Table C - Appendix # 8 – SOW, Concrete Ties & Rail Material.pdf

Maryland Department of Transportation (MDOT)

Maryland Transit Administration (MTA)

LIGHT RAIL

PROCUREMENT

OF

CONCRETE CROSS TIES & RAIL FASTENINGS

IFB LR271001 - Concrete Ties & Rail Material

Table D – Exhibit # 4

SOW – Concrete Ties & Rail Material

Revised September, 2026

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS TOC-1

MARYLAND TRANSIT ADMINISTRATION

LIGHT RAIL

PROCUREMENT

OF

CONCRETE CROSS TIES & RAIL FASTENINGS

TABLE OF CONTENTS

DESCRIPTION PAGE NO.

SPECIFICATIONS

SUMMARY OF WORK SP-1

SUBMITTALS SP-3

QUALITY ASSURANCE AND QUALITY CONTROL SP-6

CONCRETE CROSS TIES & RAIL FASTENERS SP-12

APPENDIX

STANDARD CONCRETE TIE

RESTRAINING RAIL CONCRETE TIE

LIGHT RAIL VEHICLE:

DYNAMIC ENVELOPE

WHEEL DIMENSIONS AND PROFILE

VEHICLE WEIGHT

STRUCTURAL LOADING

SUMMARY OF WORK 3

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-3

SUMMARY OF WORK

PART 1: GENERAL

1.01 GENERAL

A. Wherever these Specifications refer to the Administration, they shall be understood to mean the Maryland Transit Administration (MTA).

B. The work shall be performed in accordance with the following documents:

1. Manual for Railway Engineering, American Railway Engineering and Maintenance of Way Association (AREMA).

2. These Specifications

1.02 DESCRIPTION

A. This Procurement is for the manufacture and delivery of new Concrete

Cross Ties with rail fastenings for replacement of damaged ties on designated Light Rail ballasted track.

B. The drawings of a typical standard concrete cross tie and a restraining rail concrete cross tie in the Appendix show the required measurements and geometry of the new ties. Each tie shall be supplied with screw-type rail fasteners comprised of rail pads, cast insulated inserts, guide plates, lag screws with washers, and compression clamps conforming to the requirements specified.

C. The Contractor shall provide the necessary labor, equipment, tools, and testing equipment to manufacture and deliver the ties to the

Administration.

D. The Contractor also shall provide 60 Orgo-Thermit rail welding kits consisting of a degradable crucible with cap, thermit portion molds, diverging plug, 10-pound bag of luting sand, and an igniter.

E. The restraining rail concrete ties provided shall be compatible with tie anchor system provided in appendix.

1.03 COMPLETION TIME AND DELIVERY SCHEDULE

A. Commence work on or before the date specified in the Notice to Proceed

(NTP) and complete the specified portions of the work within the timeframe specified in the table below.

Delivery of Materials Duration from NTP

1,000 Concrete Cross Ties with specified accessories

60 Orgo-thermit rail welding kits

240 CD

SUMMARY OF WORK 4

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-4

1.04 DELIVERY AND HANDLING:

A. Notify the Administration at least 30 days before scheduled day(s) for delivery of materials to the MTA Cromwell Light Rail Maintenance

Facility located at 7390 Baltimore/Annapolis Blvd., Glen Burnie, Maryland 21217.

B. Coordinate delivery arrangements with Acting Superintendent, Light Rail

Maintenance of Way at

Donald Martin Jr, Acting Superintendent MOW

(301) 366 6331 DMartin6@mdot.maryland.gov

C. Contract materials shall be handled, shipped and unloaded with special care to avoid damage. Damaged Contract materials noted during final inspection shall be replaced in accordance with the schedule specified above, to avoid any delays in the scheduled installations of these materials by others.

mailto:DMartin6@mdot.maryland.gov

SUBMITTALS 1

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-5

1.01 DESCRIPTION

SUBMITTALS

PART 1: GENERAL

A. This Section specifies the general requirements and procedures for preparing and transmitting data to the Administration for informational purposes or for approval. This Section includes:

1. Shop Drawings

2. Product Data

3. Sources of Supply and Samples

4. Manufacturers' Instructions

5. Manufacturers' Certificates

1.02 CONTRACTOR'S SUBMITTALS:

A. General:

1. The Drawings in the Appendix show the general arrangement and such details as are necessary to provide a comprehensive description of the work to be performed.

2. The Contractor shall prepare such Shop and Working Drawings as are necessary to adequately plan and perform the work.

3. Unless noted otherwise, all Contractor submittals shall be made in electronic (.pdf) format.

4. All Shop and Working Drawings shall be formatted to produce printed sheets measuring 11 inches by 17 inches. Each drawing shall have a blank area five inches by five inches adjacent to the title block to provide space for Contractor and Authority review stamps. The title block shall display the following:

a. Contract Number and Name

b. Number and Title of the Drawing

c. Date of Drawing or revision

d. Name of Contractor and Subcontractor submitting drawing

e. Clear identification of contents and location of work

5. A Contractor's transmittal letter shall accompany each individual submittal. The Contractor's transmittal letter and submittal shall be

SUBMITTALS 2

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consecutively numbered and shall clearly and completely describe any variation from the contract requirements.

6. A sequential number shall be shown on each Shop or Working

Drawing submission. Re-submittals will be followed by a revision letter (A, B, C, etc.) and handled in the same manner as first submitted.

7. Submittals not conforming to the requirements of this specification shall be summarily rejected.

8. Review and Acceptance shall not relieve the Contractor from his responsibility for accuracy of submittals, for conformity of submittals to requirements of Contract Drawings and

Specifications, for compatibility of the described product with contiguous products and the rest of the system, or for protection of completion of the Contract in accordance with the Contract

Drawings and Specifications.

