1502000_-J.pdf

SECTION J

DOCUMENTS, EXHIBITS, AND OTHER ATTACHMENTS

TABLE OF CONTENTS

ATTACHMENT NUMBER ATTACHMENT TITLE

J-1502000-01 Definitions and Acronyms J-1502000-02 References and Technical Documents J-1502000-03 Facilities Property Inventory (Switch Turnouts) J-1502000-05 Switch Maintenance Requirements

J-1502000-06a Unified Facilities Criteria (UFC 4-860-03) Railroad Track Maintenance & Safety Standards

J-1502000-06b NAVFAC Instruction 11230.e J-1502000-07 Daily Report to Inspector

ATTACHMENT J-1502000-01

DEFINITIONS AND ACRONYMS

DEFINITION DESCRIPTION

CRANE, CATEGORY 1 Portal cranes, Hammerhead cranes, Locomotive cranes, Derricks, Floating cranes (YD), Tower cranes, Container cranes, Mobile cranes (except those indicated as category 4), including truck, cruiser, crawler, warehouse/industrial cranes, and cranes used for dragline, pile driving, clamshell, magnet, bucket work, and Aircraft crash cranes.

CRANE, CATEGORY 2 & 3 Cranes with rated capacities of 20,000 pounds or greater are category 2. Examples are Over head traveling cranes, Gantry cranes (rail mounted), Wall cranes, Jib cranes, Pillar cranes, Pillar jib cranes, Monorails and associated hoists, Fixed hoists, including chain falls. Pedestal mounted commercial boom assemblies (fixed length, telescoping, and articulating types) attached to stake trucks, trailers, flatbeds, or railcars, or stationary mounted to piers, etc., with OEM rated capacities less than 2,000 pounds.

CRANE, CATEGORY 4 Commercial truck mounted cranes, Truck mounted articulating boom cranes, Pedestal mounted commercial boom assemblies (fixed length, telescoping, and articulating types) attached to stake trucks, trailers, flatbeds, or railcars, or stationary mounted to piers, etc., with OEM rated capacities of 2,000 pounds and greater. Commercial truck mounted cranes and truck mounted articulating boom cranes with OEM capacities of 2,000 pounds and greater require a licensed operator even if the cranes are down rated below 2,000 pounds capacity for administrative purposes.

EQUIPMENT, COLLATERAL Encompasses built-in and large substantially affixed equipment/property that is normally acquired and installed as part of a facility project.

EQUIPMENT, INSTALLED Encompasses building-type equipment, built-in equipment, and large, substantially affixed equipment/property, and is normally acquired and installed as part of a facility project. Installed equipment is normally required to make a facility useful and operable. Removing such equipment would impair the usefulness, safety, or environment of the facility or the facility restoration work required after its removal, is substantial.

EQUIPMENT, PERSONAL

PROPERTY

Personal property equipment includes all equipment other than collateral equipment. Such equipment, when acquired and used in a facility or a test apparatus, can be severed and removed aster erection or installation without substantial loss of value or damage thereto or to the premises where installed.

FACILITIES LIFE CYCLE A facilities life cycle is divided into four stages, requirements (planning and design), acquisition (construction and acceptance), stewardship (operations, maintenance and repair), and disposal.

FACILITIES MAINTENANCE

MANAGEMENT

The planning, prioritizing, organizing, controlling, reporting, evaluating, and adjusting of facilities maintenance operations to support the CNO/NAVFAC facilities policy and objectives and satisfy customers’ facility needs. Defined by the International Facility Management Association as “the practice of coordinating the physical workplace with the people and work of the organization.”

Integrated Maintenance Program

(IMP)

IMP is a recurring state-of-the-art, reliability-centered inspection, testing, maintenance and repair program that determines best practices for managing the functions and consequences of failures of facilities equipment and system components. IMP encompasses accepted commercial practices, including reactive, preventive, predictive and proactive maintenance, into one optimal program. The IMP approach gives the Contractor full responsibility to maintain systems and equipment and perform repairs whenever necessary to ensure equipment and systems are operational and remain in a constant state of readiness. Service calls will not be issued for accomplishment of repairs on systems and equipment maintained under IMP.

LIFE-CYCLE COSTS A form of economic analysis that considers the total cost of owning, operating, and maintaining a building or system over its useful life.

MAINTENANCE, PREVENTIVE Maintenance designed to increase the availability of the facilities/equipment by reducing the number of unexpected breakdowns or service interruptions. It is any planned maintenance activity that improves equipment life and avoid any unplanned maintenance requirements.

MANAGEMENT

INFORMATION SYSTEMS-

MAINTENANCE

A computerized system that will provide sufficient information for management to evaluate differences between budgets and actual costs and evaluate performance.

REPAIR Repair is the restoration of facilities or equipment to such a condition that it may be effectively utilized for its designated purposes by overhaul, reconstruction, or replacement of constituent parts or materials which have deteriorated by action of the elements or usage, and which have not been corrected through maintenance. This term also applies to replacement of the entire unit or system if beyond economical repair. The intent of repair is to have the equipment at normal working condition.

REPLACEMENT Replacement, as a distinct work element, is confined to a program of planned replacement of a facility or its components. It may be further limited to major components such as air conditioning compressors, furnaces or hot water heaters. Replacement is performed when the equipment has reached the end of its useful life; when it no longer can perform due to degradation of its internal components and repair is no longer cost effective. Included under the replacement would be the major rebuilding of any component, since rebuilding also restores performance.

RESTORATION Restoration of real property to such a condition that it can be used for its intended purpose. Includes repair or replacement work to restore facilities damaged by inadequate sustainment, excessive age, natural disaster, fire, accident or other causes.

SUSTAINMENT Maintenance and repair activities necessary to keep a typical inventory of facilities in “normal working condition”.

