Attachment AL - 1806701Amend0008-SPC.pdf

Dr y Dock 3 Moder ni zat i on ePr oj ect No. 1806701 Nor f ol k Naval Shi pyar d, Por t smout h, VA

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RAI LROAD TRACK AND ACCESSORI ES

PART 1 GENERAL

1. 1 REFERENCES

The publ i cat i ons l i s t ed bel ow f or m a par t of t hi s speci f i cat i on t o t he ext ent r ef er enced. The publ i cat i ons ar e r ef er r ed t o wi t hi n t he t ext by t he basi c desi gnat i on onl y.

AMERI CAN ASSOCI ATI ON OF STATE HI GHWAY AND TRANSPORTATI ON OFFI CI ALS

( AASHTO)

AASHTO M 288 ( 2021) St andar d Speci f i cat i on f or Geosynt het i c Speci f i cat i on f or Hi ghway Appl i cat i ons

AMERI CAN RAI LWAY ENGI NEERI NG AND MAI NTENANCE- OF- WAY ASSOCI ATI ON

( AREMA)

AREMA Eng Man ( 2023) Manual f or Rai l way Engi neer i ng

AMERI CAN WOOD PROTECTI ON ASSOCI ATI ON ( AWPA)

AWPA M2 ( 2019) St andar d f or t he I nspect i on of Pr eser vat i ve Tr eat ed Wood Pr oduct s f or I ndust r i al Use

AWPA M6 ( 2024) Br ands Used on Pr eser vat i ve Tr eat ed Mat er i al s

AWPA P2 ( 2024) St andar d f or Cr eosot e Sol ut i ons

AWPA U1 ( 2024) Use Cat egor y Syst em: User Speci f i cat i on f or Tr eat ed Wood

AMERI CAN SOCI ETY OF MECHANI CAL ENGI NEERS ( ASME)

ASME B18. 2. 1 ( 2012; R 2021) Squar e, Hex, Heavy Hex, and Askew Head Bol t s and Hex, Heavy Hex, Hex Fl ange, Lobed Head, and Lag Scr ews ( I nch Ser i es)

ASME B18. 2. 2 ( 2022) Nut s f or Gener al Appl i cat i ons:

Machi ne Scr ew Nut s, and Hex, Squar e, Hex Fl ange, and Coupl i ng Nut s ( I nch Ser i es)

ASTM I NTERNATI ONAL ( ASTM)

ASTM A36/ A36M ( 2019) St andar d Speci f i cat i on f or Car bon St r uct ur al St eel

ASTM A183 ( 2014; R 2020) St andar d Speci f i cat i on f or Car bon St eel Tr ack Bol t s and Nut s

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ASTM A283/ A283M ( 2024) St andar d Speci f i cat i on f or Low and I nt er medi at e Tensi l e St r engt h Car bon St eel Pl at es

ASTM C117 ( 2023) St andar d Test Met hod f or Mat er i al s Fi ner t han 75- um ( No. 200) Si eve i n Mi ner al Aggr egat es by Washi ng

ASTM C127 ( 2015) St andar d Test Met hod f or Densi t y, Rel at i ve Densi t y ( Speci f i c Gr avi t y) , and Absor pt i on of Coar se Aggr egat e

ASTM C131/ C131M ( 2020) St andar d Test Met hod f or Resi st ance t o Degr adat i on of Smal l - Si ze Coar se Aggr egat e by Abr asi on and I mpact i n t he Los Angel es Machi ne

ASTM C136/ C136M ( 2019) St andar d Test Met hod f or Si eve Anal ysi s of Fi ne and Coar se Aggr egat es

ASTM C142/ C142M ( 2017; R 2023) St andar d Test Met hod f or Cl ay Lumps and Fr i abl e Par t i c l es i n Aggr egat es

ASTM C157/ C157M ( 2017) St andar d Test Met hod f or Lengt h Change of Har dened Hydr aul i c- Cement Mor t ar and Concr et e

ASTM C307 ( 2023) St andar d Test Met hod f or Tensi l e St r engt h of Chemi cal - Resi st ant Mor t ar , Gr out s, and Monol i t hi c Sur f aci ngs

ASTM C535 ( 2016) St andar d Test Met hod f or Resi st ance t o Degr adat i on of Lar ge- Si ze Coar se Aggr egat e by Abr asi on and I mpact i n t he Los Angel es Machi ne

ASTM C579 ( 2023) St andar d Test Met hods f or Compr essi ve St r engt h of Chemi cal - Resi st ant Mor t ar s, Gr out s, Monol i t hi c Sur f aci ngs, and Pol ymer Concr et es

ASTM C702/ C702M ( 2018) St andar d Pr act i ce f or Reduci ng Sampl es of Aggr egat e t o Test i ng Si ze

ASTM C88 ( 2018) St andar d Test Met hod f or Soundness of Aggr egat es by Use of Sodi um Sul f at e or Magnesi um Sul f at e

ASTM C881/ C881M ( 2020a) St andar d Speci f i cat i on f or Epoxy- Resi n- Base Bondi ng Syst ems f or Concr et e

ASTM D1310 ( 2014) Fl ash Poi nt and Fi r e Poi nt of Li qui ds by Tag Open- Cup Appar at us

ASTM D217 ( 2021a) St andar d Test Met hods f or Cone Penet r at i on of Lubr i cat i ng Gr ease

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ASTM D2171/ D2171M ( 2018) St andar d Test Met hod f or Vi scosi t y of Asphal t s by Vacuum Capi l l ar y Vi scomet er

ASTM D3740 ( 2019) Mi ni mum Requi r ement s f or Agenci es Engaged i n t he Test i ng and/ or I nspect i on of Soi l and Rock as Used i n Engi neer i ng Desi gn and Const r uct i on

ASTM D3776/ D3776M ( 2009a; R 2017) St andar d Test Met hods f or Mass Per Uni t Ar ea ( Wei ght ) of Fabr i c

ASTM D402/ D402M ( 2014) Di st i l l at i on of Cut - Back Asphal t i c ( Bi t umi nous) Pr oduct s

ASTM D4355/ D4355M ( 2014) Det er i or at i on of Geot ext i l es f r om Exposur e t o Li ght , Moi st ur e and Heat i n a Xenon- Ar c Type Appar at us

ASTM D445 ( 2019a) St andar d Test Met hod f or Ki nemat i c Vi scosi t y of Tr anspar ent and Opaque Li qui ds ( and Cal cul at i on of Dynami c Vi scosi t y)

ASTM D4491/ D4491M ( 2017) St andar d Test Met hods f or Wat er Per meabi l i t y of Geot ext i l es by Per mi t t i v i t y

ASTM D4751 ( 2020) St andar d Test Met hod f or Det er mi ni ng Appar ent Openi ng Si ze of a Geot ext i l e

ASTM D4791 ( 2019) Fl at Par t i c l es, El ongat ed Par t i c l es, or Fl at and El ongat ed Par t i c l es i n Coar se Aggr egat e

ASTM D566 ( 2017) St andar d Test Met hod f or Dr oppi ng Poi nt of Lubr i cat i ng Gr ease

ASTM D75/ D75M ( 2019) St andar d Pr act i ce f or Sampl i ng Aggr egat es

ASTM E11 ( 2024) St andar d Speci f i cat i on f or Woven Wi r e Test Si eve Cl ot h and Test Si eves

ASTM F3125/ F3125M ( 2019) St andar d Speci f i cat i on f or Hi gh St r engt h St r uct ur al Bol t s and Assembl i es, St eel and Al l oy St eel , Heat Tr eat ed, I nch Di mensi ons 120 ksi and 150 ksi Mi ni mum Tensi l e St r engt h, and Met r i c Di mensi ons 830 MPa and 1040 MPa Mi ni mum Tensi l e St r engt h

U. S. FEDERAL HI GHWAY ADMI NI STRATI ON ( FHWA)

MUTCD ( 2009; Rev 2022) Manual on Uni f or m Tr af f i c Cont r ol Devi ces

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U. S. DEPARTMENT OF DEFENSE ( DOD)

MI L- STD- 1699 ( 1992; Rev B) Nondest r uct i ve Eval uat i on of But t Wel ds i n Cr ane and Rai l r oad Rai l s

1. 2 SUBMI TTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" or " S" c l assi f i cat i on. Submi t t al s not havi ng a " G" or " S" c l assi f i cat i on ar e f or Cont r act or Qual i t y Cont r ol appr oval . Submi t t he f ol l owi ng i n accor dance wi t h Sect i on 01 33 00. 00 22 SUBMI TTAL PROCEDURES.

