail anchors.

f. Track spikes.

1.5 PROJECT/SITE CONDITIONS

1.5.1 Temporary Work

Provide, during construction, suitable roads and crossings with all necessary lights, signs, drainage, and other appurtenances required for safe public and local travel. Erect and maintain suitable temporary fences where required to prevent trespass upon work or damage to adjoining property. Drainage shall be maintained, and the accumulation of water that might affect the stability of the roadbed will not be permitted.

1.5.2 Traffic Control

Traffic control devices shall comply with MUTCD. Suitable warning signs shall be placed near the beginning of the work site and well ahead of the work site for alerting approaching traffic from both directions.

1.5.3 Welding

Welding shall not be performed in rain, snow, or other inclement weather without adequately protecting the weld from the elements.

PART 2 PRODUCTS

2.1 BALLAST

Submit samples of the ballast and subballast material for testing. Submit samples a minimum of 30 days prior to the installation of the material.

Samples shall be obtained from the quarry, supplier, or other source that will be used to provide the ballast and subballast materials for this project using the methods described in ASTM D75/D75M. One representative sample of not less than 200 lbs of ballast material shall be submitted. One representative sample of not less than 200 lbs of subballast material shall be submitted. Prepared ballast shall be crushed stone, Size No. 4, or 4A, conforming to Chapter 1, Part 2, of AREMA Eng Man for quality, soundness and gradation. In the portion retained on each sieve specified, the crushed gravel shall contain at least 90 percent by weight of crushed pieces having two or more freshly fractured faces with the area of each face being at least equal to 75 percent of the smallest midsectional area of the plane. When two fractures are contiguous, the angle between planes of the fractures shall be at least 30 degrees in order to count as two fractured faces. Flat and elongated particle dimension ratio used in ASTM D4791 shall be 1:3. Submit certificates of Compliance for the ballast and subballast materials to be installed in this project. Ballast materials shall meet the property requirements shown in TABLE I.

TABLE I. MINIMUM PROPERTY REQUIREMENTS - BALLAST

Property Maximum Value Minimum Value Test Method

Percent passing 1.0 percent -- ASTM C136 No. 200 Sieve ASTM C117

Bulk specific gravity Rock -- 2.60 ASTM C127 Blast furnace slag -- 2.30

Absorption Rock 2.0 percent -- ASTM C127 Blast furnace slag 5.0 percent --

Clay lumps and 0.5 percent -- ASTM C142/C142M friable particles

Degradation 35 percent -- ASTM C535 Soundness

Sodium sulfate 10 percent -- ASTM C88

- 5 cycles

Flat or elongated 5 percent -- ASTM D4791 particles

2.2 SUBBALLAST

Subballast shall consist of aggregate-soil materials conforming to an ASTM D1241 Type I, Gradation C mixture.

2.3 JOINT BARS

Joint bars shall be of the size, shape, and punching pattern to fit the rail being joined.

2.3.1 New Joint Bars

New joint bars shall be used with new rail, and shall be of the "toeless" and "head free design" to match rail section. New joint bars shall conform to the requirements of "Specifications For High-Carbon Steel Joint Bars" or "Specifications For Quenched Carbon-Steel Joint Bars and Forged Compromise Joint Bars" found in Chapter 4, Part 2 of AREMA Eng Man for the joint bar and assemblies recommended in Chapter 4, Part 1 of AREMA Eng Man.

2.3.2 Compromise Joint Bars

Compromise joint bars shall be of the size, shape, and punching pattern to fit the rail sizes and sections being joined. Only factory designed and constructed (forged or cast) compromise joint bars shall be used to join rails of different sizes.

2.3.2.1 New Compromise Joint Bars

Compromise joint bars shall conform to the requirements of "Specifications For Quenched Carbon-Steel Joint Bars and Forged Compromise Joint Bars" found in Chapter 4, Part 2 of AREMA Eng Man.

2.4 OIL FOR CORROSION PROTECTION

Oil for protecting rail and other track materials from corrosion, except joints, shall conform to the following general specification:

Asphalt, 100 penetration minimum 45 percent ASTM D402

Flash point, minimum 130 degrees F ASTM D1310

Viscosity, kinematic, 140 degrees F ASTM D2171/D2171M 480 to 700 centistokes

2.5 RAIL

Submit manufacturer's data on new rail including: rail weight, rail section, drilling, rail length, date rolled, and the name of the mill where the rail was rolled. The design of the joint bars and compromise joint bars proposed to be furnished with each rail section shall also be provided.