Sustainment includes regularly scheduled maintenance as well as cyclical major repairs or replacement of components that occur periodically over the expected service life of the facilities.

WEIGHT HANDLING

EQUIPMENT (WHE)

Any work required to return a facility, system, equipment or component to normal working condition. Trouble calls are minor facility problem requests or requests for facilities-related work that are too small to be planned and estimated.

Acronym Title BPVC Boiler and Pressure Vessel Code HVAC Heating, Ventilation, and Air Conditioning SRM Sustainment, Restoration and Modernization UFC Unified Facilities Criteria UPV Unfired Pressure Vessel VTE Vertical Transportation Equipment

ATTACHMENT J-1502000-02

REFERENCES AND TECHNICAL DOCUMENTS

Attachment Reference Title J-1502000-06a UFC 4-860-03 RAILROAD TRACK MAINTENANCE & SAFETY STANDARDS J-1502000-06b NAVFAC INST 11230.1e INSPECTION, CERTIFICATION AND AUDIT OF CRANE AND RAILROAD TRACKAGE

EM 385-1-1 U.S. Army Corps of Engineers Safety and Health Requirements P.L. 91-596 Occupational Safety and Health Act NAVFACINST 11230.1 Inspection, Certification, and Audit Crane and Railroad Trackage OPNAVINST 5100.23 Chapter 2, NAVOSH Manual NAVFAC P-300 Management of Civil Engineering Support Equipment NAVFAC P-307 Management of Weight Handling Equipment 49 CFR Part 215 Railroad Freight Car Safety Standards 49 CFR Part 219 Control of Alcohol and Drug Abuse 49 CFR Part 229 Railroad and Locomotive Safety Standards 49 CFR Part 231 Railroad and Safety Appliance Standards 49 CFR Part 232 Railroad Power Brakes and Drawbars NAVSEA OP-5 VOL1 Ammunitions and Explosives Ashore Safety Regulations for Handling, Storage, Production, Renovati and Shipping

NAVSEA SW023-AG-

WHM-010

Technical Manual On-Station Movement of Ammunition and Explosives by Truck and Railcar

OPNAVINST 8023.2C Navy Explosive Safety Policies, Requirements and Procedures NAVSEA 8023.11 Standard Operating Procedure for Processing Expendable Ordnance at Naval Activities EM 385-1-1 U.S. Army Corps of Engineers Safety and Health Requirements P.L. 91-596 Occupational Safety and Health Act NAVFACINST 11230.1 Inspection, Certification, and Audit Crane and Railroad Trackage OPNAVINST 5100.23 Chapter 2, NAVOSH Manual NAVFAC P-300 Management of Civil Engineering Support Equipment NAVFAC P-307 Management of Weight Handling Equipment 49 CFR Part 215 Railroad Freight Car Safety Standards 49 CFR Part 219 Control of Alcohol and Drug Abuse 49 CFR Part 229 Railroad and Locomotive Safety Standards 49 CFR Part 231 Railroad and Safety Appliance Standards 49 CFR Part 232 Railroad Power Brakes and Drawbars NAVSEA OP-5 VOL1 Ammunitions and Explosives Ashore Safety Regulations for Handling, Storage, Production, Renovati and Shipping

NAVSEA SW023-AG-

WHM-010

Technical Manual On-Station Movement of Ammunition and Explosives by Truck and Railcar

OPNAVINST 8023.2C Navy Explosive Safety Policies, Requirements and Procedures NAVSEA 8023.11 Standard Operating Procedure for Processing Expendable Ordnance at Naval Activities

ENGINEERED

PERFORMANCE

STANDARDS BOOK NUM

13 - Trackage

NAVSEA SW023-AG-

WHM-010

Technical Manual On-Station Movement of Ammunition and Explosives by Truck and Railcar

OPNAVINST 8023.2C Navy Explosive Safety Policies, Requirements and Procedures NAVSEA 8023.11 Standard Operating Procedure for Processing Expendable Ordnance at Naval Activities ENGINEERED PERFORMANCE STANDARDS BOOK NUMBER 13 - Trackage

FEDERAL SPECIFICATIONS:

FF-B-561C BOLTS, SCREWS, LAG

TT-P-645 PRIMER, ZINC CHROMATE

FF-S-611A SPIKES, TRACK, SQUARE-SHANK

MM-T-371E TIE, RAILRAOD, WOOD (CROSS AND SWITCH)

QQ-S-632C STEEL BAR, REINFORCING (FOR CONCRETE)

TT-C-645 CREOSOTE, COAL TAR, TECHNICAL

TT-W-535C WOOD PRESERVATIVE: FLOUR CHROME ARSENATE PHENOL MIXTURE

TT-W-546D WOOD PRESERVATIVE: ACID COPPER CHROMATE MIXTURE

TT-W-549D WOOD PRESERVATIVE: AMMONIACAL COPPER ARSENATE MIXTURE

TT-W-551F WOOD PRESERVATIVE: CHROMATED ZINC CHLORIDE MIXTURE

TT-W-568E WOOD PRESERVATIVE: CREOSOTE-PETROLEUM SOLUTION

TT-W-570 WOOD PRESERVATIVE: PENTACHLOROPHENOL

TT-W-571J WOOD PRESERVATIVE: TREATING PRACTICES

TT-W-572B WOOD PRESERVATIVE: WATER REPELLANT

MILITARY SPECIFICATIONS

MIL-R-3911C RAIL, TEE, RAILWAY; RELAYER RAIL

MIL-S-22473E SEALING, LOCKING, AND RETAINING COMPOUNDS: (SINGLE COMPONENT)

MIL-T-12270C TIE-PLATES, RAILWAY

MIL-T-11292C TURNOUT, RAILWAY (UNASSEMBLED, COMPLETE WITH LOW STAND THROW AND RIGID BOLTED FROG)