9. The Administration’s review, correction and acceptance of submittals shall not relieve the Contractor of responsibility for errors and omissions in submittals and associated calculations.

10. The Contractor's liability to the Administration, in case of deviations in the submittals from requirements of the Contract

Documents, is not relieved by the Administration's review and acceptance of submittals containing deviations unless the

Administration expressly approves the deviation through the issuance of a contract change order.

11. If the material/equipment/components proposed to be used do not conform to the stipulated standards, the Contractor shall submit the copies of the conforming standards highlighting the deviations from the stipulated standards. The impact of the derivations on cost and performance shall be brought out in the related submittal and the deviation request.

12. Schedule submittals to expedite the delivery to the Administration.

Coordinate submission of related items.

1.03 PRODUCT DATA:

A. Submit an electronic copy of information for the following products to be furnished by the Contractor:

1. Monoblock Concrete Tie

2. Monoblock Restraining Rail Concrete Tie

SUBMITTALS 3

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3. Tension Clamp

4. Threaded inserts

5. Elastomeric rail seat pads

6. Angled guide plates

7. Lag screws and washers

8. Orgo-Thermit Weld Kit

1.04 SOURCE OF SUPPLY:

A. As soon as practicable after Notice to Proceed, furnish for approval of the

Engineer the proposed source of supply of materials to be utilized in the project.

B. Label each product indicating:

1. Name of Project and Contract Number

2. Name of Contractor and Subcontractor

3. Material or equipment represented

4. Source

C. Approval of a product shall be only for characteristics or use named in such approval and shall not be construed to change or modify any Contract requirements.

1.05 MANUFACTURERS' INSTRUCTIONS:

A. When specified in individual Specification Sections, submit manufacturers printed instructions for delivery, storage, assembly, installation, start-up, adjusting, and finishing, in quantities specified for

Product Data.

B. Identify conflicts between manufacturers' instructions and Contract

Specifications.

1.06 MANUFACTURERS' CERTIFICATES:

A. Submit manufacturers' certificate to the Administration for review, in quantities specified for Product Data.

B. Indicate where material or product conforms to or exceeds specified requirements. Submit supporting reference date, affidavits, and certifications as appropriate.

C. Certificates may be recent or previous test results for Material or Product, but must be acceptable to the Administration.

QUALITY ASSURANCE AND QUALITY CONTROL 1

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-8

QUALITY ASSURANCE AND QUALITY CONTROL

PART 1: GENERAL

1.01 DESCRIPTION:

A. This Section specifies the general Quality Assurance/Quality Control

(QA/QC) requirements for the following:

1. Quality Assurance/Quality Control (QA/QC) Plan

2. Calibration and Certification

3. Inspection and Tests

4. Handling and Delivery

5. Testing

6. Test Reports

7. Certificates of Compliance

B. Related Work Specified Elsewhere:

1. Section – Summary of Work

2. Section – Submittals

3. Section – Concrete Cross Ties & Rail Fastenings

1.02 QUALITY ASSURANCE/QUALITY CONTROL PLAN:

A. Develop and maintain a quality assurance/quality control plan for regulating the methods, procedures, and processes for the design and manufacture of restraining rail concrete ties to ensure compliance with the standards of quality required by these Purchase Order documents.

B. Within fifteen (15) calendar days after the issuance of the Notice to

Proceed, the Contractor shall submit a detailed QA/QC Plan to the

Administration for approval. The detailed plan shall cover all work to be performed under the Contract and define the following:

1. The Contractors’ on-site organization chart including a quality control organization showing the proposed QC Plan Manager and staff.

2. Authority, duties and responsibilities of quality control personnel.

A copy of the letter of direction to the Contractor’s representative and QC staff, which defines their duties, responsibilities, and delegated authorities, shall be provided to the Administration.

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3. Operational procedures for accomplishing and reviewing work, supervision, inspection, tests, certifications, documentation of

QA/QC activities, including those of subcontractors for all on-site and off-site work under the contract.

4. Inspection and test records shall include, but not limited to, the factual evidence that tests have been made, the applicable type and number of tests, the dates and results of the tests, nature and number of observations made, the number and type of deficiencies found and proposed corrective actions to be taken. All records shall provide identification and signature of the individual in charge of the inspection, test, or other QA/QC activity. These records shall be certified by the QA/QC Manager and include, as a minimum, the results of:

a. Inspection results, observations, conclusions and recommendations.

b. Testing with reference to set-up conditions, observations and concerns.

c. Fabrication procedures and controls.

d. Identity of the Personnel present and their certification.

e. Discrepant material details (including disposition records).

5. Inspection to be performed by the QC Staff for all definable items of work during following phases.

a. Preparatory inspections shall be performed prior to beginning of each item of work and shall include a review of specified requirements and QA/QC Plan test and inspection schedule mentioned above.

b. Initial inspections shall be performed as soon as a representative portion of the work has been accomplished.

Initial inspections shall verify compliance with specified requirements, establish acceptable levels of quality and workmanship, review quality control testing and confirm that defective, damaged or unapproved materials are not incorporated into the work.

c. Follow-up inspections shall be performed regularly by QC

Staff to assure continued compliance with the Purchase

Order requirements and established levels of quality and workmanship.

