Statement_of_Work_Railroad_2019_DRAFT.pdf

SECTION 34 11 00 Page 101

STATEMENT OF WORK

1. DESCRIPTION OF WORK: Maintenance of 27.7 miles of railroad system, 44 turnouts and 4 sidings.

1.1. LOCATION: The site of the proposed work is on Fort Leonard Wood Military Reservation, Fort Leonard Wood Missouri.

1.2. WORK HOURS: Contractor shall schedule his working hours to coincide with the working hours of the military reservation. Normal working hours of the reservation are 7:30 a.m. to 4:00 p.m., Monday thru Friday, legal public holidays accepted. The Contractor shall not perform work on the reservations beyond the aforementioned working hours without the written approval of the Contracting Officer.

1.3. HOUSEKEEPING: The Contractor shall remove all trash and disposal material from the work site and sweep the work area clean at the end of each day. The Contractor shall take all possible precautions to maintain the work site, at all times, in a condition that will prevent damage or injury to person or property, Government or otherwise. The above precautions shall include protection from weather conditions.

Note: Army Rail/track is regulated and inspected to meet the standards of UFC 4-860-03. AREMA standards state that if a government system does not have circuited track or commercial rail is not in use, the exact standards are not followed. The standards in this UFC provide maintenance standards for each possible type of deficiency addressed in the Federal Railroad Administration (FRA) Track Safety Standards. DOD policy is to maintain its railroad track at a standard that exceeds FRA Class 2 safety standards and adhere to additional DOD speed restrictions as stated in this UFC. The UFC standards specifically identify separate thresholds for safety standards and maintenance standards.

For this contract the UFC will be followed. Drawing and examples will come from the UFC.

2. PRINCIPAL FEATURES: The work to be performed shall include, but is not limited to the following principle features for the Base Year, Option Year 1, 2 & Option Year 3:

2.1. QUALITY ASSURANCE

2.1.2. Track Construction

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

2.2. Welding

Welder must be a certified rail welder. Note: A hot work permit through the Fort Leonard Wood Fire Department @ 573-596-0886 is required before any welding/torch operation on the installation. Contractor personnel will be required to attend a class through the Fire Department to attain permits.

2.3. DELIVERY, STORAGE, AND HANDLING

2.3.1. Materials and Samples

DRAFT

SECTION 34 11 00 Page 102

Submit a complete schedule of the materials proposed for installation within 60 days of receipt of notice to proceed, and before installation of the materials;

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

Rail.

Tie plates.

Track bolts, nuts, and spring washers.

Joint bars.

Rail anchors.

Track spikes.

Turnouts.

Rail welding process.

Premanufactured car bumpers.

Premanufactured road crossings and/or crossing surfaces.

2.4. PROJECT/SITE CONDITIONS

2.4.1. Temporary Work

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

2.4.2 Traffic Control

Traffic control devices shall comply with MUTCD. Suitable warning signs shall be placed near the beginning of the work site and well ahead of the work site for alerting approaching traffic from both directions. Small markers shall be placed along newly painted lines or freshly placed raised markers to control traffic and prevent damage to newly painted surfaces or displacement of raised pavement markers. Derails will be used ahead and behind all work to prevent run away equipment.

2.4.3. Welding

Welding shall not be performed in rain, snow, or other inclement weather without adequately protecting the weld from the elements. Hot work permits must be obtained through the installation fire department before any welding or torch/flame work can begin.

2.5. PRODUCTS

2.5.1. BALLAST

SECTION 34 11 00 Page 103

Submit samples of the #4 ballast and #4A subballast material for testing. Submit samples a minimum of 30 days prior to the installation of the material. Samples shall be obtained from the quarry, supplier, or other source that will be used to provide the ballast and subballast materials for this project using the methods described in ASTM D75/D75M. One representative sample of not less than 200 lbs of ballast material shall be submitted for each 10,000 ton of ballast to be installed. One representative sample of not less than 200 lbs of subballast material shall be submitted for each 10,000 ton of subballast to be installed. Prepared ballast shall be crushed stone, Size No. 4 ballast 4A subballast conforming to Chapter 1, Part 2, of AREMA Eng Man for quality, soundness and gradation. In the portion retained on each sieve specified, the crushed gravel shall contain at least 90 percent by weight of crushed pieces having two or more freshly fractured faces with the area of each face being at least equal to 75 percent of the smallest midsectional area of the plane. When two fractures are contiguous, the angle between planes of the fractures shall be at least 30 degrees in order to count as two fractured faces. Flat and elongated particle dimension ratio used in ASTM D4791 shall be 1:3. Submit certificates of Compliance for the ballast and subballast materials to be installed in this project.