MILITARY STANDARDS

MIL-STD-615A TURNOUTS, RAILWAY, WITH BOLTED RIGID FROGS

MIL-STD-1699(YD) NONDESTRUCTIVE EVALUATION OF BUTT WELLS IN CRANE AND RAILROAD BAILS

OTHER PUBLICATIONS

NAVY MO-103 MAINTENANCE OF TRACKAGE

49 CFR 213 FEDERAL RAILROAD ADMINISTRATION (FRA) TRACK SAFETY STANDARDS (REPRINTED AS APPENDIX B OF

NAVY MO-103)

40 CFR 162 FEDERAL INSECTICIDE, FUNGICIDE, AND RODENTICIDE ACT

AREA MANUAL AMERICAN RAILWAY ENGINEERING ASSOCIATION (AREA)

VOLS I & II MANUAL FOR RAILWAY ENGINEERING

AREA PORTFOLIO AREA PORTFOLIO OF TRACKWORK PLANS

ENGINEER MANUAL U.S. ARMY CORPS OF ENGINEERS SAFETY AND HEALTH REQUIREMENTS

MANUAL (EM 385-1-1)

NAVFAC DM 5 CIVIL ENGINEERING: CHAPTER 6, RAILROAD TRACKAGE

NAVFAC DM 25 WATERFRONT OPERATIONAL FACILITIES: CHAPTER 1, RAIL INSTALLATION CRITERIA

NAVFAC MO-322 INSPECTION OF SHORE FACILITIES

NAVFAC P-300 MANAGEMENT OF TRANSPORTATION EQUIPMENT

NAVFAC P-701.0 ENGINEERED PERFORMANCE STANDARDS FOR REAL PROPERTY MAINTENANCE ACTIVITIES: PLANNER –

ESTIMATOR DESKGUIDE

NAVFAC P-712.0 ENGINEERED PERFORMANCE STANDARDS (EPS): ROADS, GROUNDS, PEST CONTROL, & REFUSE COLLECTION

NAVFAC P-713.0 SHEET METAL, STRUCTURAL IRON & WELDING

NAVFAC P-714.0 ENGINEERED PERFORMANCE STANDARDS (EPS): TRACKAGE

ASNT SNT-TC-1A AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT) SNT-TC-1A – NON DESTRUCTIVE TEST PERSONNEL

QUALIFICATION AND CERTIFICATION

AWS D1.1 AMERICAN WELDING SOCIETY (AWS) D1.1 – STRUCTURAL WELDING CODE

AWPA P5 NOS. AMERICAN WOOD PRESERVERS’ ASSOCIATION (AWPS) P5

ATTACHMENT J-1502000-03

FACILITY PROPERTY INVENTORY

ELIN Description Historical Data

Historical # of

Cleanings

Monthly

PM /

Cleanings

Annual

PM /

Cleaning

MAINTENANCE & CLEANING OF RAILROAD SWITCHES

A 001AB RR Switch "A" Track- Siding track at Bldg 1500 A-20-1 Bi-Weekly A 001AB RR Switch "B" Track- into Bldg 163 B-7-1 Bi-Weekly A 001AB RR Switch "A" Track- Start of "B" at Bldg 1505 A-13 Bi-Weekly A 001AB RR Switch "A" Track- at Bldg 414 A-14 Bi-Weekly A 001AB RR Switch "A" Track- Start of "C" RR at Bldg 195 A-17 Bi-Weekly A 001AB RR Switch "A" Track- Into NW corner of Bldg 171 A-18 Bi-Weekly A 001AB RR Switch "A" Track- Siding track at Bldg 1500 A-20 Bi-Weekly A 001AB RR Switch "A" Track- Start of "D" RR A-21 Bi-Weekly A 001AB RR Switch "A" Track- Siding track at Bldg 184 A-22 Bi-Weekly A 001AB RR Switch "A" Track- Siding track at Bldg 184 A-23 Bi-Weekly A 001AB RR Switch "A" Track- into Bldg 1499 A-25 Bi-Weekly A 001AB RR Switch "A" Track- Start of "E" RR A-26 Bi-Weekly A 001AB RR Switch "A" Track- Start of "F" RR A-27 Bi-Weekly A 001AB RR Switch "A" Track- at Borum Overpass A-28 Bi-Weekly A 001AB RR Switch "A" Track- at Borum Overpass A-29 Bi-Weekly A 001AB RR Switch "A" Track- East side of trash plant A-30 Bi-Weekly A 001AB RR Switch "A" Track- into Bldg 260 A-31 Bi-Weekly A 001AB RR Switch "A" Track- End of "B-18" RR A-32 Bi-Weekly A 001AB RR Switch "A" Track- to the Scale House A-33 Bi-Weekly A 001AB RR Switch "A" Track- at the Scale House A-34 Bi-Weekly A 001AB RR Switch "A" Track- near the Scale House A-35 Bi-Weekly A 001AB RR Switch "B" Track- at Bldg 414 B-1 Bi-Weekly A 001AB RR Switch "B" Track- at Bldg 414 B-1-1 Bi-Weekly A 001AB RR Switch "B" Track- at end of "D" RR B-13 Bi-Weekly A 001AB RR Switch "B" Track- into Bldg 268 B-15 Bi-Weekly A 001AB RR Switch "B" Track- onto Pier 6 B-16 Bi-Weekly A 001AB RR Switch "B" Track- (siding track at Bldg 298) B-17 Bi-Weekly A 001AB RR Switch "B" Track- (siding track at Bldg 298) B-17-1 Bi-Weekly