6. The QA/QC Plan shall provide well-defined procedures and forms to include, but not limited to the following:

QUALITY ASSURANCE AND QUALITY CONTROL 3

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-

a. Identifying and evaluating quality-related problems.

b. Recommending solutions to quality-related problems and verifying that those problems are resolved.

c. Controlling further fabrication, delivery, or installation of nonconforming or deficient item(s) until disposition instructions have been obtained.

d. Conducting quality inspections, surveillance and compliance audits of subcontractors, suppliers/manufacturers on a scheduled basis.

e. Maintaining quality control reports, approved shop drawings and submittals, as-built drawings, changes to the drawings and specifications.

7. The QA/QC Plan shall also provide written procedures to include, but not be limited to:

a. Control of subcontractors, manufacturers /suppliers.

b. Production and process quality control.

c. Discrepant and nonconforming material control.

d. Functional testing.

e. Calibration and/or certification of Measuring and Test equipment.

f. Shipping and receiving inspection of materials.

8. Approval of the Contractor’s QA/QC Plan shall not relieve the

Contractor of its responsibility to comply with the Purchase Order requirements. The QA/QC Plan shall be revised or updated as directed by the Administration. No additional cost or time extensions will be allowed for the Contractor’s re-submission of rejected QA/QC Plans or for revising or updating of the QA/QC

Plan during the course of the Contract, as directed by the

Administration.

1.03 CALIBRATION AND CERTIFICATION:

A. The QA/QC Plan shall include the procedures to provide and maintain gauges; measuring devices and test equipment necessary to assure that the article conforms to Purchase Order requirements. These devices shall be calibrated in accordance with national standards and certifications.

Calibration certificates shall be maintained current and submitted to the

Administration. Any equipment exceeding its required re-calibration date or that becomes damaged or otherwise unreliable, shall be isolated, tagged

QUALITY ASSURANCE AND QUALITY CONTROL 5

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-11

or marked to prevent its use without written permission of the

Administration.

1.04 INSPECTION AND TESTS:

A. The QA/QC Plan shall include methods for ensuring that all required inspections and tests are performed and that the status of each work product, material item’s inspections/tests is known. Identify nonconforming work product and material items by physical segregation and status indicators such as tags, markings, serialization, stamps, and/or inspection records. The identification system used shall ensure that only those work items that have passed inspection shall be used, shipped, or installed. The nonconforming work product and material items shall be removed from the project site and storage areas as soon as possible.

B. Work products, materials and/or equipment manufactured or assembled under this Contract shall be accepted for use or released for shipment, as appropriate, when the following conditions(s) have been met.

1. After release by the Administration and/or certification by the

Contractor that the work product or material item is complete and in compliance with the Specifications.

2. Upon request for acceptance or a release for shipment submitted by the Contractor and supported by a satisfactory inspection report or certification of compliance accompanied by certified copies of test data. The certificate of compliance shall clearly identify the work product or material item covered by the certificate and shall also contain the test date and the name and address of the organization performing the require tests, as applicable.

C. Supplies, services, materials, and products procured from suppliers and subcontractors shall conform to the Purchase Order requirements and the approved QA/QC Plan. Inspect all supplies, materials, services, and products upon receipt.

1.05 HANDLING AND DELIVERY:

A. The QA/QC Plan shall ensure that proper instructions are provided and followed for handling, preservation, packaging, and shipping to protect the quality of products and to prevent damage, loss, deterioration, degradation, or substitution of products. The Contractor shall provide for any necessary protection against deterioration or damage to products in storage and handling.

1.06 TESTING:

A. The quality control testing is the testing of specific work product or materials during placement, as specified in the various sections of the

QUALITY ASSURANCE AND QUALITY CONTROL 5

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-12

specifications to ensure compliance with the Purchase Order Documents.

The Contractor shall assume full responsibility for control testing at the expense of the Contractor and shall be performed by a certified independent testing laboratory that has been approved by the

Administration.

B. The Contractor shall submit the name, address, and qualifications together with the scope of proposed services of the proposed testing firm or individual to the Administration for approval at least thirty (30) days prior to the scheduled commencement of any work involving such testing.

Should the Contractor desire to use more than one firm for control testing, the required information shall be submitted for each proposed firm as specified herein.

C. The Contractor shall be responsible for furnishing all accessories, tools necessary to prepare and preserve the test samples as prescribed and delivering them to the approved testing laboratory.

D. The Contractor shall perform all quality control testing and furnish all equipment, instruments, qualified personnel and facilities necessary to perform all tests required by the Purchase Order. All tests performed, and test results for each day shall be recorded in a daily report. These records shall remain complete and available to the Administration at all times during the performance of the work and for a three-year period thereafter.

Test records shall indicate the reference test, nature and number of observations made, and the number and type of deficiencies found.

1.07 TEST REPORTS:

A. Within five days after completion of testing performed by or for the

Contractor, submit an electronic copy of certified test results to the

Administration. Indicate the name and address of the organization performing the test, and the date of the tests.

1.08 CERTIFICATES OF COMPLIANCE:

A. The Contractor may use certificates of compliance for certain materials and products in lieu of the specified sampling and testing procedures.

Submit any certificate required for demonstrating proof of compliance of materials with specification requirements in duplicate with each lot of material delivered to the Administration. The lot so certified shall be clearly identified by the certificate. Certificates shall be signed by an authorized representative of the producer or manufacturer and state that the material complies in all respects with the Purchase Order requirements.

QUALITY ASSURANCE AND QUALITY CONTROL 6

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-13

B. Materials used on the basis of a certificate of compliance may be sampled and tested at any time. The fact that material is used on the basis of a certificate of compliance shall not relieve the Contractor of responsibility for incorporating material in the work which conforms to the requirements of the Purchase Order and any such material not conforming to such requirements will be subject to rejection, whether in place or not.