2.5.1 New Jointed Rail

2.5.1.1 General Requirements

New jointed rail shall comply with the following:

a. Rail Lengths: New rail shall be a 100 lbs/yd section or heavier and shall conform to the specifications in Chapter 4, Parts 1 and 2 of AREMA Eng Man that were in effect at the time of its manufacture. New rail shall be provided in 39 ft lengths.

b. Rail Drilling: New rail shall be provided with the rail ends drilled. Drilling shall be uniform and to the patterns specified.

RAIL DRILLING

100 ARA-B FIELD VERIFY AND MATCH EXISTING

2.6 TIE PLATES

2.6.1 General

Tie plates shall be of the dimensions and punching pattern (A or B) to fit the rail. New tie plates conforming to Chapter 5, Part 1 of AREMA Eng Man shall be used with new rail. Both flat and canted plates will be required to match the existing tie plates that are in track. Canted tie plates shall be used in all new rail and relay out-of-face rail replacements.

2.7 WOOD TIES

Submit name of the tie manufacturer, Rail Tie Association membership, the wood species proposed, the quantities of ties for each specie proposed, and product data for the ties to be furnished, including the type of seasoning to be utilized, prior to ordering the ties. All ties shall be new.

Species shall be Red and White Oak.

a. Conditioning and seasoning shall conform to the requirements of AWPA C6 for the individual wood species. Ties shall be well seasoned.

Prior to preservative treatment, wood ties shall be dried to the oven dry moisture content, or less, as specified in paragraph 3.14 of AWPA C6.

The wood may be air dried, vapor dried, or boultonized.

b. Ties which are to be dried by artificial means shall be conditioned and treated as soon as possible after sawing, but no more than 30 days later. The temperature used for boultonizing shall be as high as possible but in no case less than 200 degrees F. Vapor dried ties shall be transferred from drying cylinders to treatment cylinders as quickly as possible to avoid loss of heat from the seasoned ties. Ties shall be pressure treated in accordance with Chapter 30, Part 3 of AREMA Eng Man by the empty cell process with a 60/40 creosote/coal tar solution (Grade C) in accordance with AWPA P2 to a minimum retention of 8 lbs/cu ft of wood. If creosote/coal tar treated ties are unavailable, ties treated with a 50/50 creosote petroleum solution as specified by AWPA standard P3 may be used.

c. Record treatment as specified in AWPA M2. Treated ties shall be permanently marked or branded by the producer in accordance with AWPA M6.

Ties shall be produced by a member of the Railway Tie Association. All ties, except Southern, Red, and Ponderosa Pine, shall be incised on all four sides in the pattern specified in AREMA Eng Man, Chapter 30, Part 3, prior to treatment.

d. Splits shall not be longer than 4 inch and not wider than 1/4 in at either end. Splits longer than 4 inch but not longer than the width of the face in which the split appears, will be acceptable if specified anti-splitting devices are installed with the splits compressed. Any required adzing and drilling for spikes shall be performed prior to treatment.

e. When inspections of onsite materials result in product rejection, promptly segregate and remove rejected material from the premises. The Government may charge the Contractor any additional cost of inspection or test when prior rejection makes reinspection or retesting necessary.

f. Submit certified test and inspection reports for crossties subsequent to treatment, a minimum of seven calendar days prior to any ties being installed in track. Test and inspection reports shall contain the information required by Part 7 of AWPA M2. Submit certificates of compliance prior to any ties being installed in track.

2.7.1 Crossties

Wood crossties shall conform to Chapter 30, Part 3 of AREMA Eng Man.

a. Wood ties shall be sawed and shall be not less than 7 inch thick and 9 inch wide. The length shall be 8.5 ft.

2.7.2 Tie Plugs

Tie plugs shall fit holes from which spikes are drawn. The plugs shall comply and be treated in accordance with Chapter 30, Part 3 Section 3.1.5 of AREMA Eng Man.

2.7.3 Anti-splitting Devices

Crossties and switch ties shall be equipped on each end with gang nail end plates anti-splitting devices of the type specified, regardless of whether or not the wood has shown any tendency to split. Products used shall conform to Chapter 30, Part 3 Sections 3.1.6 and 3.1.7 of AREMA Eng Man.

2.8 MISCELLANEOUS TRACK MATERIALS

Submit manufacturer's data for all track materials to be furnished.