2.5.2. SUBBALLAST

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

2.5.3. JOINT BARS

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

2.5.4. New Joint Bars

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

2.5.5. Used Joint Bars

Used joint bars in good condition shall be used with relay rail only. The type of joint bar shall be "toeless" type. The used "long toe" type of joint bar shall not be employed where, because of the tie plate punching pattern, the spike slots are used to spike the rail to alignment at the joints. Used joint bars shall be straight, free from cracks, breaks, and other visual defects.

Excessive rust, dirt, and other foreign materials on the joint bars are not permitted. Used joint bars shall be of the proper size to make good contact with the underside of the rail head and the top of the rail base on the rails being joined. Joint bars shall have alternating round and oval bolt holes. Bolt holes shall not show excessive wear that would prevent use of the oval neck track bolt normally used with that joint bar. Joint bars that have been flame-gouged, flame cut, or otherwise altered shall be considered scrap and shall not be used.

2.5.6. Compromise Joint Bars

Compromise joint bars shall be of the size, shape, and punching pattern to fit

SECTION 34 11 00 Page 104 the rail sizes and sections being joined. Only factory designed and constructed (forged or cast) compromise joint bars shall be used to join rails of different sizes.

2.5.7. New Compromise Joint Bars

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

2.5.8. Used Compromise Joint Bars

Requirements for joint bars in paragraph Used Joint Bars shall also apply to use compromise joint bars.

2.5.9. GREASE

Grease for lubricating moving parts in turnouts and other track work shall have the following typical characteristics:

Calcium Soap, percent 9.0

Solid Additive (Graphite),percent 11.5

Penetration, ASTM D217 at 25 degrees C 77 degrees F worked 340

Dropping Point ASTM D566 at 25 degrees C 77 degrees F 101/214

Oil Viscosity, square mm/record at 40 degrees C cSt at 104 degrees F

81.8

ASTM D445 SUS at 38 degrees C 100 degrees F 379

Other types of grease or lubricating oil (like SoyTrak) may be used provided that the grease or oil has been used successfully by local commercial railroads and has the approval of the Contracting Officer.

2.5.10. OIL FOR CORROSION PROTECTION

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

Asphalt, 100 penetration minimum 45 percent ASTM D402/D402M

Flash point, minimu m

55 degree s

C 130 degree s

F ASTM D1310

2.5.11. RAIL

Submit manufacturer's data on new rail including: rail weight, rail section, drilling, rail length, date rolled, and the name of the mill where the rail was

Viscosity, kinematic, 60 degrees C 480 to 700 sq mm/s 140 Degrees F 480 to 700 centistokes

ASTM D2171/D2171M

SECTION 34 11 00 Page 105 rolled. Include chemical analysis for Industrial Grade Rail.

For relay rail the required information shall include weight, section, lengths, and the name of the supplier. Provide the maximum allowable vertical wear on the rail head and the maximum allowable horizontal wear on the side of the rail. The design of the joint bars and compromise joint bars proposed to be furnished with each rail section shall also be provided.

2.5.11.1. New Jointed Rail

General Requirements

New jointed rail shall comply with the following:

2.5.11.2. Rail Lengths

New rail shall be a 110RE lbs/yd section or heavier and shall conform to the specifications in Chapter 4, Parts 1 and 2 of AREMA Eng Man that were in effect at the time of its manufacture. New rail shall be provided in 39 ft lengths.

2.5.11.3. Rail Drilling

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

RAIL DRILLING

110RE Three hole pattern, 2 1/2” x 5”

2.5.11.4. New Industrial Grade Rail

All steel shall be produced in an electric furnace and be continuous cast, free of hydrogen. All injurious hot marks, or surface imperfections shall be culled out and eliminated. Rail shall control cooled to AREMA specifications. Rail shall be rolled in accordance with the general physical dimensional requirements of AREMA design but shall meet the Section tolerances and Chemical Composition listed below.