SD- 02 Shop Dr awi ngs

Tur nout s and Tr ack Cr ossi ngs; G

Exi st i ng r ai l conf i gur at i on sur vey; G

Rai l conf i gur at i on sur vey pl an; G

Layout dr awi ngs; G

Base Pl at es; G

SD- 03 Pr oduct Dat a

Wood Ti es

Name of t he t i e manuf act ur er , Rai l Ti e Associ at i on member shi p, t he wood speci es pr oposed, t he quant i t i es of t i es f or each speci e pr oposed, and pr oduct dat a f or t he t i es t o be f ur ni shed, i ncl udi ng t he t ype of seasoni ng t o be ut i l i zed, pr i or t o or der i ng t he t i es.

Geot ext i l e Fabr i c; G

Rai l ; G

Joi nt Bar s

Wel dabl e, adj ust abl e r ai l c l i ps; G

Anchor bol t s; G

Epoxy Gr out ; G

Compr omi se Joi nt Bar s

Mi scel l aneous Tr ack Mat er i al s

Accept abl e Repl acement Mat er i al s; G

Per f or mance dat a f or component s or pr oduct s pr oposed as an equi val ent t o t hose speci f i ed. The Cont r act i ng Of f i cer ' s wr i t t en appr oval i s r equi r ed f or any such equi val ent t ype component or pr oduct pr oposed t o be used.

Mat er i al s and Sampl es

A compl et e schedul e of t he mat er i al s pr oposed f or i nst al l at i on

SECTI ON 34 11 00 Page 4 I ssued May 30, 2025 wi t hi n 60 days of r ecei pt of not i ce t o pr oceed, and bef or e i nst al l at i on of t he mat er i al s; t he schedul e shal l i ncl ude a l i s t of equi pment pr oposed f or t he wor k.

SD- 04 Sampl es

Geot ext i l e

Geot ext i l e sampl es f or t est i ng. Submi t sampl es a mi ni mum of 60 days pr i or t o t he begi nni ng of i nst al l at i on of t he geot ext i l es.

One sampl e shal l be pr ovi ded f or each 20 uni t s ( r ol l s, panel s, et c. ) of geot ext i l e t o be used i n t he cont r act . Al l sampl es shal l be f r om t he same pr oduct i on l ot as wi l l be suppl i ed f or t he cont r act . Sampl es shal l be i dent i f i ed by t he manuf act ur er ' s name, br and name, l ot desi gnat i on, and pr oj ect name. The mi ni mum si ze of sampl e submi t t ed f or t est i ng shal l be t he f ul l wi dt h of t he geot ext i l e by10 f t .

Bal l ast

Sampl es of t he bal l ast mat er i al f or t est i ng. Submi t sampl es a mi ni mum of 60 days pr i or t o t he i nst al l at i on of t he mat er i al .

Sampl es shal l be obt ai ned f r om t he quar r y, suppl i er , or ot her sour ce t hat wi l l be used t o pr ovi de t he bal l ast mat er i al s f or t hi s pr oj ect usi ng t he met hods descr i bed i n ASTM D75/ D75M.

Wel dabl e, adj ust abl e r ai l c l i ps; G

Base Pl at e gr out i ng mock- up; G

SD- 06 Test Repor t s

Test f or epoxy gr out ; G

Vi sual i nspect i on; G

Adhesi ve f or Anchor Bol t s; G

Ul t r asoni c i nspect i on of wel ded r ai l j oi nt s; G

Thr ow mechani sm oper at i onal t est ; G

Ret est i ng; G

Load t est ; G

Sampl i ng and Test i ng

One cer t i f i ed copy of Test Repor t s f or each t est per f or med on t he bal l ast wi t hi n 2 wor ki ng days of t he t est compl et i on.

Wood Ti es

Cer t i f i ed r epor t s f or cr osst i es and swi t ch t i es subsequent t o t r eat ment , a mi ni mum of seven cal endar days pr i or t o any t i es bei ng i nst al l ed i n t r ack. Test r epor t s shal l cont ai n t he i nf or mat i on r equi r ed by Par t 7 of AWPA M2.

Geot ext i l es

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I ndependent t est i ng l abor at or y ' s cer t i f i ed t est r epor t s f or geot ext i l es, i ncl udi ng necessar y anal ysi s and i nt er pr et at i on.

These r epor t s shal l pr ovi de r esul t s of t he l abor at or y t est i ng per f or med on sampl es of t he geot ext i l e mat er i al del i ver ed t o t he j obsi t e. Test r epor t s shal l be submi t t ed at l east 5 wor ki ng days pr i or t o t he i nst al l at i on of t he geot ext i l e.

SD- 07 Cer t i f i cat es

Base pl at es; G

Epoxy Gr out ; G

Wood Ti es

Cer t i f i cat es of compl i ance pr i or t o any t i es bei ng i nst al l ed i n t r ack.

Bal l ast

Cer t i f i cat es of Compl i ance f or t he bal l ast mat er i al s t o be i nst al l ed i n t hi s pr oj ect .

Mat er i al s and Sampl es

Manuf act ur er ' s cer t i f i cat es of conf or mance f or t he f ol l owi ng mat er i al s:

a. Rai l .

b. Ti e pl at es.

c. Tr ack bol t s, nut s, and spr i ng washer s.

d. Joi nt bar s.

e. Rai l anchor s.

f . Tr ack spi kes.

g. Tur nout s.

SD- 08 Manuf act ur er ' s I nst r uct i ons

Wel dabl e, adj ust abl e r ai l c l i ps; G

Joi nt Bar s

Adhesi ve f or anchor bol t s; G

SD- 10 Oper at i on and Mai nt enance Dat a

Rai l

Tur nout s and Tr ack Cr ossi ngs

Swi t ches

Submi t Dat a package 1 i n accor dance wi t h Sect i on 01 78 23

OPERATI ON AND MAI NTENANCE DATA.

SD- 11 Cl oseout Submi t t al s

Recor d Dr awi ng Sur vey; G

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1. 3 QUALI TY ASSURANCE

1. 3. 1 Tr ack Const r uct i on

Per f or m t r ack const r uct i on under t he di r ect i on of qual i f i ed and compet ent super vi sor y per sonnel exper i enced i n r ai l r oad const r uct i on.

1. 3. 2 Layout Dr awi ngs

Submi t f or appr oval by t he Cont r act i ng Of f i cer bef or e wor k i s st ar t ed and bef or e mat er i al s ar e or der ed. I ncl ude on t he l ayout dr awi ngs l ocat i ons of t ur nout s, f r ogs, t r ansi t i on s l abs, t i e spaci ng changes, and r ai l accessor i es.

1. 3. 3 Wel der , Wel di ng Met hod, and Wel der Qual i f i cat i on

Ther mi t e Wel di ng Met hod: Wel der qual i f i cat i on r equi r ement s f or t her mi t e wel di ng met hod ar e def i ned i n Sect i on 34 11 19. 00 20 WELDI NG CRANE AND

RAI LROAD RAI L - THERMI TE METHOD.