C. The Administration reserves the right to refuse to permit the use of certain materials / supplies on the basis of a certificate of compliance.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-14

1.1 RELATED DOCUMENTS

1. Plans and general provisions of the Contract, including General Provisions for

Construction Contracts and Supplementary General Provisions for Construction

Contracts.

1.2 SUMMARY

1. This Section includes specifications for the design, manufacture, testing, and handling of prestressed concrete cross ties and rail fastenings for installation in standard ballasted track and restraining rail concrete ties for ballasted track within designated restraining rail curves.

2. Related Requirements:

a) Section – Submittals

b) Section – Quality Assurance and Quality Control

1.3 REFERENCES

1. For additional references, refer to the General Provisions and Supplementary

Provisions.

2. Abbreviations and Acronyms:

ASTM: American Society for Testing and Materials

AASHTO: American Association of State Highway and Transportation Officials

ACI: American Concrete Institute

PCI: Precast Concrete Institute

AREMA: American Railway Engineering and Maintenance-of-Way Association

American Railway Engineering and Maintenance-of-Way Association Manual for

Railway Engineering, AREMA Manual, Chapter 30, Part 4, Concrete Ties

American Railway Engineering and Maintenance-of-Way Association Manual for

Railway Engineering, AREMA Manual, Chapter 8, Section 1.4

1.4 ACTION/INFORMATIONAL SUBMITTALS

1. Submit the following not later than 30 days after NTP:

a. Shop drawings for the concrete ties and restraining rail ties, including all dimensions, and the size and layout of the steel prestressing tendons, embedded clip shoulders and anchor inserts, and other associated parts specified in this

Section.

b. Structural calculations from the manufacturer including bending moment analysis and other criteria of ACI Standard 318, Chapters 8 and 9 and

AREMA Manual - Volume 1, Chapter 30, Section 4.4.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-15

c. Concrete mix design, including description and chemical composition of all materials and admixtures. Provide sources and gradations of aggregates.

d. Fabrication plan describing the tie manufacturing process.

e. Tie-marking scheme for identification of concrete ties.

f. Quality Control Program for monitoring the production, including manufacturing control test procedures and tests specified herein.

g. Letter stating that the concrete tie manufacturer is currently certified in PCI's

Plant Certification Program or will be certified before production of ties for this Contract.

2. Submit the following not later than 30 days prior to delivery:

a. Schedule of the work, including design, shop drawing submittals, design testing, manufacturing of each component, in-plant inspections, and shipment.

b. Methods of handling, shipping, and stacking of ties.

3. Submit the following not later than 30 days after completion of tests:

a. Test reports for all specified design tests.

b. Test reports of all control tests conducted during manufacturing and all other required test documentation.

1.5 DELIVERY, STORAGE AND HANDLING

1. The Contractor will be responsible for furnishing, handling, and delivery of ties to the area as designated by the Light Rail Superintendent, Maintenance of Way.

2. Shipping and Handling:

a. Do not preassemble rail fasteners, rail support pads or contact rail support plates on ties. Package these items separately for shipment. Securely insert protective plastic caps or plugs in all open anchor inserts before shipment. The plugs/caps shall be threaded or similarly designed to prevent loosening or falling out during shipment of handling.

b. Securely brace ties for shipment to prevent any movement that could cause damage. Ship ties in a horizontal position, braced with wooden spacer blocks so that the top surface of cast-in-place hardware does not contact ties loaded above. Place vibration, weather and abrasion resistant separating sheets or other dunnage between separate stacks of ties and at each end of each stack, to help prevent damage to ends and sides of the ties during shipment. Do not load ties higher than the top of the cars nor more than six layers deep. Do not drop or skid ties.

c. Lift ties using purpose-built concrete tie lifting frames or other approved device specifically designed for lifting concrete ties. Do not use tie tongs or tie grappling devices designed for use with timber ties that can scrape or chip the sides of the concrete ties.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-16

3. Delivery: Deliver all concrete ties and associated parts to the Administration material storage site located at 1298 Bellona Avenue, Baltimore or as otherwise directed by the

Superintendent, MOW.

2.1 PEFORMANCE /DESIGN CRITERIA REQUIREMENTS

1. Design: The Contractor shall prepare the final design of the concrete ties in accordance with AREMA Chapter 30 - Part 4 – Section 4.4 Flexural Strength of Prestressed

Monoblock Ties, except as modified herein.

2. One design shall be used for regular rail concrete cross ties and restraining rail concrete cross ties used for installation in standard ballasted track.

3. Configuration:

a. Prestressed concrete cross ties shall be designed for use in standard ballasted track on the Baltimore Light Rail system.

b. Running Rails: 115RE, placed at 1:40 cant.

c. Gauge: 4 feet – 8 ½ inches.

d. The tie dimensions and locations of cast shoulder inserts shall be in accordance with the Reference Drawings in the Appendix.

4. Operating Conditions:

a. Design concrete ties for vehicle dimensions, axle spacing, and loads of the

Baltimore Light Rail vehicles defined in the Appendix.

b. Design concrete ties for maximum vehicle speeds of 55 mph. Load impact factor used in design shall not be less than 200 percent.

c. Tie spacing on tangent track is 30” on centers and on curved track is 27” on centers.

d. The compaction of ballast under and around the tie will be done by using hydraulic or electric activated tamping tools on a production ballast tamper.

The cross tie shall resist these tamping forces without spalling of concrete on the sides and bottom corners.