Miscellaneous track materials shall be as follows:

2.8.1 Spikes

2.8.1.1 Track Spikes

Track spikes shall be new and shall conform to Chapter 5, Part 2 of AREMA Eng Man. Track spikes size 6 by 5/8 inch shall be used with 100 lbs or heavier rail. Track spikes 5-1/2 by 9/16 inch shall be used with 90 lb and under rail.

2.8.2 Bolts, Nuts, and Spring Washers

New track bolts, nuts, and spring washers shall be used throughout the project for both new and relay rail.

2.8.2.1 Bolts and Nuts

The various rail, joint bars, and rail drillings require various lengths and diameters of bolt assemblies. Determine the number of bolt assemblies of each size required. All bolt diameters shall be the largest possible for a given rail drilling and joint bar punching. Track bolts and nuts shall conform to Chapter 4, Part 2 of AREMA Eng Man. Track bolts shall be long enough to leave at least two threads exposed after the nut is tightened.

2.8.2.2 Spring Washers

Spring washers and nuts shall be sized to ensure that the spring washer develops its full reactive force and does not jam into the joint bar hole.

Spring washers shall be of the size to fit the bolt and nut used and shall conform to Chapter 4, Part 2 and Section M12 of AREMA Eng Man.

2.8.3 Rail Anchors

2.8.3.1 New Installation

Rail anchors for new installations shall be new. Sizes shall conform to the various sizes of rail on the project and conform to "Specifications for Rail Anchors" in Chapter 5, Part 7 of AREMA Eng Man. Anchors may be either drive-on or spring type.

2.8.4 Gage Rods

2.8.4.1 New Gage Rods

New gage rods shall be the double-clamp style manufactured in conformance with "Specifications for Special Trackwork" of AREMA Eng Man. The double clamp style gage rods shall be threaded on both ends and shall be equipped with four malleable steel casting clamps to rigidly hold both sides of the base of both rails.

2.9 WELDING

2.9.1 Electrodes

Provide AWS low-hydrogen, high tensile 140-16 (extrapolation) or 25-20 electrode, Grade 310-16 and 310-15 stainless steel rod welding electrodes.

Provide electrodes of the smallest practical diameter worked at the lowest compatible current. Coating on low-hydrogen type electrodes shall be thoroughly dry when the electrode is provided. Use electrodes taken from hermetically sealed packages within one hour of the time the package is opened. Electrodes not used within this one-hour period and electrodes taken from non-hermetically sealed packages shall be dried for at least one hour between 700 and 800 degrees F. Electrodes so dried may be stored at temperatures between 225 and 400 degrees F until used, or, if not stored and not used within one hour after this drying is completed, shall be re-dried before use. Do not use electrodes which have been wet.

PART 3 EXECUTION

3.1 REMOVAL, SALVAGE, AND DISPOSITION OF MATERIALS

Tracks and segments of track shall not be dismantled until approved to do so by the Contracting Officer.

3.1.1 Methods and Procedures

The Contractor may use any methods to dismantle the track, provided proper measures are taken to ensure the safety of the laborers and the general public, and no damage is caused to track components to be salvaged or other tracks and structures which are indicated to remain. Methods of removal of existing tracks shall not cause damage to adjacent sidewalks or paved roadways. Damage to these facilities caused by the Contractor shall be restored at Contractor's expense.

3.1.2 Material to be Scrapped

All material shall be scrapped and shall become the property of the Contractor.

3.2 PLACEMENT OF BALLAST AND SUBBALLAST

Ballast and Subballast shall be placed to the lines and grades indicated.

The average thickness shall be within 0.25 inch of the thickness shown on the drawings Subgrade shall conform to the requirements of Section 31 23 00.00 22 EXCAVATION AND FILL (PWD ME). Ballast and Subballast shall not be placed on soft, muddy, or frozen areas. Where the prepared subgrade (roadbed) is soft, muddy, rutted, exhibits severe depressions, or is otherwise damaged, the ballast and subballast shall not be placed until the damaged subgrade has been repaired and the area has been approved by the Contracting Officer.

3.2.1 Subballast

3.2.1.1 Subballast Placement

Subballast shall be placed in two uniform horizontal lifts of not more than 6 inch for the full width of the cross-section to the total depth indicated. Each subballast layer shall be shaped to a section conforming to the subballast section shown on the drawings and shall be thoroughly compacted.

3.2.1.2 Subballast Compaction

Each subballast lift shall be compacted using approved compaction equipment. The roller weights, vibration frequencies (where applicable), tire pressures (where applicable), and number of passes shall be sufficient to obtain in-place densities across the full width of the subballast and throughout the entire depth of the layer of not less than 95 percent of the ASTM D1557 laboratory maximum dry density for the subballast material.