1. 4 DELI VERY, STORAGE, AND HANDLI NG

1. 4. 1 Mat er i al s and Sampl es

The Cont r act i ng Of f i cer wi l l not i f y t he Cont r act or of t he mat er i al s appr oved or di sappr oved. Di sappr oved mat er i al s t hat have al r eady been del i ver ed t o t he pr oj ect s i t e, shal l be pr ompt l y segr egat ed f r om t he appr oved mat er i al s and r emoved f r om t he pr emi ses. I f mat er i al s ar e di sappr oved, accept abl e r epl acement mat er i al s shal l be pr ovi ded at no addi t i onal cost t o t he Gover nment . I ni t i al appr oval by t he Cont r act i ng Of f i cer wi l l not pr event t he r emoval and r epl acement of mat er i al s t hat ar e mat er i al l y def ect i ve or mat er i al s not meet i ng t hi s speci f i cat i on t hat ar e di scover ed dur i ng const r uct i on and/ or r out i ne qual i t y cont r ol / qual i t y assur ance oper at i ons.

1. 4. 2 Geot ext i l es

Shi p and st or e geot ext i l es i n t hei r or i gi nal ul t r avi ol et r esi st ant cover unt i l t he day of i nst al l at i on. Pr ot ect geot ext i l es f r om vandal i sm, t emper at ur es gr eat er t han 140 degr ees F, di r t , dust , mud, debr i s, moi st ur e, sunl i ght , and ul t r avi ol et r ays. Geot ext i l es del i ver ed t o t he pr oj ect s i t e shal l be c l ear l y l abel ed on t he mat er i al cover t o show t he manuf act ur er ' s name, br and name, f abr i c t ype, l ocat i on and dat e manuf act ur ed, l ot i dent i f i cat i on, wi dt h, and l engt h.

1. 5 EXI STI NG CONDI TI ONS

Conf i r mPr i or t o demol i t i on of exi st i ng r ai l r oad t r ack syst em, conf i r m exi st i ng r ai l conf i gur at i on, r ai l f i t t i ngst ur nout s, f r ogs, f oundat i ons, and ut i l i t y l ocat i ons by means of a f i el d sur vey. Do not pr epar e dr awi ngs bef or e t he compl et i on of f i el d sur vey and measur ement s.

Submi t det ai l s f or cast i ng and f abr i cat i on of f i t t i ngs. I ncl ude compl et e di mensi oni ng, al i gnment dat a, shop i nst r uct i ons, and a mat er i al l i s t i ndi cat i ng descr i pt i on and quant i t y of component s and f ast ener s f or each f i t t i ng. Submi t dr awi ngs f or each i ndi v i dual f i t t i ng whi ch i s adequat e t o det er mi ne t he conf or mance of f i t t i ngs wi t h pr oj ect dr awi ngs and as pr ovi ded f or her ei n. Show det ai l s of dr ai nage connect i ons f r om f i t t i ngs

SECTI ON 34 11 00 Page 7 I ssued May 30, 2025 and housi ngs t o dr ai n pi pes.

Do not manuf act ur e mat er i al s unt i l dr awi ngs have been appr oved.

1. 6 PROJECT/ SI TE CONDI TI ONS

1. 6. 1 Tempor ar y Wor k

Pr ovi de, dur i ng const r uct i on, sui t abl e r oads and cr ossi ngs wi t h al l necessar y l i ght s, s i gns, dr ai nage, and ot her appur t enances r equi r ed f or saf e publ i c and l ocal t r avel . Er ect and mai nt ai n sui t abl e t empor ar y f ences wher e r equi r ed t o pr event t r espass upon wor k or damage t o adj oi ni ng pr oper t y. Dr ai nage shal l be mai nt ai ned, and t he accumul at i on of wat er t hat mi ght af f ect t he st abi l i t y of t he r oadbed wi l l not be per mi t t ed.

1. 6. 2 Tr af f i c Cont r ol

Tr af f i c cont r ol devi ces shal l compl y wi t h MUTCD. Sui t abl e war ni ng si gns shal l be pl aced near t he begi nni ng of t he wor k s i t e and wel l ahead of t he wor k s i t e f or al er t i ng appr oachi ng t r af f i c f r om bot h di r ect i ons. Smal l mar ker s shal l be pl aced al ong newl y pai nt ed l i nes or f r eshl y pl aced r ai sed mar ker s t o cont r ol t r af f i c and pr event damage t o newl y pai nt ed sur f aces or di spl acement of r ai sed pavement mar ker s. Pai nt i ng equi pment shal l be mar ked wi t h l ar ge war ni ng si gns i ndi cat i ng s l ow- movi ng pai nt i ng equi pment i n oper at i on.

1. 6. 3 Wel di ng

Wel di ng shal l not be per f or med i n r ai n, snow, or ot her i ncl ement weat her wi t hout adequat el y pr ot ect i ng t he wel d f r om t he el ement s.

1. 7 WORK LAYOUT

Submi t f or r evi ew and appr oval a sur vey pl an and dat a t hat shows how t he r ai l conf i gur at i on wi l l be st aked out i n t he f i el d pr i or t o const r uct i on.

PART 2 PRODUCTS

2. 1 BALLAST

Pr epar ed bal l ast shal l be cr ushed st one, Si ze No. 4A conf or mi ng t o Chapt er 1, Par t 2, of AREMA Eng Man f or qual i t y, soundness and gr adat i on.

I n t he por t i on r et ai ned on each si eve speci f i ed, t he cr ushed gr avel shal l cont ai n at l east 90 per cent by wei ght of cr ushed pi eces havi ng t wo or mor e f r eshl y f r act ur ed f aces wi t h t he ar ea of each f ace bei ng at l east equal t o 75 per cent of t he smal l est mi dsect i onal ar ea of t he pl ane. When t wo f r act ur es ar e cont i guous, t he angl e bet ween pl anes of t he f r act ur es shal l be at l east 30 degr ees i n or der t o count as t wo f r act ur ed f aces. Fl at and el ongat ed par t i c l e di mensi on r at i o used i n ASTM D4791 shal l be 1: 3.

Bal l ast mat er i al s shal l meet t he pr oper t y r equi r ement s shown i n TABLE I .

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TABLE I . MI NI MUM PROPERTY REQUI REMENTS - BALLAST

Pr oper t y Maxi mum Val ue Mi ni mum Val ue Test Met hod

Per cent passi ng No. 200 si eve 1. 0 per cent - - ASTM C136/ C136M

ASTM C117

Bul k speci f i c gr avi t y

Rock - - 2. 60 ASTM C127

Bl ast f ur nace sl ag - - 2. 30

Absor pt i on

Rock 2. 0 per cent - - ASTM C127

Bl ast f ur nace sl ag 5. 0 per cent - -

Cl ay l umps and f r i abl e par t i c l es

0. 5 per cent - - ASTM C142/ C142M

Degr adat i on Soundness 35 per cent - - ASTM C535

Sodi um sul f at e - 5 cycl es 10 per cent - - ASTM C88

Fl at or el ongat ed par t i c l es 5 per cent - - ASTM D4791

2. 2 GEOTEXTI LE

2. 2. 1 Physi cal Pr oper t y Requi r ement s

The geot ext i l e shal l be a nonwoven, per vi ous sheet of pol ymer i c mat er i al and shal l consi st of l ong- chai n synt het i c pol ymer s composed of at l east 95 per cent by wei ght pol yol ef i ns, pol yest er s, or pol yami des. The use of woven sl i t f i l m geot ext i l es ( i . e. geot ext i l es made f r om yar ns of a f l at , t ape- l i ke char act er ) wi l l not be al l owed. The geot ext i l e shal l cont ai n st abi l i zer s and/ or i nhi bi t or s as necessar y t o make t he f i l ament s r esi st ant t o det er i or at i on f r om ul t r avi ol et l i ght and heat exposur e, par t i cul ar l y pr i or t o pl acement and cover age. The f i ber s shal l be f or med i nt o a net wor k whi ch wi l l be di mensi onal l y st abl e. The edges of t he geot ext i l e shal l be f i ni shed i n a way t o pr event t he out er f i ber s f r om bei ng pul l ed away f r om t he geot ext i l e. The geot ext i l e shal l exceed t he appl i cabi l i t y pr oper t y r equi r ement s st at ed i n TABLE I I .