A 001AB RR Switch "B" Track- at DD8 B-18 Bi-Weekly A 001AB RR Switch "B" Track- along N side of Bldg 369 B-19 Bi-Weekly A 001AB RR Switch "B" Track- at NE corner of Bldg 369 B-19-1 Bi-Weekly A 001AB RR Switch "B" Track- into E end of Bldg 369 B-19-4 Bi-Weekly A 001AB RR Switch "B" Track- at Bldg 414 B-2 Bi-Weekly A 001AB RR Switch "B" Track- at end of "A" RR B-20 Bi-Weekly A 001AB RR Switch "B" Track- Head of DD4 to DD6 B-3 Bi-Weekly A 001AB RR Switch "B" Track- onto old Bldg ways B-7 Bi-Weekly A 001AB Between Bldgs 171 and 202 D-4 Bi-Weekly A 001AB Between Bldgs 171 and 202 D-5 Bi-Weekly A 001AB RR Switch "A" Track- into Bldg 1499 E-1 Bi-Weekly A 001AB At Borum overpass- crossover from "E" to "A" RR E-2 Bi-Weekly A 001AB RR Switch "A" Track- on Williams Ave. to Bldg 276 F-1 Bi-Weekly A 001AB RR Switch "A" Track- on Williams Ave. to Bldg 276 F-3 Bi-Weekly A 001AB RR Switch "B" Turn Table Frog B-13-F Bi-Weekly A 001AB RR Switch "B" Track- on Pier 6 B-16-1 Monthly A 001AB RR Switch "B" Track- onto DD8, N side B-18-1 Monthly A 001AB RR Switch "B" Track- at open track B-21 Monthly A 001AB RR Switch "B" Track- at open track B-22 Monthly A 001AB RR Switch "B" Track- at open track B-23 Monthly A 001AB RR Switch "B" Track- at open track B-24 Monthly A 001AB RR Switch "B" Track- at open track B-25 Monthly A 001AB RR Switch "B" Track- between DD3 & 4 to DD7 B-3-2 Monthly A 001AB RR Switch "A" Track- at Bldg 195 to Bldg 236 C-1 Monthly

A 001AB RR Switch "A" Track- NW corner of Bldg 163 to DD4 A-16-A Weekly

A 001AB RR Switch "A" Track- S side DD4 to Rays A-16-A-1 Weekly A 001AB RR Switch "A" Track- S side DD4 to Rays A-16-A-2 Weekly A 001AB RR Switch "B" Track- along S side of DD8 B-19-A Weekly

A 001AB RR Switch "B" Track- into "Remote Site" at Bldg 369 B-19-R Weekly

MAINTENANCE & CLEANING OF 135 LB CRANE RAIL

SWITCH

A 001AB DD#1 CRN SW 3 & 4 Weekly A 001AB DD#2 CRN SW 5 & 6 Weekly A 001AB DD#2 CRN SW 7 & 8 Weekly A 001AB DD#3 CRN SW 9 & 10 Weekly A 001AB DD#3 CRN SW 11 & 12 Weekly A 001AB DD#3 CRN SW 13 & 14 Weekly A 001AB DD#3 CRN SW 15 & 16 Weekly A 001AB DD#4 CRN SW 17 & 18 Weekly

A 001AB Pier 3 CRN SW E-1-N Weekly A 001AB Pier 3 CRN SW E-1-S Weekly A 001AB Pier 3 CRN SW E-2-E Weekly A 001AB Pier 3 CRN SW E-2-W Weekly

MAINTENANCE & CLEANING OF 175 LB CRANE RAIL

SWITCH

A 001AC DD 8 N Side SW "F-1" & "F (9-33)" (WELLMAN) 36 Annually A 001AC DD 8 N Side SW "F-1" & "F (9-33)" 37 Weekly A 001AC DD 8 N Side SW "F-1" & "F (9-33)" (WELLMAN) 38 Annually A 001AC DD 8 N Side SW "F-1" & "F (9-33)" 39 Weekly A 001AC DD 8 S Side SW "F-4" 40 Bi-Weekly A 001AC DD 8 S Side SW "F-4" (WELLMAN) 41 Annually A 001AC DD 8 S Side SW "F-4" 42 Bi-Weekly A 001AC DD 8 S Side SW "F-4" (WELLMAN) 43 Annually A 001AC DD 8 S Side SW "F-3" 44 Bi-Weekly A 001AC DD 8 S Side SW "F-3" (WELLMAN) 45 Annually A 001AC DD 8 S Side SW "F-3" 46 Bi-Weekly A 001AC DD 8 S Side SW "F-3" (WELLMAN) 47 Annually

MAINTENANCE & CLEANING OF

TURNTABLE FROG

A 001AD Pier 6 TF (Stay in Curve) 1 Annually A 001AD Pier 6 TF (Stay in Curve) 2 Annually A 001AD Pier 6 TF (Stay Straight) 3 Annually A 001AD Pier 6 TF (WELLMAN) 4 Annually A 001AD Pier 6 TF "F-1" (Stay in Curve) 6 Annually A 001AD Drydock # 8 Area N Side TF 70 Weekly A 001AD Drydock # 8 Area N Side TF 71 Weekly A 001AD Drydock # 8 Area N Side TF (Stay in RR Straight) 72 Annually A 001AD Drydock # 8 Area N Side TF (Stay in RR Straight) 73 Annually A 001AD Drydock # 8 Area N Side TF (Stay in "F-1" Curve) 74 Annually A 001AD Drydock # 8 Area N Side TF (WELLMAN) 76 Annually A 001AD Drydock # 8 Area N Side TF (Stay "F" Straight) 77 Annually A 001AD Drydock # 8 Area N Side TF (Stay in "F-1" Curve) 78 Annually A 001AD Drydock # 8 Area N Side TF (Stay in "F-1" Curve) 79 Annually A 001AD Drydock # 8 Area S Side TF RR & "F-3" CRN 84 Monthly A 001AD Drydock # 8 Area S Side TF RR & "F-3" CRN 85 Monthly