Prior to placement of subsequent subballast layers the top of the previous layer shall be scarified to a depth of approximately 2 inch to insure proper bond of the layers. Density shall be field measured in accordance with ASTM D1556(base plate, as shown in the drawing shall be used). One field density test shall be taken for each layer of material placed in each area.

3.2.2 Ballast

3.2.2.1 Ballast Placement

Number 4 or 4A AREMA ballast shall be placed in the tracks where indicated.

3.2.2.2 Ballast Distribution

Ballast shall not be distributed until the subballast has been approved by the Contracting Officer. No payment will be made for ballast which is distributed without the Contracting Officer's approval.

a. Ballast distribution shall be to the depth indicated from trucks.

A government locomotive is not available for unloading ballast.

b. Forming of ruts that would impair proper roadway drainage shall be prevented when distributing ballast from trucks and off track equipment. Any ruts formed greater than 1 inch shall be leveled and graded to drain.

c. Ballast shall be unloaded as close as possible to the point of use so that unnecessary handling is prevented. Excess ballast shall be picked up and redistributed at the Contractor's expense. If additional ballast is required for dressing, it shall be added at no increase in unit price.

3.2.2.3 Ballast Below Ties

For new construction, the last 4 inches ballast below the tie, the shoulder ballast and the ballast in the tie cribs shall be placed subsequent to the rail and tie installation.

3.3 TRACK CONSTRUCTION AND OUT-OF-FACE RELAY

Track construction not covered specifically herein shall be in accordance with AREMA recommendations and recommended practices.

3.3.1 Roadbed Preparation

Grading, excavation, and subgrade preparation shall be performed in accordance with Section 31 23 00.00 22. Roadbed surface, grade, and drainage shall be approved prior to any distribution of construction material. Where the subgrade or roadbed is damaged during distribution of materials, ruts and depressions shall be filled and compacted and the roadbed surface reapproved prior to track construction.

3.3.2 Unloading the Materials

The use of picks in the handling of ties will not be permitted. Rails shall be unloaded from cars with an approved derrick or crane and placed with the head up without dropping and with sufficient support under the base. Rails of proper length shall be distributed as necessary for road crossings, switches, joint spacing, and other special conditions.

3.3.3 Ties

Standard center-to-center spacing of crossties shall be 19.5 inch. Ties shall be laid perpendicular to the center line of the track with the grain up (heartwood side down) for wood ties. The best ties shall be used at the rail joints. The ends of ties on one side of the track shall be parallel to the rail and the center of the tie shall be on the approximate center line of the track. The ends shall be aligned on the inside of curves and shall continue on that side until reaching a curve in the opposite direction. On double tracks, the ties shall be aligned on the outside ends. The top surface of ties shall provide full bearing for the tie plates. Adzing of wood ties shall be restricted to that necessary to provide a sound true bearing for the tie plate. Adzing in excess of 0.2 inch will not be permitted. Where adzing is necessary, the cut surface of the wood tie shall be completely saturated with creosote or other approved preservatives.

3.3.4 Tie Plates

Tracks shall be fully tie-plated. Tie plates shall be free of dirt and other foreign material when installed. Tie plates shall be placed so that the rails will have full bearing on the plate, and the plate will have full bearing on the tie. Tie plates shall be set at right angles to the rail with the outside shoulder against the base of the rail, and centered on the tie. Canted tie plates shall be installed to cant the rail inward.

3.3.5 Rail

The base of the rail and the surface of the tie and tie plate shall be free of dirt and other foreign materials prior to laying rail.

3.3.5.1 Laying Rail

Rail shall be laid without bumping or striking, to standard gage (4 ft 8-1/2 inch between points 5/8 inch below the top of the rail) on tangents and on curves up to 12 degrees. For curves 12 degrees and greater, the gage shall be widened 1/8 in for each increment of 2 degrees to a maximum of 4 ft 9 inch, in accordance with TABLE V. The track shall be gaged at every third tie as spikes are being driven.

TABLE V. TRACK GAGE FOR HIGH DEGREE OF CURVATURE

Degree of Curvature per 100-ft chord

Equal to or But Equal to or Greater Than Less Than Track Gage (Deg - Min) (Deg - Min) (Ft - In.)