5. Rail Fastening Components:

a. Two insulating elastomeric type rail seat pads for placement under each running rail.

b. Four tension clamps

c. Four threaded inserts

d. Four angled guide plates

e. Four lag screws and pre-assembled washers

f. The restraining rail assembly consists of a modified 115RE rail connected directly into the adjoining running rail with a spacer block and bolt to maintain

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-17

a 2 ¼” flangeway gap. The restraining rail concrete tie rail seat and adjoining shoulder shall accommodate the twin rails.

g. Rail fastening assemblies shall be comprised of as few components as economically and technically feasible for ease of assembly, disassembly, and maintenance. The rail clamps, rail seat pads, shoulder inserts, and associated hardware shall be furnished by the tie manufacturer.

6. Design strength and electrical isolation requirements.

a. Concrete cross ties shall be tested to confirm the minimum strength and electrical insulation requirements specified in Part 3 of this Section.

b. In lieu of the concrete ties strength testing and electrical testing requirements specified in Part 3 of this Section, the Contractor may submit certification from prior successful testing of the same type of concrete ties and have proven five years of successful performance history.

7. Tie Dimensions

a. Protrusions: Do not use sharp angles or protrusions that are easily damaged by handling or tamping.

b. Weight: 700 pounds, maximum.

c. Length: 8 feet 3 inches, plus or minus ¼ inch.

d. Width:

1) Ballast bearing area (bottom of tie), 10 inches minimum

2) Top surface measured from rail seat to end of tie, 6 inches minimum

3) Maximum width, 13 inches

4) Manufacturing tolerance: Plus or minus 1/8 inch.

e. Depth:

1) 6 inches minimum and 10 inches maximum

2) Maximum depth at rail seat, 71/2 inches

3) Manufacturing tolerance: Plus ¼ inch or minus 1/8 inch.

f. Track Gauge:

1) Design gauge at 4 feet 8 1/2 inches

2. Manufacturing tolerances: The concrete tie and fasteners shall hold track gauge to plus or minus 1/16 inch from that specified, exclusive of mill tolerance in rail. The centerline of the tie shall be within 1/2 inch of the centerline of the track gauge.

8. Tie Surface Features:

a. Rail Cant:

1) Cant of the rail seats at 1:40 toward centerline of tie.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-18

2) Manufacturing tolerance: Cants between one in 35 and one in 45 will be permitted as tolerances.

b. Rail Seat Plane: Flat smooth surface with a tolerance of plus or minus 1/32 inch.

c. Differential Tilt of Rail Seats: The differential tilt in the direction parallel to the rail of one rail seat to the other shall not exceed 1/16 inch over a width of six inches.

d Protrusion of Pre-tensioning Tendons: 1/8 inch maximum beyond the ends of the ties.

e. Concrete Cover for Prestressing Tendons, Ducts, and Prestressing End Fittings:

1) Design dimension: 3/4-inch minimum cover. Measure cover from outside of embedded items to surface of concrete.

2) Manufacturing tolerances for clear concrete protection (cover) and depth of prestressing tendons:

+1/8 inch for any two rows of tendons and

+3/16 inch for the third row.

f. Surface Finish:

1) The top and side surfaces shall present a smooth, uniform appearance.

Except at the rail seat, a random scattering of surface voids will not be cause for rejection. Heavy concentrations of surface voids or evidence of improper mixing, vibrating, or curing will be cause for rejection.

2) The bottom shall have a rough finish as per manufacturer’s recommendation.

g. Markings: Mark ties with indented or raised letters to indicate the manufacturer, day and year of manufacture. A pour indicator button with the year and pour number shall be an acceptable alternative for the production date requirement.

9. Rail Fastening Components

a. Screw-type rail fastening assemblies shall be designed for use with 115 RE rail.

b. Cross ties shall have, on both sides of the rail base, a positive means of preventing more than 1/8-inch total lateral movement of the rail base relative to the fastener in case of failure or loosening of one or both rail clamps. The positive means shall extend at least 3/8 inch above the base of rail in the installed position.

10. Tie Shoulder Inserts

a. Shoulder inserts shall be threaded and shall be designed to provide and maintain proper position and alignment of the rail clamp, rail seat pad, and running rail base.

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b. The shoulder inserts shall not be directly anchored to the pretensioned steel.

2.2 MATERIALS

1. CONCRETE:

a. Minimum 28-Day Design Compressive Strength: 7,000 psi. Secure samples in accordance with ASTM C 172. Make and cure specimens in accordance with

ASTM C 31. Specimens made to check the adequacy of curing and protection of concrete shall be cured entirely under production conditions. Test 6-inch by

12-inch or 4-inch by 8-inch cylinders for strength in accordance with ASTM C

39. For each day of production, test at least three cylinders. Minimum transfer requirement is f'ci = 4,500 psi for wire and strand.

b. Minimum 28-Day Flexural Strength: 750 psi. Make specimens in accordance with ASTM C 31. Specimens to check the adequacy of curing and protection of concrete shall be cured entirely under production conditions. Strength tests shall be made on 6-inch by 6 inch by 20-inch beams in accordance with ASTM

C 78. Test one beam per every 1,000 ties of production.

c. Cement

1) Cement shall conform to ASTM C 150, Type II or III low alkali (less than 0.60 percent). The false set penetration, when tested in accordance with ASTM C 359, shall not be less than 50 mm initially, 35 mm at intermediate times, and 40 mm after remix.

2) Separate random samples of cement shall be taken each day of production to represent the cement used on each bed. Each sample shall not be less than one pound and shall be clearly identified with the date and bed number. Each sample shall be kept in airtight containers until the corresponding 28-day cylinder tests have been carried out and results accepted by the Engineer.