A 001AD Drydock # 8 Area S Side TF "F-3" CRN ("F-3" Curve) 86 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN ("F-3" Curve) 90 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN ("F" Straight) 93 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN (WELLMAN) 94 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN (RR Straight) 95 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN (RR Straight) 96 Annually

A 001AD Drydock # 8 Area S Side TF RR & "F-3" CRN 97 Monthly A 001AD Drydock # 8 Area S Side TF RR & "F-3" CRN 98 Monthly

A 001AD Drydock # 8 Area S Side TF "F-3" CRN ("F-3" Curve) 99 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN (RR Straight) 100 Annually

A 001AD Drydock # 8 Area S Side TF "F-3" CRN (RR Straight) 101 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (RR Straight) 102 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (RR Straight) 103 Annually

A 001AD Drydock # 8 Area S Side TF RR & "F-4" CRN 104 Monthly A 001AD Drydock # 8 Area S Side TF RR & "F-4" CRN 105 Monthly A 001AD Drydock # 8 Area S Side TF "F-4" CRN (Curve) 106 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (RR Straight) 107 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (RR Straight) 108 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (WELLMAN) 109 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN (RR Straight) 110 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN ("F-4" Curve) 113 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN ("F-4" Curve) 117 Annually

A 001AD Drydock # 8 Area S Side TF "F-4" CRN 118 Monthly A 001AD Drydock # 8 Area S Side TF "F-4" CRN 119 Monthly A 001AD "L" CRN / "B" RR Hitchcock St RR/CRN TF L-2 Weekly A 001AD "L" CRN / "B" RR Hitchcock St RR/CRN TF L-3 Weekly A 001AD "L" CRN / "B" RR Hitchcock St RR/CRN TF L-4 Weekly

ATTACHMENT J-1502000-05

SWITCH MAINTENANCE REQIREMENTS

Split Switch Hinged Access Cover Plates

Hinged, Switch Stand are inside gage

TYPICAL, SPLIT TYPE, RAILROAD SWITCH,

ENCASED IN ASPHALT WITH

PAVING FRAME

All Riser Plates/Gage Plates and all moving parts shall be coated with GLIDEX or equal non-graphite based product after cleaning

Most switch Stands

TYPICAL, DOUBLE TONGUE TYPE, RAILROAD

SWITCH, ENCASED IN ASPHALT

(TOP VIEW)

All bearing surfaces and all moving parts shall be coated with GLIDEX or equal non-graphite based product after cleaning

Hinged Switch Stand Access Cover Plates

(Some Double Tongue Switch Stands may be located between the points instead of along the side)

Switch Component Access Covers (Covers set in place)

TYPICAL, 135 LB. CRANE RAIL SWITCH

ENCASED IN ASPHALT

Switch Boxes and covers

Switch Points

Note: One throw mechanism operates two sets of points on a 135 lb. crane switch, therefore both boxes and points are considered one.

Outer throw mechanism covers are bolted to frame

All switch point boxes and throw mechanism inner access covers are hinged.

All bearing surfaces and all moving parts (including hinges) shall be coated with GLIDEX or equal non-graphite based product after cleaning

Switch Box Throw Mechanism Access Plate (Sits in place)

Numbered Switch Alignment "H" Block

Switch Points

TYPICAL, 175 LB. CRANE RAIL SWITCH

ENCASED IN ASPHALT

moving parts shall be coated with GLIDEX or equal non-graphite based product after cleaning

Throw Lever

Frog Casing

Turn-table Frog Disk

Socket Handle (2 ea)

Turn-table Frog Lifting Handle

TYPICAL, TURN-TABLE FROG

ENCASED IN SPHALT

moving parts shall be coated with GLIDEX or equal non-graphite based product after cleaning

TYPICAL SECTION OF FLOWED RAIL

Typical Section of Flowed Rail: A thin layer of steel has flowed longitudinally from the head that can cause a switch to bind.

Flowed rail shall be removed by the use of an electric or pneumatic grinder. (Flowed material may also be along edge of rail)

No torch cutting of any rail is allowed.

Head of Rail

FABRICATION AND INSTALLATION OF STATION MARKERS

1/2" X 6" Steel Rod

1/4" X 2" Steel Plate welded to steel rod with number welded to plate

INSTALL WELD ON RAIL STOPS

1/2" 1/2" 4"

12"

Rail Head

NOTE:

2" Thick plate for 115RE

RR

2 1/2" Thick plate for 135lb

CR

3 1/2" Thick plate for 175lb

CR

3"

8"

REPAIR/REPLACE LIFTING HANDLE ON TURN-TABLE FROG

5 1/4" 5/8"

4"

Self Locking Nuts

Threaded Ends

REPLACE TURNTABLE FROG HANDLE SOCKETS

S 2-6 1" from ends

12"

24"

Handle socket to be skip welded to base plate

1 1/4" x 4" Steel channel with end plate welded to 1/2" x 12" x 24" steel base plate

UFC 4-860-03

13 FEBRUARY 2008

UNIFIED FACILITIES CRITERIA (UFC)

RAILROAD TRACK MAINTENANCE & SAFETY STANDARDS

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

UNIFIED FACILITIES CRITERIA (UFC)

RAILROAD TRACK MAINTENANCE

& SAFETY STANDARDS

Any copyrighted material included in this UFC is identified at its point of use. Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS (Preparing Activity) NAVAL

FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

This UFC supersedes the TM 5-628/AFR 91-44 dated 1 April 1991, Navy draft MO 103.9 dated 2001, and UFC 4-860-03FA Railroad Track Standards dated 16 January 2004.

UFC

)(%58$5<

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD(AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA).

Therefore, the acquisition team must ensure compliance with the more stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Support Agency (AFCESA) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request (CCR). The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure that they are current.