TABLE I I - PROPERTY REQUI REMENTS- GEOTEXTI LE

PROPERTY MI NI MUM REQUI REMENTS* TEST METHOD

Wei ght * * 15 oz/ sq yd ASTM D3776/ D3776M Opt i on B

Col or Gr ey or t i nt ed - -

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TABLE I I - PROPERTY REQUI REMENTS- GEOTEXTI LE

PROPERTY MI NI MUM REQUI REMENTS* TEST METHOD

St r engt h Cl ass 1 AASHTO M 288

Appar ent openi ng si ze ( AOS) ( maxi mum r equi r ed val ve)

Less t han No. 70 si eve ASTM D4751

Per mi t t i v i t y 0. 1 per sec ASTM D4491/ D4491M

Ul t r avi ol et degr edat i on at 500 hour s

50 per cent st r engt h r et ai ned ASTM D4355/ D4355M

* These pr oper t y r equi r ement s ar e Mi ni mum Aver age Rol l Val ues i n t he weaker pr i nci pal di r ect i on.

* * Geot ext i l e sel ect i on shal l not be l i mi t ed by t he mi ni mum wei ght shown. Sel ect i on shal l be based on t he ot her pr oper t y r equi r ement s l i st ed. Heavi er geot ext i l es have shown gr eat er r esi st ance t o abr asi on.

2. 2. 2 Di mensi onal Requi r ement s

Each r ol l of geot ext i l e shal l mat ch t he r ai l bed wi dt h and be at l east 12 f t .

2. 3 JOI NT BARS

Joi nt bar s shal l be of t he s i ze, shape, and punchi ng pat t er n t o f i t t he r ai l bei ng j oi ned. Joi nt bar s ar e onl y t o be used bet ween r ai l and r ai l swi t ches and f r ogs, al l r ai l - t o- r ai l j oi nt s shal l be wel ded.

2. 3. 1 New Joi nt Bar s

Pr ovi de 6- hol e j oi nt bar s. New j oi nt bar s shal l be used wi t h new r ai l , and shal l be of t he " t oel ess" and " head f r ee desi gn" t o mat ch r ai l sect i on. New j oi nt bar s shal l conf or m t o t he r equi r ement s of " Speci f i cat i ons For Hi gh- Car bon St eel Joi nt Bar s" or " Speci f i cat i ons For Quenched Car bon- St eel Joi nt Bar s and For ged Compr omi se Joi nt Bar s" f ound i n Chapt er 4, Par t 2 of AREMA Eng Man f or t he j oi nt bar and assembl i es r ecommended i n Chapt er 4, Par t 1 of AREMA Eng Man.

2. 4 GREASE

Gr ease f or l ubr i cat i ng movi ng par t s i n t ur nout s and ot her t r ackwor k shal l have t he f ol l owi ng t ypi cal char act er i st i cs:

Cal ci um Soap, per cent 9. 0

Sol i d Addi t i ve ( Gr aphi t e) , per cent 11. 5

Penet r at i on, ASTM D217 at 77 degr ees F wor ked 340

Dr oppi ng Poi nt ASTM D566 at 77 degr ees F 101/ 214

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Oi l Vi scosi t y, cSt at 104 degr ees F 81. 8

ASTM D445 SUS at 100 degr ees F 379

Ot her t ypes of gr ease or l ubr i cat i ng oi l ( l i ke SoyTr ak) may be used pr ovi ded t hat t he gr ease or oi l has been used successf ul l y by l ocal commer ci al r ai l r oads and has t he appr oval of t he Cont r act i ng Of f i cer .

2. 5 OI L FOR CORROSI ON PROTECTI ON

Oi l f or pr ot ect i ng r ai l and ot her t r ack mat er i al s f r om cor r osi on, except j oi nt s, shal l conf or m t o t he f ol l owi ng gener al speci f i cat i on:

Asphal t , 100 penet r at i on mi ni mum 45 per cent ASTM D402/ D402M

Fl ash poi nt , mi ni mum 130 degr ees F ASTM D1310

Vi scosi t y, k i nemat i c, 140 degr ees F 480 t o 700 cent i st okes ASTM D2171/ D2171M

2. 6 RAI L

Submi t manuf act ur er ' s dat a on new r ai l i ncl udi ng: r ai l wei ght , r ai l sect i on, r ai l l engt h, dat e r ol l ed, and t he name of t he mi l l wher e t he r ai l was r ol l ed. I ncl ude chemi cal anal ysi s f or I ndust r i al Gr ade Rai l r ai l .

Pr ovi de t he maxi mum al l owabl e ver t i cal wear on t he r ai l head and t he maxi mum al l owabl e hor i zont al wear on t he si de of t he r ai l . The desi gn of t he j oi nt bar s and compr omi se j oi nt bar s pr oposed t o be f ur ni shed wi t h each r ai l sect i on shal l al so be pr ovi ded.

2. 6. 1 Wel ded Rai l

New r ai l shal l be, 115 l bs, RE sect i on and shal l conf or m t o Chapt er 4, Par t 2 of AREMA Eng Man. Al l new r ai l r aod r ai l used must be cont r ol cool ed r ai l . Rai l t hat i s t o be wel ded shal l meet t he cr i t er i a speci f i ed i n Chapt er 4, Par t 2 of AREMA Eng Man f or wel ded r ai l .

2. 7 WOOD TI ES

Submi t name of t he t i e manuf act ur er , Rai l Ti e Associ at i on member shi p, t he wood speci es pr oposed, t he quant i t i es of t i es f or each speci e pr oposed, and pr oduct dat a f or t he t i es t o be f ur ni shed, i ncl udi ng t he t ype of seasoni ng t o be ut i l i zed, pr i or t o or der i ng t he t i es. Al l t i es shal l be new. Speci es shal l be Ash, Beech, Red or Whi t e Oak.

a. Swi t ch t i es shal l be Ash or Oak. Condi t i oni ng and seasoni ng shal l conf or m t o t he r equi r ement s of AWPA U1 f or t he i ndi v i dual wood speci es. Ti es shal l be wel l seasoned. Pr i or t o pr eser vat i ve t r eat ment , wood t i es shal l be dr i ed t o t he oven dr y moi st ur e cont ent , or l ess, as speci f i ed i n par agr aph 3. 14 of AWPA U1. The wood may be ai r dr i ed, vapor dr i ed, or boul t oni zed.

b. Ti es whi ch ar e t o be dr i ed by ar t i f i c i al means shal l be condi t i oned and t r eat ed as soon as possi bl e af t er sawi ng, but no mor e t han 30 days l at er . The t emper at ur e used f or boul t oni z i ng shal l be as hi gh as possi bl e but i n no case l ess t han 200 degr ees F. Vapor dr i ed t i es shal l be t r ansf er r ed f r om dr yi ng cyl i nder s t o t r eat ment cyl i nder s as qui ckl y as possi bl e t o avoi d l oss of heat f r om t he seasoned t i es.