0 - 00 12 - 00 4 - 8-1/2 12 - 01 14 - 00 4 - 8-5/8 14 - 01 16 - 00 4 - 8-3/4 16 - 01 18 - 00 4 - 8-7/8 18 - 01 20 - 00 4 - 9

a. Jointed rails shall be laid, one at a time, with space allowance for expansion being provided between rail ends in accordance with TABLE

VI.

b. A standard rail thermometer shall be used to determine the rail temperature. The thermometer shall be laid close to the web on the side of the rail base which is shaded from the sun's rays in advance of the laying operation and left there long enough to accurately record the temperature. The Contractor quality control representative shall see that rail temperature is checked frequently and that proper rail expansion shims are used. All thermometers shall be calibrated against the Contracting Officer's rail thermometer which will have been accurately calibrated and will be considered as the standard.

c. Except through turnouts and at insulated joints, the staggering of the joints on one side shall not vary more than 20 inch in either direction from the center of the opposite rail.

e. Rails less than 33 ft in length shall not be used in out-of-face rail relay. However, rails not less than 13 ft long may be used for final connections to existing rails to prevent joints from occurring at prohibited locations or to provide the specified joint stagger in curves.

3.3.5.2 Joints

The joints in opposite rails shall be staggered one-half the rail length but not less than 12 ft apart, except closer joints may be required at turnouts and insulated joints. Rail less than 13 ft in length shall not be installed in track.

3.3.5.3 Expansion Allowance

Allowance for expansion shall be provided at rail joints by using rail-expansion metal shims. Shims shall be removed to within 12 rails of the laying. Shims shall be of the thickness shown in TABLE VI. The temperature of the rail shall be determined by use of a thermometer placed on the rail base on the side away from the sun. Typical rail gap gages are as shown.

TABLE VI. SHIM THICKNESS

33-Ft Rail 39-Ft Rail 78-Ft Rail 160 Joints per Mi 135 Joints per Mi 68 Joints per Mi

Rail Shim Rail Shim Rail Shim Temperature Thickness Temperature Thickness Temperature Thickness (degrees F) (in.) (degrees F) (in.) (degrees F) (in.)

Below -10 5/16 Below 6 5/16 Below 35 5/16 -10 to 14 1/4 6 to 25 1/4 35 to 47 1/4 15 to 34 3/16 26 to 45 3/16 48 to 60 3/16 35 to 59 1/8 46 to 65 1/8 61 to 73 1/8 over 60 1/16 over 66 1/16 over 74 1/16

3.3.5.4 Cutting Rail

Only rail saws or track chisels shall be used to cut rail. New holes shall be drilled using a standard template. Holes shall not be burned in rail.

Holes cut with a torch will not be accepted. When drilling of rail is necessary, all chips and burrs shall be removed before applying joints.

3.3.5.5 Matching Rails

Matching adjacent rails shall not cause lipped or uneven joints. Any mismatched rail ends shall be welded to provide proper match. Rail end mismatch shall not exceed 1/16 in on gage or tread portions of rail.

3.3.5.6 Spot Rail Replacement

Spot rail replacements shall be made where necessary to replace existing defective rails or to compensate for rail joint gap adjustments.

a. Replacement Rail: Replacement rail shall be of equal length or longer than the rail it replaces. The minimum length of rail used shall be 13 ft.

b. Spot Rail Replacement Resulting in Joint Staggers: Unless otherwise approved by the Contracting Officer on a case by case basis, spot rail replacement shall not result in joint staggers less than 4 ft.

3.3.6 Joint Bars

Joint bars shall be clean. Rail joints shall be installed so that bars are not cocked between the base and head of the rail. Bars shall be properly seated in the rail and the full number of correct-size bolts, nuts, and spring washers installed. Bolts shall be placed with nuts alternately on inside and outside of rail. A corrosion resistant lubricant shall be applied to the bolt threads prior to application of nuts. Bolts shall be tightened to torque of approximately 350 ft-lbs, beginning at the center of the joint and working both ways to the ends of the joint. Rail of different sections shall be connected by properly fitting compromise joint bars. The mismatch for compromise joints for either tread surface or on the gage side shall not exceed 1/8 inch. Defective joint bars designated on the contract drawings, discovered by the Contractor during track repair operations, or as identified by the Contracting Officer shall be replaced with acceptable joint bars.

3.3.7 Spiking

3.3.7.1 Spiking Procedures

Rail shall be spiked promptly after being laid. Spikes shall be started and driven vertically and square with the rail. Spikes shall be driven to allow approximately 1/8 to 3/16 inch space between the underside of the spike and the top of the rail base. Spikes shall not be overdriven, or straightened while being driven. Spikes shall not be installed through the slots in skirted-type, slotted joint bars (angle bars). Spikes shall not be driven against the ends of joint bars.