SECTION TOLERANCES

Height +0.060 to -0.025 inch

Head Width +0.045 to -0.045 inch

Base Width +0.060 to -0.060 inch

Web Width +0.060 to -0.025 inch

GENERAL COMPOSITION

PRODUCT ANALYSIS PERCENT

ELEMENT CHEMICAL ANALYSIS

PERCENT

UNDER MINIMUM OVER MAXIMUM

Carbon 0.65 to 0.85 0.04 0.04

SECTION 34 11 00 Page 106

Manganese 0.70 to 1.30 0.06 0.06

Phosphorus Maximum 0.040 0.008

Sulfur Maximum 0.050 0.008

Silicon 0.10 to 0.50 0.50

2.5.11.5. Testing

Test rail ultrasonically to the following calibration guidelines:

CALIBRATION GUIDLINES

Head 0.10 inch Flat bottom Hole

Web 0.13 inch Flat Bottom Hole

CALIBRATION GUIDLINES

Base .013 x 0.50 inch Slot

2.5.11.6. Straightness

Straighten rail for line in a press or roller straightener. End straightness must meet the following guidelines:

Droop 0.040 inch Maximum

Dip 0.040 inch Maximum

Hook 0.040 inch Maximum

2.5.11.7. Used Jointed Rail

2.5.11.7.1. Relief Rail

Used rail for spot rail replacement of defective rails (relief rail) shall be the same weight, section, drilling, and length as the rail being replaced.

Relief rail shall meet the requirements specified for relay rail.

2.5.11.7.2. Relay Rail

Relay rail shall be control cooled. [Used rail for out of face replacement and new construction shall be 110 lb/yd and shall have the same section and drilling pattern for each rail weight. Acceptable rail weights and sections are: 110 AREA. All relay rail provided shall be the same section. Relay rail shall not be cut into jointed rail from continuous welded rail. Specifying relay rail that meets AREMA is not adequate for military track. AREMA permits excessive end batter because rail ends are intended to be cropped off before welding. All relay rail should have ultrasonic inspection after it is installed.

SECTION 34 11 00 Page 107

2.5.11.7.3. Rail Drilling

Relay rail shall be provided with the rail ends drilled. Drilling shall be uniform and to the patterns specified.

RAIL DRILLING

110RE Three hole pattern, 2 1/2” x 5”

2.5.11.7.4. Length

Relay rail shall be standard 39 ft lengths. Not more than 10 percent of the lot may be shorts. No rail shorter than 13 ft will be accepted.

2.5.11.7.5. Maximum Allowable Wear

For each rail, the average top wear shall meet the requirements on Table IV, except rail in turnouts which shall conform to paragraph Maximum Wear Used Rails Installed in Turnouts. Side wear shall be measured 16 mm 5/8 in below the original top of rail.

TABLE IV. ALLOWABLE WEAR LIMITS FOR RELAY RAIL

Nominal Rail Weight, lbs/yds

Maximum Allowable Wear, mm inch

Top Side

57.0 or Less than 115 0.375 0.375

Greater than 57.0115 or Greater

0.375 0.375

2.6. Condition and Appearance

Relay rail shall be free from obvious defects and clean in appearance. Rail that has severe pitting and corrosion or has been flame-gouged, or spike nipped will not be accepted. Rail shall be straight from line and surface and free from any kinks or bends. Rail bases shall be solid and free from visual defects such as plate wear, spike notching, pitting, and flame-gouging. All existing bond wires shall be removed from relay rail by shear cutting old cables immediately adjacent to the weld or pin. Bond wire heads shall be completely removed from the gage side.

2.6.1. Maximum Allowable Lip

Lip or overflow shall not exceed 1/8 inch on either side of the rail head.

2.6.2. Engine Burns

Engine burns shall not be greater than 1/2 inch diameter and 1/32 inch deep. A maximum of 6 engine burns is allowed per rail and engine burns shall not affect more than 25 percent of the total order.

2.6.3. End Batter and Chipping

Rail end batter shall not exceed a maximum of 0.5 inch when measured 1/2 inch from the rail end with an 18 inch straightedge laid only on the rail being measured. Chipped or broken rail ends will not be accepted.

SECTION 34 11 00 Page 108

2.6.4. Running Surface Damage

Running surface damage shall not exceed 1/4 inch long by 1/2 inch wide, and shall be not greater than 1/32 inch deep measured at the midpoint of an 18 inch straightedge laid on the railhead over the defect. Flat spots are not permitted on the rail head.