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Ti es shal l be pr essur e t r eat ed i n accor dance wi t h Chapt er 30, Par t 3 of AREMA Eng Man by t he empt y cel l pr ocess wi t h a 60/ 40 cr eosot e/ coal t ar sol ut i on ( Gr ade C) i n accor dance wi t h AWPA P2 t o a mi ni mum r et ent i on of 8 l bs/ cu f t of wood.

c. Spl i t s shal l not be l onger t han 4 i nch and not wi der t han 1/ 4 i n at ei t her end. Spl i t s l onger t han 4 i nch but not l onger t han t he wi dt h of t he f ace i n whi ch t he spl i t appear s, wi l l be accept abl e i f speci f i ed ant i - spl i t t i ng devi ces ar e i nst al l ed wi t h t he spl i t s compr essed. Any r equi r ed adzi ng and dr i l l i ng f or spi kes shal l be per f or med pr i or t o t r eat ment .

d. Not i f y t he Cont r act i ng Of f i cer at l east 15 days pr i or t o t he shi pment of any t r eat ed t i es or t i mber s f r om t he manuf act ur er ' s pl ant , t o pr ovi de t he Gover nment t he oppor t uni t y t o i nspect t he mat er i al s bef or e shi pment . When i nspect i ons of onsi t e mat er i al s r esul t i n pr oduct r ej ect i on, pr ompt l y segr egat e and r emove r ej ect ed mat er i al f r om t he pr emi ses. The Gover nment may al so char ge t he Cont r act or any addi t i onal cost of i nspect i on or t est when pr i or r ej ect i on makes r ei nspect i on or r et est i ng necessar y.

e. Submi t cer t i f i ed t est and i nspect i on r epor t s f or cr osst i es and swi t ch t i es subsequent t o t r eat ment , a mi ni mum of seven cal endar days pr i or t o any t i es bei ng i nst al l ed i n t r ack. Test and i nspect i on r epor t s shal l cont ai n t he i nf or mat i on r equi r ed by Par t 7 of AWPA M2. Submi t cer t i f i cat es of compl i ance pr i or t o any t i es bei ng i nst al l ed i n t r ack.

2. 7. 1 Cr osst i es

Wood cr osst i es shal l conf or m t o Chapt er 30, Par t 3 of AREMA Eng Man.

a. Wood cr osst i es except at r oad cr ossi ngs: Wood t i es shal l be sawed and shal l be not l ess t han 7 i nch t hi ck and 9 i nch wi de. The l engt h shal l be 8 f t 6 i n.

b. Wood cr osst i es at r oad cr ossi ngs: Wood t i es shal l be sawed and shal l not be l ess t han 7 i nch t hi ck and 9 i nch wi de. The l engt h shal l be 9 f t , unl ess r ecommended ot her wi se by t he manuf act ur er of cr ossi ng sur f ace mat er i al s.

2. 7. 2 Swi t ch Ti es

Swi t ch t i es shal l conf or m t o Chapt er 30, Par t 3 of AREMA Eng Man and shal l be sawed 7 i nch t hi ck and 9 i nch wi de. The l engt h and quant i t i es shal l be as shown.

2. 7. 3 Ti e Pl ugs

Ti e pl ugs shal l f i t hol es f r om whi ch spi kes ar e dr awn. The pl ugs shal l compl y and be t r eat ed i n accor dance wi t h Chapt er 30, Par t 3 Sect i on 3. 1. 5 of AREMA Eng Man.

2. 7. 4 Ant i - spl i t t i ng Devi ces

Cr osst i es and swi t ch t i es shal l be equi pped on each end wi t h gang nai l end pl at es ant i - spl i t t i ng devi ces of t he t ype speci f i ed, r egar dl ess of whet her or not t he wood has shown any t endency t o spl i t . Pr oduct s used shal l conf or m t o Chapt er 30, Par t 3 Sect i ons 3. 1. 6 and 3. 1. 7 of AREMA Eng Man.

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2. 8 TURNOUTS AND TRACK CROSSI NGS

The component par t s of t he t ur nout s t o be f ur ni shed shal l be t he pr oduct s of manuf act ur er s r egul ar l y engaged i n t he manuf act ur e of such pr oduct s, and shal l essent i al l y dupl i cat e i t ems t hat have been i n sat i sf act or y use at l east 5 year s pr i or t o bi d openi ng. The par t s need not al l be made by t he same manuf act ur er , but each t ur nout shal l be t he pr oduct of a s i ngl e f i r m. Swi t ch assembl i es, st ands, f r ogs, and guar dr ai l s assembl i es shal l conf or m t o t he r equi r ement s of AREMA Eng Man.

2. 8. 1 Rai l and Joi nt Bar s

Rai l , j oi nt bar s, and mi scel l aneous t r ack mat er i al s used i n t ur nout and t r ack cr ossi ng const r uct i on shal l be f ur ni shed and i nst al l ed as par t of t he compl et e t ur nout or cr ossi ng. Rai l and mi scel l aneous t r ack mat er i al s used i n t ur nout and t r ack cr ossi ng const r uct i on shal l be t he wei ght and sect i on shown on t he cont r act dr awi ngs.

2. 8. 2 Fr ogs, Swi t ches, Guar dr ai l s and Appur t enances

Fr ogs, swi t ches, guar dr ai l s and appur t enances shal l be mat er i al s sui t abl e f or use i n heavy t onnage mai n t r ack. Mat er i al s used i n t he t ur nout shal l be of t he same wei ght and sect i on. Mat er i al s shal l be i n good condi t i on and f r ee f r om excessi ve r ust , di r t , and ot her f or ei gn mat er i al s. The r ai l wei ght and sect i on shal l be as speci f i ed.

2. 8. 2. 1 Swi t ches

Swi t ches f or new t ur nout const r uct i on or compl et e t ur nout r epl acement shal l be 16 f eet and 6 i nches r ei nf or ced st r ai ght spl i t swi t ches wi t h gr aduat ed r i ser s gener al l y conf or mi ng t o AREMA Eng Man, Pl an Number 112.

a. Swi t ch poi nt s shal l be new. Swi t ch poi nt det ai l shal l be AREMA Eng Man, Pl an No. 221, Det ai l 4000 or 6100. One swi t ch poi nt i n each t ur nout shal l be manganese t i pped i n accor dance wi t h AREMA Eng Man, Pl an No.

220- 52- E- 82, i nst al l ed on t he si de opposi t e t he t ur nout s i de of t he swi t ch ( exampl e t he r i ght swi t ch poi nt shal l be manganese t i pped on a l ef t hand t ur nout ) .

b. Swi t ch r ods and connect i ng r ods shal l be new.

c. Gage pl at es, swi t ch pl at es, s l i de pl at es, and heel pl at es shal l be new. Rai l br aces shal l be ei t her r i gi d or adj ust abl e. For a gi ven t ur nout al l r ai l br aces shal l be of t he same desi gn.

d. Heel bl ocks shal l be ei t her cast or f or ged st eel and be new. New heel bl ock bol t assembl i es shal l be pr ovi ded and shal l be heat t r eat ed.

The heel j oi nt bar s shal l be new . I f f l oat i ng heel bl ocks ar e used, speci al no. 5 doubl e shoul der pl at es shal l be used t o mai nt ai n 6. 25 i nch heel spr ead.

2. 8. 2. 2 Fr ogs

Fr ogs shal l be r ai l bound manganese i n t he s i zes i ndi cat ed.

a. Fr ogs shal l be new. Cr acked or br oken used f r og cast i ngs shal l not be used. Cr acked or br oken f r og cast i ngs t hat have been r epai r ed by wel di ng ar e not accept abl e and shal l not be used.

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b. Fr og bol t s, nut s, l ock washer s, and headl ocks shal l al l be new.

2. 8. 2. 3 New Guar d Rai l s

New guar d r ai l s shal l be a mi ni mum of 15 f t i n l engt h. Guar d r ai l s shal l be of any of t he f ol l owi ng desi gns: Tee r ai l i n accor dance wi t h AREMA Eng Man, Pl an No. 504, sol i d manganese st eel i n accor dance wi t h AREMA Eng Man, Pl an No. 510, or an accept abl e hook f l ange desi gn. Guar d r ai l s bol t ed t o t he r unni ng r ai l s shal l be equi pped wi t h f i l l er s. Al l bol t s, nut s, and associ at ed har dwar e shal l be new. Cl amped guar d r ai l s shal l be equi pped wi t h bl ock wedges, f i l l er wedges, and cot t er keys.