AUTHORIZED BY:

JAMES C. DALTON, P.E.

Chief, Engineering and Construction U.S. Army Corps of Engineers

JOSEPH E. GOTT, P.E.

Chief Engineer and Director, Capital

Improvements, Acting Naval Facilities Engineering Command

PAUL A. PARKER

The Deputy Civil Engineer DCS/Logistics, Installations & Mission Support Department of the Air Force

Dr. GET W. MOY, P.E.

Director, Installations Requirements and Management Office of the Deputy Under Secretary of Defense

(Installations and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&amp;c=4 http://dod.wbdg.org/

UNIFIED FACILITIES CRITERIA (UFC) REVISION

SUMMARY SHEET

Description of Changes: UFC 4-860-03 unifies the Army/Air Force Handbook of Railroad Track Standards with the Navy’s Railroad Trackage Field Assessment Manual the into one Department of Defense UFC manual.

Reasons for Changes:

• Consolidation of DOD railroad track standards into one single document.

• Consolidation of both railroad track maintenance standards and safety standards into a singular technical manual.

Impact: Inspection frequencies remain unchanged and the quality of track required remains nearly the same. These factors reflect a negligible cost impact as a result of the required track maintenance activities.

However, the following benefits should be realized:

• Improvement in installation personnel’s ability to determine the level of effort required for each track inspection.

• DOD Inspections that will be more consistent with the Federal Railway Administration

(FRA) safety standards used for commercial trackage.

• Proper and expanded use of new technology and materials, such as new types of ties that have gained industry acceptance.

• Improvement of railroad track inspections and overall railroad management due to the much greater use of table formats for clarity and understanding.

• Improved inspections since the UFC now differentiates between railroad maintenance requirements and the very minimal FRA safety standards.

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CONTENTS

CHAPTER 1. INTENT AND APPLICATION ................................................................................................................... 1-1

CHAPTER 2. INSPECTION OF TRACK AND

RECORD KEEPING ............................................................................................................................................. 2-1 CHAPTER 3. ROADWAY .................................................................................................................................................. 3-1 CHAPTER 4. BALLAST ..................................................................................................................................................... 4-1 CHAPTER 5. TIES ............................................................................................................................................................... 5-1

CHAPTER 6. OTHER TRACK MATERIALS (OTM), TIE

PLATES, ANCHORS, RAIL

FASTENINGS, ETC. ............................................................................................................................................ 6-1

CHAPTER 7. RAIL .............................................................................................................................................................. 7-1 CHAPTER 8. TURNOUTS .................................................................................................................................................. 8-1 CHAPTER 9. RAIL CROSSINGS ...................................................................................................................................... 9-1 CHAPTER 10. ROAD CROSSINGS ................................................................................................................................ 10-1 CHAPTER 11. BRIDGES .................................................................................................................................................. 11-1 CHAPTER 12. TRACK GEOMETRY .............................................................................................................................. 12-1 CHAPTER 13. CLEARANCES......................................................................................................................................... 13-1 CHAPTER 14. MISCELLANEOUS TRACK APPLIANCES ........................................................................................ 14-1 CHAPTER 15. MAINTENANCE ACTIVITIES FOR CATEGORY C TRACK ............................................................ 15-1

APPENDIX A. REFERENCES ...................................................................................................... A-1 APPENDIX B.

TRACK INSPECTION RECORD AND TURNOUT INSPECTION CHECKLIST.. B-1 APPENDIX C. FIELD

IDENTIFICATION OF RAIL DEFECTS .....................................................C-1 APPENDIX D. DETAILS OF RAIL SECTIONS.............................................................................D-1 APPENDIX E. FRA PART 213...................................................................................................... E-1 APPENDIX F. SUMMARY OF STANDARD ................................................................................. F-1 iii

FIGURES

Figure 5-1. Examples of Good and Defective Ties .................................................................................................. 5-2 Figure 5-2 Required Tie Support at Joints .............................................................................................................. 5-3 (Safety Standard) ..................................................................................................................................................... 5-3 Figure 6-1. Single Shoulder Tie Plate ..................................................................................................................... 6-1 Figure 6-2. Double Shoulder Tie Plate ................................................................................................................... 6-1 Figure 6-3. Spiking Pattern for Tangents and Curves of 4 Degrees or Less ........................................................... 6-2 Figure 6-4. Spiking Pattern for Curves Greater than 4 Degrees but Less than 36 Degrees ..................................... 6-2 Figure 6-5. Spiking Pattern for Curves 36 Degrees and Greater ................................................................................... 6-3 Figure 6-6. Incorrect Spiking of Angle Bars .......................................................................................................... 6-3 Figure 6-7. Correct Spiking of Angle Bars ............................................................................................................. 6-3 Figure 6-8. Proper Bolt Installation ........................................................................................................................ 6-5 Figure 6-9. Alternating Bolt Pattern ....................................................................................................................... 6-5 Figure 6-10. Recommended Minimum Anchoring Pattern for 39-foot Rails. ........................................................ 6-7 Figure 7-1. Rail Wear Measurement ....................................................................................................................... 7-5 Figure 7-2. Rail Base Corrosion Measurement ...................................................................................................... 7-5 Figure 7-3. End Batter Measurement ..................................................................................................................... 7-6 Figure 8-2. Reversing Tangent Length and Switch Stand Placement .................................................................... 8-2 Figure 8-3. Switch Point Contour. .......................................................................................................................... 8-3 Figure 8-4. Switch Point Plan and Elevation. ......................................................................................................... 8-4 Figure 8-5. Frog Point and Tread Contours ........................................................................................................... 8-6 Figure 8-6. Allowable Wear on Guarding Face of Self-Guarded Frog .................................................................. 8-6 Figure 8-7. Measurement of Flangeway Width, Flangeway Depth, Guard Check Gage, and Guard Face Gage .. 8-8 Figure 10-1. Track Construction for Road Crossing ............................................................................................ 10-2 Figure 12-1. Gage Measurement ........................................................................................................................... 12-1 Figure 12-2. Required Gage Measurement Locations Within Turnouts .............................................................. 12-3 Figure 12-3. Crosslevel Measurement................................................................................................................... 12-4 Figure 12-4. Determination of Warp ..................................................................................................................... 12-7 Figure 12-5. Measurement of Curve Alignment ................................................................................................... 12-8 Figure 13-1. Minimum Clearances for Tangent Track ........................................................................................ 13-3 Figure B-1. Example Track Inspection Record.....................................................................................B-4 Figure B-2. Example Turnout Inspection Record .................................................................................B-5 Figure B-3 Highway Grade Crossing Warning System Inspection/ Test Report .................................B-6 Figure B4 Safety Inspection Worksheet ...............................................................................................B-7