3) Not more than two sources of clinker or ground cement shall be used by the manufacturer during any one month. Cement from each source shall be clearly identified and stored in separate weathertight silos. If two sources of cement are used on one bed, the tests shall be performed on the first batch of concrete made with each type of cement and thereafter as required. Strength tests shall also be conducted on concrete made with each type of cement.

4) Cement mill certificates shall be provided weekly by each supplier and shall contain the results of the following tests on cement delivered during that week.

Fineness by air permeability (ASTM C 204).

False Set (ASTM C 359) - Penetration at 3, 5, 8, 11 minutes and after remix.

Setting Time (ASTM C 191).

Compressive Strength (ASTM C 109) at 1 day, 3 days, and 7 days.

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Chemical Analysis (ASTM C 114) - Including SiO2, Al2O3, Fe2O3, CaO, MgO, SO3, K2O, Na2O, and calculated alkalies as Na2O equivalent, C3S, C2S, C3A, C4AF.

Residue on 325 mesh sieve (ASTM C 430).

5) At least once prior to delivery, a randomly chosen sample of cement from each source used shall be analyzed for alkali content in accordance with ASTM C 114 by an outside testing laboratory.

6) Fine and Coarse Aggregates: AREMA Aggregates, Section 1.4, Chapter 8 of the AREMA Manual, except as modified herein. Coarse aggregates shall be gravel, crushed gravel, crushed stone, or a combination thereof.

7) Aggregates shall be natural aggregates complying with ASTM C 33

Class 4S.

8) The manufacturer shall provide evidence that concrete containing aggregate from the proposed source with a cement content and alkali burden similar to the job mix has a satisfactory service history of at least 5 years. This evidence shall include structures requiring a Class

4S aggregate.

9) The maximum size of aggregate shall be 3/4 inch. If the coarse or fine aggregate is supplied in more than one size, each size shall be stored separately.

10) Washed aggregate shall be allowed to drain, in stockpiles, before use.

All aggregates shall be free from ice when used.

11) In addition to the requirements of ASTM C 33, the following tests shall be conducted by an outside testing laboratory.

12) A separate test shall be conducted at every change in the concrete mix design. For concrete not containing supplementary cementitious materials, the expansion at 1 year shall be less than 0.04%. For concrete containing supplementary cementitious materials, the expansion at 2 years shall be less than 0.04%.

13) When there is insufficient time for testing in accordance with ASTM

C 1293, potential alkali reactivity may be evaluated by ASTM C 1260 or, for concrete containing pozzolans, potential alkali reactivity may be evaluated by ASTM C 1567.

14) Mixing Water: Water shall be potable and free from harmful amounts of oils, acids, alkalis, salts, organic materials, or other substances that may be deleterious to concrete or steel. Mixing water, including that portion of the mixing water contributed in the form of free moisture on aggregates, shall have a chloride ion content of less than 100 ppm. Test mixing water in accordance with AASHTO T 26.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-21

15) Admixtures

Air-Entraining Admixtures: ASTM C 260

Accelerating, Retarding, and Water-Reducing Agents: ASTM C 494.

Other Pozzolanic Admixtures: ASTM C 618.

Do not use admixtures containing chlorides, fluorides, sulphites, nitrates, or aluminum powder.

16) Cement Content: 600 pounds per cubic yard, minimum.

Water-Cement Ratio: 0.45 maximum.

17) Entrained Air: Total air content shall be a maximum of 5 percent in hardened concrete. Conduct a minimum of two tests of air content on the plastic concrete for each bed of ties cast or each 50 cubic yards of concrete, whichever is less volume of concrete. Air content shall be a maximum of 5 percent in plastic concrete.

18) Freeze-Thaw Test: Test three 3x3x11-inch samples in accordance with

ASTM C 666, “Resistance of Concrete to Freezing and Thawing, Procedure A – Freezing and Thawing in Water”. Results shall indicate that the samples are freeze-thaw durable after 300 cycles. Perform this test whenever the concrete mix or materials are changed.

19) Duggan Concrete Expansion Test: Perform as specified in the AREMA

Manual, Chapter 30, Article 4.2.3, “Duggan Concrete Expansion Test.”

The average expansion of the 5 cores at Day 20 shall not exceed 0.15%.

Perform this test whenever the concrete mix or materials are changed.

20) Slump: Conduct at least two slump tests on separate batches of concrete for each bed cast or each 50 cubic yards of concrete, whichever is less volume, in accordance with ASTM C 31 and C 143.

2. PRESTRESSING TENDONS

a. Prestressing tendons shall be pretensioned in accordance to ASTM 416 or

ASTM 886:

Break stream 23,000 lbs.

Yield (1% Elongation) 19,550 lbs.

b. Wire for tendons in prestressed concrete per ASTM A 864 or A 864M. If wire is used, do not use strands larger than 3/8-inch diameter.

c. Strand for tendons in prestressed concrete per ASTM A 416, A 886 / A 886M or equal. Do not use strands larger than 7/16-inch diameter.

d. Sampling plan for Acceptable Quality Levels of 1 percent for major dimensions and 4 percent for minor dimensions shall be used (see ASTM

E122). The manufacturer shall decide which are major and minor dimensions.

These shall be indicated on the shop drawings.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-22

3. RAIL FASTENING COMPONENTS:

a. Rail Seat Pads:

1) Rail seat pads shall be used on all concrete ties. They shall be single-durometer, single-piece molded pads.

2) Dimensions: Thickness shall be ¼ inch (tolerance plus zero-inch, minus 1/32 inch). Length, as measured in the direction of the rail, shall be one inch longer than the rail-bearing surface of the tie, so that there is a minimum of ½ inch overhang beyond the top of chamfer on both sides of the tie (tolerance plus 1/16 inch, minus zero inch). Width shall equal the spacing of the rail clamp shoulders (tolerance plus zero-inch, minus 1/16 inch).