2.6.5. Defects Not Permitted

Relay rail having any of the following defects shall not be accepted: bolt hole cracks or breaks, broken base, breaks, crushed head, detail fracture, engine burn fracture, head-web separation, piped rail, horizontal split head, vertical split head, torch cut rail ends, torch cut bolt holes, and compound or transverse fissures. The presence of any of these defects in the rail render that rail as scrap.

2.7. TIE PLATES

2.7.1. General

Tie plates shall be of the dimensions and punching pattern (A or B) to fit the rail. New tie plates conforming to Chapter 5, Part 1 of AREMA Eng Man shall be used with new rail. Used tie plates in good condition may be used with relay rail and shall be the dimensions as originally specified by AREMA Eng Man. The used tie plates shall not be smaller than 7-1/2 by 11 inch double-shoulder for use with relay rail having nominal weights of 100 lbs/yd and greater. Both flat and canted plates will be required to match the existing tie plates that are in track. Canted tie plates shall be used in all new rail and relay out-of-face rail replacements. Canted plates are preferred, particularly in curves:

however, canted and flat plates cannot be mixed together.

2.7.1. Used Tie Plates

Used tie plates shall be free from excessive rust, pitting, mechanical damage, and dirt and other foreign materials. Cracked or broken plates shall be considered as scrap and shall not be used. Shoulders on the tie plates shall project a minimum of 1/4 inch above the plane of the rail seat. The thickness of the tie plate shall be at least 1/2 inch when measured anywhere in the rail seat area. Spike holes shall be square and not corroded, worn, or mechanically enlarged.

2.8. WOOD TIES

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

Species shall be Ash, Beech, Red and White Oak.

Switch ties shall be mixed oak hardwood. Conditioning and seasoning shall conform to the requirements of AWPA U1 for the individual wood species. Ties shall be well seasoned. Prior to preservative treatment, wood ties shall be pressure-treated in accordance with the most current version of the American Wood Preserver's Association (AWPA) Standard C6. See UFGS 05650 for tie treatment recommendations.

New ties selected for the maintenance of track shall be adequately seasoned and treated and meet the requirements specified in the AREMA

SECTION 34 11 00 Page 109

Manual for Railway Engineering, Chapter 30, Part 1, for 7-inch grade ties. The preferred species for ties are the following hardwoods: red oak, white oak, beech, ash, and hickory ties.

Bridge ties shall be treated in accordance with paragraph BRIDGE TIES. Record treatment as specified in AWPA M2. Treated ties shall be permanently marked or branded by the producer in accordance with AWPA M6. Ties shall be produced by a member of the Railway Tie Association, 6” x 8” x 10’ties and replace with new (treated) mixed hard wood bridge ties. Ties will be anchored to the bridge. Tie replacement is to be done only on the timber portions of the 12.0 and 10.7 Rail Bridge. Each tie will have anti-splitting devices, nails or plates attached to each end of the tie.

All ties, except Southern, Red, and Ponderosa Pine, shall be incised on all four sides in the pattern specified in AREMA Eng Man, Chapter 30, Part 3, prior to treatment. Bridge ties shall match existing ties on the 12.0 & 10.7 bridges.

Rail anchors shall not be installed on track over open deck bridges.

Splits shall not be longer than 4 inch and not wider than 1/4 in at either end.

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

Notify the Contracting Officer at least 15 days prior to the shipment of any treated ties or timbers from the manufacturer's plant, to provide the Government the opportunity to inspect the materials before shipment. When inspections of onsite materials result in product rejection, promptly segregate and remove rejected material from the premises. The Government may also charge the Contractor any additional cost of inspection or test when prior rejection makes reinspection or retesting necessary.

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

2.8.1. Crossties

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

2.8.2. Except at Road Crossings

Wood ties shall be sawed and shall be not less than 7 inch thick and 9 inch wide. The length shall be 9.0 ft.

2.8.3. At Road Crossings

Wood ties shall be sawed and shall not be less than thick and wide 7 inch thick and 9 inch wide. The length shall be 9 ft, unless recommended otherwise by the manufacturer of crossing surface materials.

2.8.4 Switch Ties

Switch ties shall conform to Chapter 30, Part 3 of AREMA Eng Man and shall be sawed 7 inch thick and 9 inch wide. The length and quantities shall be as shown.