Guar d r ai l pl at es shal l be new or accept abl e r epl acement s.

Si ngl e- shoul der t i e pl at es used wi t h guar d r ai l s shal l be i nst al l ed wi t h t he shoul der on t he i nsi de f l ush agai nst t he base of t he guar d r ai l .

2. 8. 2. 4 Hook Pl at es

Hook pl at es shal l be new and shal l be of t he desi gns and l engt hs i ndi cat ed on AREMA Eng Man, Pl an Nos. 112 and 241.

2. 8. 2. 5 Swi t ch St ands

a. New swi t ch st ands shal l conf or m t o AREMA Eng Man, Pl an 251- 64, l ow- st and t ype wi t h model number Bet hl ehem St eel model 51A. Swi t ch st and shal l be posi t i ve- act i on ( r i gi d) wi t h adj ust ment f r om t he t op wi t h shi ms t hr ough a moveabl e cover .

b. Exi st i ng swi t ch st ands, st af f s and t ar get s, wher e not desi gnat ed f or r epl acement , shal l be r econdi t i oned by c l eani ng t o bar e met al and t hen pai nt ed wi t h one coat of met al pr i mer . The i nt er i or por t i on of t he st ands, i ncl udi ng mechani sms, shal l be c l eaned and r e- l ubr i cat ed. The swi t ch st and st af f shal l be pai nt ed wi t h t wo coat s of bl ack enamel pai nt . Swi t ch t ar get s shal l be s i mi l ar l y pr epar ed and pai nt ed wi t h t wo coat s of r ed or whi t e enamel pai nt t o i ndi cat e swi t ch posi t i on i n accor dance wi t h nor mal r ai l r oad pr act i ce.

c. Each st and shal l be equi pped wi t h one of t he f ol l owi ng swi t ch l amps as i ndi cat ed on t he pr oj ect pl ans:

( 1) Ref l ect i ng Type: Appr oved r ef l ect i ng swi t ch l amps f i t t ed wi t h st andar d commer ci al - t ype doubl e r ed and whi t e r ef l ect i ng l enses but wi t hout day si gnal t ar get s.

( 2) Ref l ect i ng Type wi t h Dayl i ght Di sk: Appr oved r ef l ect i ng swi t ch l amps f i t t ed wi t h st andar d commer ci al - t ype doubl e r ed and whi t e r ef l ect i ng l enses, and wi t h day si gnal t ar get s.

( 3) I l l umi nat ed Type: Appr oved i l l umi nat ed l amps wi t h pr i mar y bat t er y, bat t er y housi ng, and cabl e.

2. 8 MI SCELLANEOUS TRACK MATERI ALS

Mi scel l aneous t r ack mat er i al s shal l be as f ol l ows:

2. 8. 1 Spi kes

2. 8. 1. 1 Tr ack Spi kes

Tr ack spi kes shal l be new and shal l conf or m t o Chapt er 5, Par t 2 of

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AREMA Eng Man. Tr ack spi kes s i ze 6 by 5/ 8 i nch shal l be used wi t h 100 l bs or heavi er r ai l .

2. 8. 2 Bol t s, Nut s, and Spr i ng Washer s

New t r ack bol t s, nut s, and spr i ng washer s shal l be used t hr oughout t he pr oj ect .

2. 8. 2. 1 Bol t s and Nut s

The var i ous r ai l , j oi nt bar s, and r ai l dr i l l i ngs r equi r e var i ous l engt hs and di amet er s of bol t assembl i es. Det er mi ne t he number of bol t assembl i es of each si ze r equi r ed. Al l bol t di amet er s shal l be t he l ar gest possi bl e f or a gi ven r ai l dr i l l i ng and j oi nt bar punchi ng. Tr ack bol t s and nut s shal l conf or m t o Chapt er 4, Par t 2 of AREMA Eng Man. Tr ack bol t s shal l be l ong enough t o l eave at l east t wo t hr eads exposed af t er t he nut i s t i ght ened.

2. 8. 2. 2 Spr i ng Washer s

Spr i ng washer s and nut s shal l be s i zed t o ensur e t hat t he spr i ng washer devel ops i t s f ul l r eact i ve f or ce and does not j am i nt o t he j oi nt bar hol e. Spr i ng washer s shal l be of t he s i ze t o f i t t he bol t and nut used and shal l conf or m t o Chapt er 4, Par t 2 and Sect i on M12 of AREMA Eng Man.

2. 8. 2. 3 Ti e Pl at es

Ti e pl at es wi t h an 8- hol e punch compat i bl e wi t h t he appr oved r ai l sect i on shal l be used on al l t i es, except i n t ur nout s and t r ack cr ossi ngs wher e speci al pl at es ar e r equi r ed. For al l j oi nt ed and wel ded r ai l sect i ons, doubl e shoul der t i e pl at es wi t h 1: 40 cant shal l be used. Ti e pl at es must be new.

2. 9 RAI L BONDI NG AND GROUNDI NG

2. 9. 1 Rai l Bonds

Rai l bonds shal l be exot her mi c t ype ( " Cadwel d" ) bonds appl i ed t o t he f i el d s i de of t he r ai l head, or 46 i nch bonds wel ded t o t he r ai l web. The bond cabl es shal l be f l exi bl e bar e copper st r anded 1/ 0 AWG cabl es wi t h pr ef or med ends. Bond cabl es shal l be f l exi bl e bar e copper st r anded cabl es wi t h pr ef or med ends and shal l conf or m t o appl i cabl e r equi r ement s of AREMA Eng Man Vol . 3.

2. 9. 2 Gr oundi ng Rods

Gr oundi ng r ods shal l be 3/ 4 i n di amet er copper c l ad st eel r ods .

2. 9. 3 Gr ound Connect i on Cabl es

Connect i ons bet ween t he gr oundi ng syst em or gr ound r ods and r ai l s shal l be made wi t h a bar e f l exi bl e copper st r anded 2/ 0 AWG cabl e.

2. 9. 4 El ect r i cal Connect i ng Har dwar e

El ect r i cal connect i ng har dwar e shal l be br onze pr essur e bar t ype mat er i al s havi ng no r ot at i ng par t s comi ng i n di r ect cont act wi t h conduct or s.

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2. 10 WELDI NG

2. 10. 1 Rai l Wel di ng Ki t s

Ki t s f or t her mi t e t ype r ai l wel ds shal l be appr oved by t he Cont r act i ng Of f i cer bef or e use. Pr ovi de wel di ng ki t s f or al l r ai l sect i ons used and no di f f er ent i at i on wi l l be made bet ween Cont r act or - f ur ni shed and Gover nment - f ur ni shed ( exi st i ng or sal vaged) r ai l sect i ons f or measur ement and payment pur poses.

2. 10. 2 El ect r odes

Pr ovi de AWS l ow- hydr ogen, hi gh t ensi l e 140- 16 ( ext r apol at i on) or 25- 20 el ect r ode, Gr ade 310- 16 and 310- 15 st ai nl ess st eel r od wel di ng el ect r odes. Pr ovi de el ect r odes of t he smal l est pr act i cal di amet er wor ked at t he l owest compat i bl e cur r ent . Coat i ng on l ow- hydr ogen t ype el ect r odes shal l be t hor oughl y dr y when t he el ect r ode i s pr ovi ded. Use el ect r odes t aken f r om her met i cal l y seal ed packages wi t hi n one hour of t he t i me t he package i s opened. El ect r odes not used wi t hi n t hi s one- hour per i od and el ect r odes t aken f r om non- her met i cal l y seal ed packages shal l be dr i ed f or at l east one hour bet ween 700 and 800 degr ees F. El ect r odes so dr i ed may be st or ed at t emper at ur es bet ween 225 and 400 degr ees F unt i l used, or , i f not st or ed and not used wi t hi n one hour af t er t hi s dr yi ng i s compl et ed, shal l be r e- dr i ed bef or e use. Do not use el ect r odes whi ch have been wet .