Figure B-5 Tie Detailed Inspection Worksheet .....................................................................................B-8 Figure B-6 Track Geometry Detailed Inspection Worksheet ................................................................B-9 Figure B-7. Turnout Inspection Worksheet (Components) ................................................................B-10 Figure B-

8. Turnout Inspection Worksheet (General, Ties and Measurements)...............................B-11 Figure B-9. Grade Crossing Detailed Inspection Worksheet (Includes Rail Crossings) ...................B-12 Figure B-10. Rail, F+OTM, Ballast, Drainage, and Appliances Detailed Inspection Worksheet

(Includes Inspection Impaired)....................................................................................................B-13 Figure C-1. Rail Nomenclature..............................................................................................................C-1

Figure C-2. Relative Positions of Planes Through a Rail .....................................................................C-1 Figure C-3. General Appearance of Bolt Hole Cracks..........................................................................C-2 Figure C-4. General Appearance of Broken Base.................................................................................C-3 Figure C-5. General Appearance of Broken Rail..................................................................................C-3 Figure C-6. General Appearance of Corrugation .................................................................................C-4 Figure C-7. General Appearance of Crushed Head ..........................................................................C-4 Figure C-8.

Rail End Batter ...................................................................................................................C-5 iv

Figure C-9. Typical Appearance of Engine Burn .................................................................................C-5 Figure C-10. General Appearance of Engine Burn Fracture...............................................................C-6 Figure C-11. General Appearance of Flaking.......................................................................................C-7 Figure C-12. General Appearance of Flow ...........................................................................................C-7 Figure C-13. General Appearance of Head/Web Separation................................................................C-8 Figure C-14. General Appearance of Horizontal Split Head................................................................C-8 Figure C-15. General Appearance of Mill Defects ................................................................................C-9 Figure C-16. General Appearance of Piped Rail...................................................................................C-9 Figure C-17. Cross-sectional View of Piped Rail ..................................................................................C-9 Figure C-18. General Appearance of Vertical Head and Side Wear..................................................C-10 Figure C-

19. General Appearance of Shelling ....................................................................................C-11

Figure C-20. General Appearance of Slivers.......................................................................................C-11 Figure C-21. General Appearance of Split Web ..................................................................................C-11 Figure C-22. General Appearance of Torch-Cut Rail.........................................................................C-12 Figure C-23. General Appearance of Transverse Defects...................................................................C-13 Figure C-24. General Appearance of Vertical Split Head ..................................................................C-13 Figure D-

1. Details of T-Rail Section ................................................................................................... D-1

TABLES

Table 7-1 - Rail Defect Standards ............................................................................................................................ 7-2 Table 8-1 - Measurements and Operating Restrictions for Frogs and Guard Rails ................................................ 8-7 Table 8-2 - Minimum length of straight guarding face in advance of frog point .................................................... 8-8 Table 12-1 - Recommended gage for curved track ................................................................................................ 12-4 Table 12-2 - Recommended Superelevation for Curved Track ............................................................................. 12-5 Table 13-1 - Clearance Requirements for Tangent Tracks ................................................................................... 13-2 Table D-1 - Details of Rail Sections ...................................................................................................... D-2 Table D-1 - Details of Rail Sections (Concluded)................................................................................. D-4 v

CHAPTER 1 INTENT

AND APPLICATION

1-1. INTRODUCTION.

a. The Department of Defense's (DOD) railroad system is a critical asset for both peacetime and mobilization missions.

b. The standards in this UFC are presented to protect investments in track maintenance and rehabilitation and to ensure that DOD's railroad track is maintained at the level needed to support mission requirements. The standards in this UFC provide maintenance standards for each possible type of deficiency addressed in the Federal Railroad Administration (FRA) Track Safety Standards. DOD policy is to maintain its railroad track at a standard that exceeds FRA Class 2 safety standards and adhere to additional DOD speed restrictions as stated in this UFC. The following standards specifically identify separate thresholds for safety standards and maintenance standards. If a standard is not specifically listed as a safety standard, it shall be used as a maintenance standard. For Navy installations, NAVFAC Instruction (NAVFACINST) 11230.1, Inspection, Certification, and Audit of Crane and Railroad Trackage, shall also be used based on category of track and amount of use.

c. Simply meeting the minimum standard required in this UFC is not necessarily the best, most cost-effective, long-term maintenance policy. The frequent occurrence of substandard or restricted conditions indicates the need for a comprehensive track evaluation to determine if major repair or rehabilitation is warranted.

1-2. DEFINITIONS. The following standards are discussed in this UFC:

a. Safety Standards. Based on the degree of hazard, these standards provide minimum safe operating limits for specific defects. FRA and DOD safety standards are addressed in Appendix F for comparison with maintenance standards. When established safety limits are exceeded, speed restrictions or “No Operation” shall be applied and enforced.

b. Maintenance Standards. These standards provide limits for specific defects and should be used to determine when maintenance is desirable and should be accomplished. This allows for maintenance or repair before the condition exceeding safety standards develops. Each installation shall develop a maintenance policy for additional defects not addressed in this UFC.