SECTION 34 11 00 Page 110

2.8.5. Open-Deck Bridge Ties

The method for treatment of bridge ties shall be in accordance with AWPA U1.

The treatment standards shall be based on the type of deck on the bridge.

Any drilling of bolt holes shall be performed prior to treatment. The ties shall be sawed to dimensions and furnished in the quantities indicated on the contract drawings. Field verify all dimensions and quantities prior to furnishing timber bridge ties. Each tie will have anti-splitting devices, nails or plates attached to each end of the tie. Bridge ties for open-deck bridges shall be sized on two sides and of adequate size to distribute the track load to all stress-carrying stringers. Preservative treatment shall be in accordance with AWPA U1 for above-ground exposure. Ties shall be produced by a member of the Railway Tie Association, 6” x 8” x 10’ties and replace with new (treated) mixed hard wood bridge ties. Ties will be anchored to the bridge. Tie replacement is to be done only on the timber portions of the 12.0 and 10.7 Rail Bridge. Each tie will have anti-splitting devices, nails or plates attached to each end of the tie. Field verify all dimensions and quantities prior to furnishing timber bridge ties.

2.8.6. Tie Plugs

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

2.8.7. Anti-splitting Devices

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

2.9. ENGINEERED POLYMER COMPOSITE TIES

Submit name of the tie manufacturer, dimensions, and the pre-drill size as recommended by the tie manufacturer for the type and size fastening system being used. Engineered polymer composite ties shall conform to Chapter 30, Part 5 of AREMA Eng Man. The ties shall incorporate a surface pattern to provide a minimum single tie lateral push result of 2,500 lbf after no more than 100,000 gross tons of accumulated traffic. Submit certified test reports for crossties and switch ties, a minimum of seven calendar days prior to any ties being installed in track. Test reports shall document compliance of the ties to the performance criteria in Chapter 30, Part 5 of AREMA Eng Man. Submit certificates of compliance prior to any ties being installed in track.

2.9.1. Crossties

2.9.1.1. Except at Road Crossings

Engineered polymer composite crossties, except at road crossings, shall be not less than 7 inch thick and 9 inch wide. The length shall be 9.0 ft.

2.9.1.2. At Road Crossings

Engineered polymer composite crossties at road crossings shall not be less than 7 inch thick and 9 inch wide. The length shall be 9 ft, unless recommended otherwise by the manufacturer of the crossing surface materials.

2.9.1. Ballasted-Deck Bridge Ties

SECTION 34 11 00 Page 111

Engineered composite ties for use in track over ballasted deck bridges shall be standard crossties.

2.9.1.1. Tie Plugs

Tie plugging shall be utilized in engineered polymer composite ties in similar fashion as they are used in sawn wood ties as needed to maintain spike.

Polymer-based plugging compounds (e.g., polyurethane) are recommended.

2.10. STEEL TIES

Submit name of the tie manufacturer, dimensions, type of fixation and the chemical analysis of the steel. Steel ties shall conform to Chapter 30 of AREMA Eng Man. Steel ties shall be constructed with hook-in shoulders of a 7 inch minimum spade. Ties shall be design and furnished with elastic type rail fixation system for Pandrol E clips or safelock, or an approved equal. Ties shall have a brand rolled into the material indicating the section and manufacturer. Steel ties shall have the following minimum section:

Steel Ties

Length 102 inch

Width 11.8 inch

Thickness 0.4 inch

Section Depth 4.6 inch

Moment of Inertia 14.6 in4

Ties shall be manufactured from steel free of injurious segregation with a minimum tensile strength of 312 MPa 45,000 psi. Steel shall have the chemical composition conforming to ASTM A242/A242M or ASTM A992/A992M

2.11. TURNOUTS AND TRACK CROSSINGS

The component parts of the turnouts to be furnished shall be the products of manufacturers regularly engaged in the manufacture of such products, and shall essentially duplicate items that have been in satisfactory use at least 2 years prior to bid opening. The parts need not all be made by the same manufacturer, but each turnout shall be the product of a single firm. Switch assemblies, stands, frogs, and guardrails assemblies shall conform to the requirements of AREMA Eng Man.

2.12. Rail and Joint Bars

Rail, joint bars, and miscellaneous track materials used in turnout and track crossing construction shall be furnished and installed as part of the complete turnout or crossing. Rail and miscellaneous track materials used in turnout and track crossing construction shall be the weight and section as listed: 110RE.