2. 11 WELDABLE, ADJUSTABLE RAI L CLI PS

Pr ovi de wel dabl e, adj ust abl e r ai l c l i ps s i zed f or 115# r ai l sect i on.

Pr ovi de r ai l c l i ps made by a manuf act ur er cur r ent l y manuf act ur i ng cr ane r ai l c l i ps. Rai l c l i ps shal l be f or ged st eel whi ch can be wel ded di r ect l y t o st r uct ur al st eel . Rai l c l i p bol t s must conf or m t o ASTM F3125/ F3125M, Gr ade A325. Pr ovi de r ai l c l i ps desi gned t o al l ow r ai l r emoval wi t hout t he r emoval of t he wel ded por t i on of t he r ai l c l i p.

2. 12 FOUNDATI ON MATERI ALS

2. 12. 1 Base Pl at es

ASTM A36/ A36M or ASTM A283/ A283M. Shape pl at es t o conf or m t o t he conf i gur at i on of r ai l cur vat ur e and t o each speci al f i t t i ng. Mi ni mum wi dt h of pl at es under r ai l s must be 12 i nches. Mi ni mum l engt h of pl at es must be 5 f eet and maxi mum l engt h 10 f eet . Mi ni mum edge di st ance f or hol es as i ndi cat ed. Pr ovi de 1 1/ 8 i nch di amet er anchor bol t hol es, f i el d or shop f abr i cat ed. Pr ovi de gr out i ng hol es 2 i nches i n di amet er i n pl at es wi der t han 3 f eet or as r equi r ed. Cent er gr out hol es, spaced appr oxi mat el y 2 f eet apar t , and l ocat e so as not t o i nt er f er e wi t h t he pr oper f unct i on of t he pl at e.

2. 12. 2 Anchor Bol t s

ASTM A183, squar e head 1 i nchdi amet er st eel . Pr ovi de each bol t wi t h t wo f i ni shed hexagon nut s and one spr i ng washer . Pr ovi de bol t t hr eads conf or mi ng t o ASME B18. 2. 1, and nut s and t hr eads t o ASME B18. 2. 2. For bol t s f ast ened t o exi st i ng gr ade beams det er mi ne l engt hs i n t he f i el d af t er t he el evat i on of t he concr et e suppor t beams has been det er mi ned and t he f i ni shed pr of i l e gr ade f r om t he dr awi ngs has been t aken i nt o consi der at i on.

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2. 12. 3 Epoxy Gr out Pad

Pr ovi de epoxy gr out under base pl at es as i ndi cat ed. Pr ovi de hi gh ear l y st r engt h, epoxy gr out , wi t h manuf act ur ed appr oved aggr egat es so as t o pr ovi de a 7- day compr essi ve st r engt h of not l ess t han 13, 000 psi as det er mi ned by ASTM C579, a t ensi l e st r engt h of 2, 000 psi as det er mi ned by ASTM C307 by ASTM C157/ C157M. Af t er i nst al l at i on, cur e t he gr out a mi ni mum of 3 days i n accor dance wi t h t he cur i ng r equi r ement s as r ecommended by t he manuf act ur er .

2. 12. 4 Adhesi ve f or Anchor Bol t s

ASTM C881/ C881M, t wo component , Type 1 and I V, Gr ade 3, Cl ass C. Pr ovi de adhesi ve f or cor ed anchor bol t hol es i n exi st i ng concr et e gr ade beams.

2. 12. 5 Por t l and Cement Concr et e

Pr ovi de concr et e f or f l angeways, gr ade beams and encasement s conf or mi ng t o Sect i on 03 30 00 CAST- I N- PLACE CONCRETE.

PART 3 EXECUTI ON

3. 1 REMOVAL AND DI SPOSI TI ON OF MATERI ALS

Tr acks and segment s of t r ack shal l not be di smant l ed unt i l appr oved by t he Cont r act i ng Of f i cer t o do so. Some of t hese i t ems wi l l be used i n t he r epai r of t r acks as i ndi cat ed.

3. 1. 1 Mat er i al t o be Scr apped

Al l mat er i al shal l be scr apped and shal l become t he pr oper t y of t he Cont r act or .

3. 2 PLACEMENT OF BALLAST

Bal l ast shal l be pl aced t o t he l i nes and gr ades i ndi cat ed. The aver age t hi ckness shal l be wi t hi n 0. 25 i nch of t he t hi ckness shown on t he dr awi ngs Subgr ade shal l conf or m t o t he r equi r ement s of Sect i on 31 23 00. 00 22 EXCAVATI ON AND FI LL. Bal l ast shal l not be pl aced on sof t , muddy, or f r ozen ar eas. Wher e t he pr epar ed subgr ade ( r oadbed) i s sof t , muddy, r ut t ed, exhi bi t s sever e depr essi ons, or i s ot her wi se damaged, t he bal l ast shal l not be pl aced unt i l t he damaged subgr ade has been r epai r ed and t he ar ea has been appr oved by t he Cont r act i ng Of f i cer .

3. 2. 1 Bal l ast

3. 2. 1. 1 Bal l ast Pl acement

Number 4A AREMA bal l ast shal l be pl aced wher e i ndi cat ed.

3. 2. 1. 2 Bal l ast Di st r i but i on

Bal l ast shal l not be di st r i but ed unt i l t he subgr ade has been appr oved by t he Cont r act i ng Of f i cer . No payment wi l l be made f or bal l ast whi ch i s di st r i but ed wi t hout t he Cont r act i ng Of f i cer ' s appr oval .

a. Bal l ast di st r i but i on shal l be t o t he dept h i ndi cat ed.

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3. 2. 1. 3 Bal l ast Bel ow Ti es

For new const r uct i on, t he l ast 4 i nches of bal l ast bel ow t he t i e, t he shoul der bal l ast and t he bal l ast i n t he t i e cr i bs shal l be pl aced subsequent t o t he r ai l and t i e i nst al l at i on.

3. 3 TRACK CONSTRUCTI ON

Tr ack const r uct i on not cover ed speci f i cal l y her ei n shal l be i n accor dance wi t h AREMA r ecommendat i ons and r ecommended pr act i ces.

3. 3. 1 Unl oadi ng t he Mat er i al s

The use of pi cks i n t he handl i ng of t i es wi l l not be per mi t t ed. Rai l s shal l be unl oaded f r om car s wi t h an appr oved der r i ck or cr ane and pl aced wi t h t he head up wi t hout dr oppi ng and wi t h suf f i c i ent suppor t under t he base. Rai l s of pr oper l engt h shal l be di st r i but ed as necessar y f or r oad cr ossi ngs, swi t ches, j oi nt spaci ng, and ot her speci al condi t i ons.

3. 3. 2 Ti es

St andar d cent er - t o- cent er spaci ng of cr osst i es shal l be 24 i nches, unl ess ot her wi se not ed. Ti es shal l be l ai d per pendi cul ar t o t he cent er l i ne of t he t r ack wi t h t he gr ai n up ( hear t wood si de down) f or wood t i es. The best t i es shal l be used at t he r ai l j oi nt s. The ends of t i es on one si de of t he t r ack shal l be par al l el t o t he r ai l and t he cent er of t he t i e shal l be on t he appr oxi mat e cent er l i ne of t he t r ack. The ends shal l be al i gned on t he i nsi de of cur ves and shal l cont i nue on t hat s i de unt i l r eachi ng a cur ve i n t he opposi t e di r ect i on. The t op sur f ace of t i es shal l pr ovi de f ul l bear i ng f or t he t i e pl at es. Adzi ng of wood t i es shal l be r est r i ct ed t o t hat necessar y t o pr ovi de a sound t r ue bear i ng f or t he t i e pl at e.