1-3. REFERENCES. Appendix A contains a list of references used in this UFC.

1-4. INTENT.

a. These standards define the minimum required maintenance condition levels for railroad track.

These standards shall be used for inspection and routine maintenance of railroad track by in-house or contract personnel.

b. These standards are not intended for, and shall not be used as specifications for, new construction or major track rehabilitation. The guidance given for Navy projects in UFC 4-860-02N, Design: Trackage, and for Army and Air Force projects in UFC 4-860-01FA, Design: Railroad Design and Rehabilitation, with Unified Facilities Guide Specification (UFGS) 05650, Railroad Track and Accessories, and/or host nation industry/government

1-1 standards will continue to apply to new construction and the complete reconstruction of segments of existing facilities.

c. Should the commercial carrier serving the installation require a more restrictive FRA standard or criteria not included in these standards, the installation track shall be maintained to meet the carrier's requirements.

d. The judgment of the designated track inspector and the criteria presented in this UFC must supplement each other in the application of these standards.

1-5. TRACK CATEGORIES. All railroad track shall be maintained in accordance with one of the following categories:

Category Types of Track and Use

A All active mainline track, or other active track with speed greater than 10 mph

B Active passing track, sidings, yard tracks, holding track, classification yard or storage track

Minimum FRA Class of Track Safety Standard

C Inactive track; no current mobilization requirements 0

1-6. APPLICATION.

a. Requirements versus Recommendations. In this UFC, the words “shall” and “is required” indicate requirements of the standards that must be met as prescribed by NAVFACINST 11230.1 for the Navy or AR 420-72 for the Army. Recommendations are indicated by the words “may,” “should,” and “it is recommended that….”

These recommendations represent good maintenance practice. DOD policy is to maintain the railroad track at full compliance with these maintenance standards and to restrict operations on any track below the safety standards.

b. Condition Levels. These standards establish four levels of track condition. These condition levels indicate relative seriousness of defects, allow comparison of different types of defects, and provide a means for prioritizing repair work. The three track condition levels are as follows:

(1) Full Compliance: Track that meets all the requirements of the standards. Track at this level has, at most, only minor defects and should be fully capable of handling all train operations within the operating rules of the installation. Routine maintenance is required to maintain this condition level, and repair work will generally be only minor.

(2) Restricted Operation: Track has defects serious enough to make it unsuitable for operations greater than 10 mph, essentially “normal yard speed.” Based on the inspector’s judgment, track which has defects serious enough to make it unsuitable for operations at 10 mph may be reduced to 5 mph. Essentially, a train may be allowed to “crawl” over the track. This level is intended as a warning zone to indicate that the track is approaching a condition that will require removal from service.

(3) No Operation: Track has defects serious enough to require removal from service. At this level, the operation of trains over the track is generally considered hazardous. Operations shall not be allowed except as noted in paragraph 1-6.c.(5).

c. Operating Restrictions.

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(1) These standards establish minimum required condition levels and also identify track conditions requiring restriction or suspension of train operations. It is intended that a track inspector apply the required restriction or suspension immediately upon discovery of the substandard condition, and that the track be repaired to meet the appropriate condition level as soon as practical. A track restriction shall require the operational speed to be less than posted speed, but not more than 10 mph.

(2) Notification of Track Restriction.

(a) Army Track. The certified track inspector shall notify both the train operating personnel first and the director of public works (DPW) immediately upon the discovery of any condition that would warrant any restriction below normal operating practices. The DPW shall notify the installation transportation officer (ITO) verbally and in writing of any condition requiring train operations to be restricted or suspended.

(b) Air Force Track. The track inspector shall notify both the train operating personnel and the base civil engineer (BCE) immediately upon the discovery of any condition that would warrant any restriction below normal operating practices. The BCE shall notify the base traffic management officer (TMO) verbally and in writing of any condition requiring train operations to be restricted or suspended.

(c) Navy Track. The track inspector shall notify both the train operating personnel and the trackage certifying official immediately upon the discovery of any condition that would warrant a restriction beyond normal operating practices or a suspension in operations. Documentation and notification of restricted or non-certification of track shall be performed by the certifying official in accordance with NAVFACINST 11230.1.

(3) Operations over Restricted Track. For locations where operating restrictions have been imposed, the speed of the train or other on-track vehicles shall be reduced to the required level before the first wheel reaches the defective area and not increased until the last wheel has passed the defective area.

(4) Removal of Track Restriction. A track restriction may be removed after all defects resulting in the restriction have been repaired.

(a) Army Track. The certified track inspector shall notify the DPW upon completion of the repairs. The DPW shall notify the ITO in writing that the restrictions have been lifted.

(b) Air Force Track. The restriction shall not be considered removed until the TMO receives written notification of removal from the BCE.

(c) Navy Track. The trackage certifying official shall recertify the trackage repaired to the level allowed by repairs made. Certification and notification will be in accordance with NAVFACINST 11230.1.

(5) Track Removed From Service. Any portion of track where conditions fall below the minimum operable track condition (track condition is at the “No Operation” level) shall be closed to operations until repairs are completed. However, such track may be used under written permit from the track management authority and in the presence of a track inspector. During operations over the closed portion of track, the track inspector shall have visual contact with the train operator at all times and be prepared to signal the train crew to stop. For Navy track, movement of hazardous materials over track removed from service will be in accordance with NAVFACINST 11230.1.

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d. Judgment of the track inspector shall govern. A track inspector shall have the authority to impose operating restrictions beyond the minimum required in these standards when conditions warrant.

e. Defective conditions or…