3) Material: Conforming to the following testing requirements:

Hardness:

Test Method: ASTM D2240. Record the average of the two hardness readings for reference in production testing.

Acceptance Criteria: Between 60 and 80 durometers, Shore A.

Tensile Strength:

Test Method: ASTM D412

Acceptance Criteria: 1500 psi, minimum.

Ultimate Elongation:

Test Method: ASTM D412

Acceptance Criteria: 250 percent minimum.

High Temperature Compression Set:

Test Method: ASTM D395, Method B, with a Type 2 specimen. Test for 22 hours at 100 degrees Celsius.

Acceptance Criteria: 25 percent maximum.

Low Temperature Compression Set:

Test Method: ASTM D1229. Test for 22 hours at minus 18 degrees

Celsius.

Acceptance Criteria: The compression set at 30 minutes after release

(t30 reading) shall not exceed 40 percent.

Accelerated Aging:

Test Method: ASTM D573. Age the elastomer for 48 hours at 100 degrees Celsius. Measure and record the change in hardness, tensile strength, and ultimate elongation.

Acceptance Criteria: After aging, the tensile strength shall not decrease more than 15 percent. The ultimate elongation after aging shall be at

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-23

least 200 percent and shall be at least 60 percent of the result before aging. The change in hardness measured on the durometer A scale shall not exceed 10 points.

Resistance to Ozone Cracking:

Test Method: Prepare test specimens in accordance with Procedure A of ASTM D518. Test the specimens in accordance with ASTM D1149 at a temperature of 40 degrees Celsius and an ozone concentration of 50 pphm, for 100 hours.

Acceptance Criteria: The specimens shall not exhibit any cracking when examined in accordance with ASTM D1149 at the end of the exposure.

Oil Absorption:

Test Method: ASTM D471. Conduct one test with ASTM No. 3 oil at

100 degrees Celsius for 70 hours. Conduct another test using the other specimen with ASTM No. 1 oil at 100 degrees Celsius for 70 hours.

Determine the volume change of each specimen.

Acceptance Criteria: For the No. 3 oil, the volume change shall not exceed 100 percent. For the No. 1 oil, the volume change shall be not exceed minus 10 percent or plus 20 percent.

Water Absorption:

Test Method: ASTM D471. Test for 70 hours at 100 degrees Celsius in distilled water.

Acceptance Criteria: The volume change shall not exceed plus 35 percent or minus zero percent.

Volume Resistivity:

Test Method: ASTM D257. Apply 100 volts dc for three minutes.

Acceptance Criteria: 1 x 1012 ohm-cm, minimum

b. Tension Clamps:

1) Tension clamp shall be made of heat-treated alloy spring steel and shall be reusable after repeated applications without any effect on the operating performance of the clamp. Clamps shall be galvanized as per manufacturer’s recommendation.

2) Installation deflection of the clamp shall be no less than 5/8 inch.

3) The load deflection curve in the normal loading range shall exhibit a linear behavior establishing the elastic characteristics of the clamp.

4) In the final assembly position, the elastic clamp shall be able to withstand a repeated amplitude of 2.6 mm.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-24

c Angled Guide Plate

1) Angled guide plate surface shall be smooth, clearly finished, and free of flash. The guide plate shall be free of internal defects and cavities and resistant to ultraviolet rays.

2) Angled guide plate shall be fabricated such that mechanical interlocking with the rail seat pad ensures restriction of longitudinal movement after installation of the rail clamp.

3) Material shall be Nylon 6, reinforced with 30% glass fibers, or approved equal.

4) Volume resistivity : 108 ohm-cm, minimum dry in accordance with IEC

60093.

5) Water absorption at saturation: 2.5% maximum after conditioning.

6) Density: 81-89 lb./ft3 measured in accordance with EN ISO 1183.

7) Melting Point: 419-4370 F. measured in accordance with ISO 11367-3

8) Impact Strength: 40kJ/m2 minimum measured in accordance with DIN

EN ISO 179

d. Threaded Inserts

1) Threaded inserts shall be made from polymide (PA) or polyoxymethylene (POM) and shall be free from cracks or other damage affecting its function.

2) Threaded inserts shall be designed to accept compatible lag screws and be replaceable with hand tools.

3) Polyamide Material Properties:

Melting Point: 419-4370F measured in accordance with ISO 11357-1/3

Density: 70-71 lb./ft3 measured in accordance with EN ISO 1183

Electrical Volume Resistivity: 108 ohm-cm measured in accordance with DIN IEC 60093

4) Polyoxymethylene Material Properties:

Melting Point: 324-3420F measured in accordance with ISO 11357-1/3

Density: 87-89 lb./ft3 measured in accordance with EN ISO 1183

Electrical Volume Resistivity: 108 ohm-cm measured in accordance with DIN IEC 60093

e. Lag Screws and Washers:

1) Lag screws and washers shall be made of galvanized steel conforming to EN 10025-2 or equivalent. The shape of the thread shall be rounded to match the threaded inserts.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-25

2) Lag screw tensile strength: 72 ksi minimum measured in accordance with UIC 864-1. Yield strength at 50 ksi minimum.

3) Lag screw elongation at break: 22% minimum, bending at 900 measured in accordance with UIC 864-1

4) Washer hardness: 185-310 HV30.

3.1 CONCRETE DESIGN MIX:

1. Trial mixtures using aggregates, water, cement, and admixtures proposed for the manufacture of the concrete ties shall be made using at least three different water-cement ratios which will produce a range of strengths. For each water-cement ratio, at least three specimens for each day of production shall be made, cured, and tested as described in Article 2.2.A and Article 3.2. Each batch of concrete shall be mixed separately in a pan mixer.