3.3.7.2 Number of Spikes

Four rail-holding spikes shall be used on each tie on tangents and curves less than 4 degrees. Spikes on the gage side of the running rail shall be placed directly across from each other and the spikes on the field side of the running rail shall be placed directly across from each other. Spikes on the gage side shall be offset longitudinally from the field spike and all four spikes shall be rail-holding spikes next to the base of the rail.

This pattern shall be held consistent. On curves 4 degrees or greater, but not more than 36 degrees, six spikes shall be used on each tie with the spikes located as follows: One rail-holding spike on the field side and two rail-holding spikes on the gage side for both rails. Curves 36 degrees and greater shall be spiked with eight spikes per tie, located as follows:

One rail-holding spike and one plate-holding spike on the field side and two rail-holding spikes on the gage side for both rails.

3.3.8 Tie Plugs

If spikes are withdrawn from wood ties, the holes shall be swabbed with creosote and plugged with creosoted tie plugs of proper size to fit the hole. If spikes are withdrawn and spikes are to be reinserted in existing spike holes, the holes shall be swabbed with creosote and plugged with creosoted tie plugs prior to redriving the spike. Tie plugs shall not be installed in prebored holes unless spikes have been driven and withdrawn.

3.3.9 Rail Anchor Placement

Rail anchors shall be located as indicated on the project plans. Where the use of rail anchors is indicated, apply anchors in the pattern indicated on the project drawings. The rail anchors shall be spaced approximately uniformly along the rail length. Rail anchors shall be installed to the gage side of the rail against the same tie face on opposite rails. Rail anchors shall grip the base of the rail firmly and shall have full bearing against the face of the tie. Rail anchors shall not be moved by driving them along the rail. Rail shall be anchored immediately after spiking and before rail has experienced a large temperature change.

3.3.10 Preliminary Surfacing

The preliminary alignment and surfacing gangs shall follow the unloading of the ballast. Rail renewal, tie renewal, bolt tightening, and ballast placement shall be complete prior to commencement of surfacing and alignment work.

3.3.10.1 Lifts

a. The track, after being aligned, shall be brought to grade and surface in lifts not exceeding 4 in each. After each lift, the ballast shall be tamped. When using jacks, they shall be placed close enough together to prevent undue bending of rail or stress of rail and joint.

Both rails shall be raised at one time and as uniformly as possible.

b. In areas where major track resurfacing is not required, perform a "skin lift" tamping operation to ensure that the ties are adequately tamped, the ballast section is adequately compacted and dressed, and to correct minor deficiencies in surface and alignment. The rise in skin lift areas shall be 1 in or less and usually will not require that additional ballast be placed.

3.3.10.2 Tamping

Raising and tamping of track shall be performed with an automatic, vibratory, squeeze type power tamper with 16 tamping heads, capable of raising both rails simultaneously and maintaining cross-level. The equipment to be used for surfacing operations is subject to approval by the Contracting Officer. Every tie in the track shall receive two or more full insertions of the tamping heads. Ballast shall be power-tamped under both sides of ties from each end to a point 15 inches inside each rail for 8 feet-6 inch ties. The center shall be filled with ballast, but tamping will not be permitted in the center of the tie between the above stated limits. Both ends of the ties shall be tamped simultaneously and tamping inside and outside of the rail shall be done at the same time. Tamping tools shall not be used with more than 35 percent wear and shall be worked opposite each other on the same tie. Ballast under switch ties and road crossing ties shall be tamped the entire length of each tie. All ties shall be tamped to provide solid bearing against the base of the rail after the track or turnout is raised to grade at final surfacing. All down ties shall be brought up to the base of rail and shall be machine tamped. The resultant track surface and alignment shall be uniform and smooth. Tamping of track in snow or frozen ballast conditions will not be permitted.

3.3.10.3 Replacement of Ties

After tamping has been completed and the jacks removed, all ties pulled loose shall be replaced to their proper position, respiked and retamped to provide full bearing against the rail.

3.3.10.4 Horizontal Realignment

Horizontal realignment of curved track shall be established using manual or mechanical means as described in the AREMA Eng Man Chapter 5, Part 3 Section 3.2, "String Lining of Curves by the Chord Method".