Adzi ng i n excess of 0. 2 i nch wi l l not be per mi t t ed. Wher e adzi ng i s necessar y, t he cut sur f ace of t he wood t i e shal l be compl et el y sat ur at ed wi t h cr eosot e or ot her appr oved pr eser vat i ves.

3. 3. 3 Ti e Pl at es

Tr acks shal l be f ul l y t i e- pl at ed. Ti e pl at es shal l be f r ee of di r t and ot her f or ei gn mat er i al when i nst al l ed. Ti e pl at es shal l be pl aced so t hat t he r ai l s wi l l have f ul l bear i ng on t he pl at e, and t he pl at e wi l l have f ul l bear i ng on t he t i e. Ti e pl at es shal l be set at r i ght angl es t o t he r ai l wi t h t he out si de shoul der agai nst t he base of t he r ai l , and cent er ed on t he t i e. Cant ed t i e pl at es shal l be i nst al l ed t o cant t he r ai l i nwar d.

3. 3. 4 Rai l

The base of t he r ai l and t he sur f ace of t he t i e and t i e pl at e or bear i ng ar ea shal l be f r ee of di r t and ot her f or ei gn mat er i al s pr i or t o l ayi ng r ai l .

3. 3. 4. 1 Layi ng Rai l

Rai l shal l be l ai d wi t hout bumpi ng or st r i k i ng, t o st andar d gage 4 f t 8- 1/ 2 i nch bet ween poi nt s 5/ 8 i nch bel ow t he t op of t he r ai l on t angent s and on cur ves up t o 12 degr ees. For cur ves 12 degr ees and gr eat er , t he gage shal l be wi dened 1/ 8 i n f or each i ncr ement of 2 degr ees t o a maxi mum of 4 f t 9 i nch, i n accor dance wi t h TABLE V. The t r ack shal l be gaged at ever y t hi r d t i e.

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TABLE V. TRACK GAGE FOR HI GH DEGREE OF CURVATURE

Degr ee of Cur vat ur e per 100- f t chor d

Equal t o or Gr eat er Than ( Deg - Mi n)

But Less Than ( Deg - Mi n) Tr ack Gage, Ft . - I n.

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

3. 3. 4. 2 Joi nt s

Wel d r ai l j oi nt s, except t hose j oi nt at f r ogs, swi t ches, and expansi on j oi nt s. The wel di ng t oget her of r ai l s whi ch have been bor ed f or bol t ed j oi nt s i s not per mi t t ed. Cl ean r ai l s of f or ei gn subst ances pr i or t o wel di ng. Do not wel d when t he r ai l t emper at ur e i s l ower t han t hat r ecommended f or t he wel di ng met hod used. Wel di ng shal l be per f or med i n accor dance wi t h Sect i on 34 11 19. 00 20 WELDI NG CRANE AND RAI LROAD RAI L -

THERMI TE METHOD.

The j oi nt s i n opposi t e r ai l s shal l be st agger ed one- hal f t he r ai l l engt h but not l ess t han 12 f t apar t , except c l oser j oi nt s may be r equi r ed at t ur nout s. Rai l l ess t han 13 f t i n l engt h shal l not be i nst al l ed i n t r ack. No j oi nt shal l be l ess t han 6 f t f r om t he ends of t r ansi t i on s l abs, or l ess t han 3 f t f r om swi t ch poi nt s. No j oi nt shal l be i nst al l ed wi t hi n 20 f t of a out er per i met er of any st r uct ur e, or any l ocat i on whi ch r est r i ct s access t o t he j oi nt .

3. 3. 4. 3 Cut t i ng Rai l

Onl y r ai l saws or abr asi ve cut t i ng wheel s shal l be used t o cut r ai l .

Ot her met hods f or cut t i ng r ai l ar e not accept abl e. Cut s shal l be squar e and cl ean. When hol es ar e necessar y, t hey shal l be dr i l l ed usi ng a st andar d t empl at e. Hol es shal l not be punched, s l ot t ed, or bur ned wi t h a t or ch. When dr i l l i ng of r ai l i s necessar y, al l chi ps and bur r s shal l be r emoved bef or e appl y i ng j oi nt s.

3. 3. 5 Joi nt Bar s

Joi nt bar s shal l be c l ean. Rai l j oi nt s shal l be i nst al l ed so t hat bar s ar e not cocked bet ween t he base and head of t he r ai l . Bar s shal l be pr oper l y seat ed i n t he r ai l and t he f ul l number of cor r ect - s i ze bol t s, nut s, and spr i ng washer s i nst al l ed. Bol t s shal l be pl aced wi t h nut s al t er nat el y on i nsi de and out si de of r ai l . A cor r osi on r esi st ant l ubr i cant shal l be appl i ed t o t he bol t t hr eads pr i or t o appl i cat i on of nut s. Bol t s shal l be t i ght ened t o t or que of appr oxi mat el y 30, 000 f t - l bs, begi nni ng at t he cent er of t he j oi nt and wor ki ng bot h ways t o t he ends of t he j oi nt . Af t er t he t r ack has been i n ser vi ce al l bol t s shal l be checked and r et i ght ened t o a t or que of appr oxi mat el y 25, 000 f t - l bs.

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3. 3. 6 Anchor Bol t s

Pr ovi de pai r s of anchor bol t s f or connect i on of r ai l c l i ps and r ai l s t o base pl at e and suppor t i ng gr ade beam. At t r ack f i t t i ngs, pr ovi de separ at e gr oups of anchor bol t s f or connect i on of f i t t i ngs t o base pl at e and t o suppor t i ng gr ade beam. Cast anchor bol t s i nt o concr et e beams or s l abs as i ndi cat ed. Ti ght en anchor bol t nut s t o snug t i ght usi ng t he ef f or t of an or di nar y man wi t h a 6' - 0" spud wr ench. Ti ght en bol t s f or r ai l c l i ps as r ecommended by t he r ai l c l i p manuf act ur er . Make l ongi t udi nal spaci ng as i ndi cat ed.

3. 3. 7 Base Pl at es

I nst al l as i ndi cat ed and as speci f i ed her ei n. I nst al l base pl at es t o suppor t r ai l , swi t ches, f r ogs, and t hr ow mechani sm housi ngs. Shape base pl at es, as necessar y, under swi t ches and f r ogs. Fur ni sh pl at es wi t h anchor bol t hol es l ocat ed and dr i l l ed i n f i el d or shop f abr i cat ed; use as t empl at e f or set t i ng anchor bol t s. Do not enl ar ge bol t hol es i n t he f i el d. Do not t or ch, cut hol es. Pr ovi de f i ni shed pl at e f r ee of bows, bends, and l i ps, and cl eaned of gr ease and oi l . Af t er i nst al l at i on of r ai l , ver t i cal l y al i gn base pl at es t o wi t hi n pl us or mi nus 1/ 8 i nch of t he pr of i l e gr ade el evat i on i ndi cat ed by adj ust ment of base l evel i ng nut and washer under neat h pl at es. Af t er i nst al l at i on, check t o ensur e pr oper gr ade and al i gnment of t he base pl at es and i nst al l t empor ar y hol d- down nut s bef or e gr out i ng wi t h epoxy gr out . Af t er gr out has har dened, and wi t h r ai l c l i ps, r ai l , and f i t t i ngs i n pl ace, t i ght en anchor bol t nut s t o snug t i ght usi ng t he ef f or t of an or di nar y man wi t h a 6' - 0" spud wr ench.

3. 3. 7. 1 Base Pl at e Gr out i ng Mock- up

Pr ovi de i n t he f i el d or at t he cont r act or s shop a base pl at e gr out i ng mock- up demonst r at i ng t he pr ocedur e t o be used dur i ng epoxy gr out i ng of t he base pl at e.