2. Design compressive strength at the time proposed for transfer of prestress forces to the concrete shall be no less than 4,500 psi, or higher if so required by the tie design or manufacturing method. Design compressive strength at 28 days shall be not less than

7,000 psi. Design flexural strength at 28 days shall be not less than 750 psi.

3. Aggregates and cement shall be measured by weight. The weight of aggregate shall be based on the saturated surface dry condition corrected for free moisture. Water shall be measured by weight or volume, and admixtures shall be measured by volume, unless otherwise directed by the admixture manufacturer.

4. Mix proportions shall be developed using the method of ACI 301, Section 3.9.

5. Restriction on design mix proportions:

a. The cement content shall be not less than 600 pounds per cubic yard.

b. The water-cement ratio shall not exceed 0.45 by weight. Water content shall be kept to the minimum consistent with strength requirements and placement needs.

c. Air content in the plastic concrete shall ensure a maximum of 5.0 percent air entrainment in the hardened concrete.

6. The proportions of aggregate to cement shall be such to produce a mixture that will work readily into corners and angles of the form and around the prestressing elements with the assistance of specified vibration, but without permitting the materials to segregate or excess of free water to collect on the surface.

7. The strength tests shall be made at:

a. The age at which transfer of prestress forces shall be made.

b. 28 days, a curve shall be developed for each design mix showing the relationship between water-cement ratio and compressive strength.

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-26

8. Acceptance of trial mix: The maximum permissible water-cement ratio for the concrete mix to be used shall be that shown by the water-cement ratio versus strength curve to produce average strengths of 110 percent of those specified in Article 3.1.B.

3.2 STRENGTH TESTS OF CONCRETE:

1. Compressive and Flexural Strength tests shall be made to check the adequacy of the mix proportions and as a basis for acceptance. Samples for compressive test specimens shall be secured in accordance with ASTM C172. Samples for flexural tests specimens shall be secured, and specimens shall be made and laboratory cured in accordance with ASTM C31. Specimens made to check the adequacy of curing and protection of concrete shall be cured entirely under production conditions.

a. Compressive Strength tests shall be made on 6-inch by 12-inch cylinders in accordance with ASTM C39. For each day of production at least six cylinders shall be prepared two for 28-day testing, and two for checking strength at transfer, and 2 spares.

b. Flexural Strength tests shall be made on 6 by 6 by 20-inch beams in accordance with ASTM C78. Minimum flexural strength (modulus of rupture) at 28 days shall be 750 psi.

3.3 FABRICATION AND FORMS:

1. Dimensions and Tolerances: The tie design shall be within the dimensional limits specified in Article 2.1.E.3.

2. Method of Production: Monoblock ties shall be manufactured by the long line process.

3. Forms:

a. Forms shall be rigid and shall be constructed of material that will result in finished ties conforming to the shape, lines, dimensions and tolerances called for on the Contract Drawings.

b. Forms shall be constructed to permit movement of the tie without damage during release of the prestressing force.

c. Forms shall provide proper marking with indented or raised letters or numerals to identify the manufacturer and year of production. Marking shall be placed on top of tie surface.

3.4 PLACEMENT OF PRESTRESSING STEEL:

1. Prestressing force in each of the strands shall be in accordance with the approved structural calculations.

2. The load shall be applied in two increments. An initial load of approximately 1,000 pounds shall be applied to the individual strands to straighten them, eliminate slack, and provide a starting or reference point for measuring elongation.

3. Prestressing force shall be determined by (1) measuring strand elongation and (2) by either checking jack pressure on a calibrated gauge or by the use of a calibrated dynamometer. The cause of discrepancy that exceeds 5 percent shall be ascertained

PROCUREMENT OF CONCRETE CROSS TIES & RAIL FASTENINGS SP-27

and corrected. Elongation requirements shall be taken from average load elongation curves for the steel used.

4. Strands shall be stretched either individually or simultaneously. If strands are stretched simultaneously, provision for taking up slack and equalizing stress shall be made individually as required to induce approximately equal stress in each strand.

5. Transfer of force from bulkheads of the pre-tensioning bed to the concrete shall be accomplished by gradual and simultaneous de-tensioning of all strands. Exposed strands shall be cut near the tie end. The projection of strands beyond the ends of the ties shall be no more than 1/4 inch.

3.5 MIXING, PLACING, AND CURING OF CONCRETE:

1. Preparation for Placing Concrete:

a. Prior to the placing of concrete, equipment for mixing the concrete shall be clean, debris shall be removed from spaces to be occupied by the concrete, the forms shall be thoroughly coated with a bond-breaker, and the reinforcement shall be thoroughly cleaned of deleterious coatings. The iron shoulder and prestressing wire shall not be contaminated with bond-breaker or other substance that would interfere with bond development. The forms shall be inspected for alignment and tightness of joints and dimensional accuracy of the position of bulkheads, prestressing steel, and shoulders shall be verified.

b. Proportioning of Component Materials:

1) Fine and coarse aggregates and cement shall be measured by weight.

Weights of aggregates shall be based on a saturated surface dry condition corrected for free moisture. Water and liquid admixtures may be measured by either weight or volume.

2) The accuracy of measurement of the various components of concrete shall be within the following limits:

Cement 1%

Water 1%

Fine aggregate 2%

Coarse aggregate 2%

Cumulative aggregate 2%

Admixtures 3%

2. Mixing of Concrete:

a. Mixing equipment shall be capable of combining specified materials within the time specified…