3.3.11 Final Surfacing

After preliminary surfacing has been completed, grade and line stakes shall be checked and the track brought to grade and alignment.

3.3.11.1 Final Tamping

Track shall be brought to grade and the ballast retamped in the manner described for preliminary surfacing, except that the tamping distance inside the rail shall be decreased from 15 to 13 inch for 8 ft 6 inch ties.

3.3.11.2 Final Alignment

The track shall be given a final aligning conforming to the established track centers.

3.3.11.3 Final Dressing

After the final alignment the ballast shall be dressed to the section indicated. After final dressing ballast shall not cover the tops of the ties. The portion of the subgrade outside the ballast line shall be left with a full, even surface and the shoulder of the subgrade shall be properly dressed to the indicated section to provide proper drainage away from the track.

3.3.11.4 Surplus Ballast

Surplus ballast remaining after final surfacing and dressing of the ballast section shall be distributed or otherwise disposed of as directed by the Contracting Officer.

3.3.12 Cleanup

Upon completion of the work, dispose of rubbish, waste, and discarded materials in an approved manner as directed by the Contracting Officer.

Areas where the Contractor has worked, including but not limited to, project areas, material storage sites, and borrow or disposal areas shall be left in a clean, well-graded, and well-drained condition.

3.3.12.1 Spoil Materials

Spoil materials removed from the track shall be disposed of as indicated.

3.3.13 Tolerances for Finished Track

Completed track shall meet the following tolerances. Track not meeting the tolerances specified below shall be repaired to meet these requirements, at no additional cost to the Government.

3.3.13.1 Gage

Track gage shall be within plus 1/4 inch or minus 1/8 inch of standard gage.

3.3.13.2 Alignment

Alignment shall be measured as the deviation of the mid-offset of a 62 ft line, with the ends of the line at points on the gage side of the line rail, 5/8 inch below the top of the railhead. Either rail may be used as the line rail on tangent track; however, the same rail shall be used for the entire length of the tangent. The outside rail in a curve is always the line rail. Alignment on tangents shall not deviate from uniformity more than 1/2 inch. Alignment on curves shall not deviate from uniformity more than 3/8 inch.

3.3.13.3 Track Surface

Track surface shall meet the following requirements:

a. The runoff at the end of a raise shall not exceed 1/2 inch in any 31 ft of rail.

b. The deviation from design profile on either rail at the mid-ordinate of a 62 ft chord shall not exceed 1/2 in.

c. Deviation from design elevations on spirals shall not exceed 1/2 inch.

d. Deviation from zero cross level at any point on tangent or from designated superelevation on curves or spirals shall not exceed 1/2 in.

e. The difference in cross level between any two points less than 62 ft apart on tangents, and on curves between spirals shall not exceed 1/2 in.

3.4 INSTALLATION OF MISCELLANEOUS TRACK MATERIALS

3.4.1 Tie Plates

Tie plates shall be furnished to the work sites as required.

3.4.2 Gage Rods

Gage rods shall be located as indicated on the project plans.

3.4.3 Installation of Joint Bars

Joint bars shall be installed with their full number of bolt assemblies unless otherwise noted. Bars shall be properly seated on the rail and the bolts tightened beginning at the center of the joint and working toward the ends of the bars, alternating between rails. Bolts used shall be of the proper diameter and length for the rail and joint bars at the joint. The use of extra washers to shim out track bolt nuts is prohibited. Bolts with nuts shall be placed alternately on inside and outside of rail.

3.5 ELECTRIC ARC WELDING

Welding to repair or rebuild rails (engine burns, battered ends, etc.)

shall be done in accordance with AREMA Eng Man, Chapter 5, Part 5,Section

5.10 and AWS D1.1/D1.1M. Submit a detailed specification covering the step-by-step procedures to be employed in making the electric arc welds. A complete description of each of the following items as applicable and any other essential characteristics shall be included in the procedure specifications.

a. Type, size, and capacity of electric welding machine (250 amp minimum), grinder and other equipment. Also, type and size of material (welding rod or wire).

b. The method to be used to remove defective and excess metal prior to welding (arcair or grinding).

c. The method to be used to prevent warping.

d. The method used for preheating, including time and temperature.

e. The method of applying metal buildup and slag removal.

f. The method of securing original contour of items welded.

g. Quality control procedures to be followed.

h. Welding materials (rod or wire), name and manufacturer of materials (low carbon steel) for welding rail.

3.5.1 Welding Supervision

Electric arc welding shall be performed under the direct supervision of an experienced welding supervisor or foreman and by a certified welder.

3.5.2 Weather Conditions

Welding shall not be performed in rain, snow, or other inclement weather without adequate protection of the welding from the elements.

3.5.3 Welding Rail Joints

Bolts in the joint bars shall be tightened and the joint pulled to a level surface. A straightedge shall be placed across the joint to determine the amount of batter. The straightedge shall be a minimum of 18 inch in length. A rail joint with less than 0.012 inch of batter shall not be welded. If batter is 0.012 inch or more, the rail joint shall be built

up. If rail cracks or chipped out places are present in rail ends, they shall be melted out with acetylene torch, gouged out with arcair or ground out with grinder. If cracks or chips extend below ball, rail shall be replaced. If horizontal crack in ball of rail extends more than 8 inch rail shall be replaced. Rail ends shall be preheated to approximately 200 degrees F before welding. Starting 1-1/2 inches from the end, the rail shall be built back as follows: A strip shall be welded 1 inch into bead;

the rail ends shall be ground to a level surface with surface grinder or cup wheel attachment; and rail joint shall be cross slotted with 3/16 inch grinding stone to keep rail ends from overlapping and chipping out.

3.6 SAMPLING AND TESTING

Sampling and testing is the responsibility of the Contractor. Submit one certified copy of Test Reports for each test performed on the ballast and subballast within 2 working days of the test completion. Sampling and testing shall be performed by an approved commercial testing laboratory, or by the Contractor, subject to approval. If the Contractor elects to establish testing facilities, approval of such facilities shall be based on compliance with ASTM D3740. Work requiring testing will not be permitted until the Contractor's facilities have been inspected and approved. The first inspection of the facilities will be at the expense of the Government and any subsequent inspections required because of failure of the first inspection shall be at the expense of the Contractor. Such costs will be deducted from the total amount due the Contractor.

3.6.1 Ballast and Subballast Tests

3.6.1.1 Sieve Analyses

Sieve analyses shall be made in conformance with ASTM C117 and ASTM C136.

Sieves shall conform to ASTM E11.

3.6.1.2 Bulk Specific Gravity and Absorption

Bulk specific gravity and absorption tests shall be made in conformance with ASTM C127.

3.6.1.3 Percentage of Clay Lumps and Friable Particles

The percentage of clay lumps and friable particles shall be determined in conformance with ASTM C142/C142M.

3.6.1.4 Degradation Resistance

Resistance to degradation of materials shall be determined in conformance with ASTM C131 and ASTM C535. Materials with gradations having 100 percent passing the 1 in sieve, shall be tested in conformance with ASTM C131.

Materials having gradations with particles larger than 1 in shall be tested in conformance with ASTM C535.

3.6.1.5 Soundness Test

Soundness tests shall be made in conformance with ASTM C88.

3.6.1.6 Percentage of Flat or Elongated Particles

The percentage of flat or elongated particles shall be determined in conformance with ASTM D4791.

3.6.2 Tie Inspection

The Contractor is responsible for the quality of the treated ties. Each tie shall be permanently marked or branded by the producer in accordance with AWPA M6. Each treated wood tie shall be inspected, in accordance with AWPA M2, for conformance with the specified AWPA standards. The 100 percent inspection shall be performed by an independent inspection agency approved by the Contracting Officer. Inspection shall be made at the wood treatment site. The agency's report of inspection shall accompany delivery of the ties. Core and check preservative treatment once for ties delivered to the construction site.

3.7 INSPECTION AND FIELD TESTING

Perform quality control inspection and field testing.

3.7.1 Track

Inspection shall be performed to ensure that all the requirements of these specifications are met. Bolted joints shall be inspected for loose bolts and for smooth transitions between rails of different sections. Rail, tie plates, and ties shall be checked to ensure that the rail is properly seated and has full bearing on the tie plate and tie. Upon completion of construction, measurements of track gage, cross level, and alignment shall be taken and recorded at least once every 20 feet of track centerline length. A copy of these measurements shall be provided to the Contracting Officer.

3.7.2 Electric Arc Welding Inspection

Electric arc welds shall be inspected to determine that the item welded conforms to the desired contour and contains no visible cracks or voids.

3.7.3 Electric Arc Weld Testing

The welds shall be visually inspected and the contours checked after completion and later tested by the ultrasonic method. The Contractor shall have the welds tested by the ultrasonic method. The testing will determine whether or not each weld meets the quality criteria. Defective welds will be removed and the item rewelded at the Contractors expense.

-- End of Section --