2.13. Maximum Wear Used Rails Installed in Turnouts

The average top (vertical) wear shall be 0.375 in or less. Gage side head wear shall not exceed 1/2 inch. All rail installed in turnouts shall be new.

SECTION 34 11 00 Page 112

Frogs, Switches, Guardrails and Appurtenances

Frogs, switches, guardrails and appurtenances shall be materials suitable for use in heavy tonnage main track. Used turnout materials shall have been fully reconditioned and shall be within plus or minus 1/8 inch of the original specification for that turnout design. Materials used in the turnout shall be of the same weight and section. Materials shall be in good condition and free from excessive rust, dirt, and other foreign materials. The rail weight and section shall be as specified.

2.14. Switches

Switches for new turnout construction or complete turnout replacement shall be 16 feet and 6 inches reinforced straight split switches with graduated risers generally conforming to AREMA Eng Man, Plan Number 112. Switch materials used to replace defective materials shall be as indicated.

Switch points shall be new. Switch point detail shall be AREMA Eng Man, Plan No. 221, and Detail 4000 or 6100. [One switch point in each turnout shall be manganese tipped in accordance with AREMA Eng Man, Plan No.

220-52-E-82, installed on the side opposite the turnout side of the switch (example the right switch point shall be manganese tipped on a left hand turnout). Switch rods and connecting rods shall be new.

Gage plates, switch plates, slide plates, and heel plates shall either be new or used and in good condition and not worn or corroded. Rail braces shall be either rigid or adjustable. For a given turnout all rail braces shall be of the same design.

Heel blocks shall be either cast or forged steel and be either new or used and in good condition. New heel block bolt assemblies shall be provided and shall be heat treated. The heel joint bars shall be either new or used in good condition and manufactured for the purpose. If floating heel blocks are used, special no. 5 double shoulder plates shall be used to maintain 6.25 inch heel spread.

2.14.1. Frogs

Frogs shall be rail bound manganese in the sizes indicated.

Frogs shall be new. Cracked or broken used frog castings shall not be used.

Cracked or broken frog castings that have been repaired by welding are not acceptable and shall not be used. Remanufactured frogs shall meet the following wear requirements:

Frog points shall be in good condition and not be worn, chipped, or broken.

Maximum allowable wear on used or reconditioned frogs shall be:

Frog Point 1/2 in

Top Surface 5/1 6in

Raised Guarding Face (Self- Guarded)

3/8 in

SECTION 34 11 00 Page 113

All Wear Surfaces 5/1 in

Minimum flange way depth for used frogs shall be 1-7/8 inch. Minimum flange way width shall be 1-7/8 inch.

Frog bolts, nuts, lock washers, and headlocks shall all be new.

2.14.2. New or Replacement Guard Rails

New or replacement guard rails shall be a minimum of 14 ft in length and shall be new or used in good condition. Guard rails shall be of any of the following designs: Tee rail in accordance with AREMA Eng Man, Plan No. 504, and solid manganese steel in accordance with AREMA Eng Man, Plan No. 510, or an acceptable hook flange design. For used guard rails the guard face shall be smooth and not worn more than 3/8 inch from its new condition. Guard rails bolted to the running rails shall be equipped with fillers. When fillers are installed or repaired new bolt assemblies shall be used. All bolts, nuts, and associated hardware shall be new. Clamped guard rails shall be equipped with block wedges, filler wedges, and cotter keys. Guard rail plates shall be new or acceptable replacements. Single-shoulder tie plates used with guard rails shall be installed with the shoulder on the inside flush against the base of the guard rail.

2.14.3. Hook Plates

Hook plates shall be new or acceptable used material and shall be of the designs and lengths indicated on AREMA Eng Man, Plan Nos. 112 and 241.

2.14.4. Switch Stands

New or replacement switch stands shall conform to AREMA Eng Man, Plan 251-64 and shall be new or fully reconditioned, low-stand type with model number Racor model 36E. Switch stand shall be positive-action (rigid) with [adjustment from the top with shims through a moveable cover adjustable connecting rods.

Trihandle throw arm.

Existing switch stands, staffs and targets, where not designated for replacement, shall be reconditioned by cleaning to bare metal and then painted with one coat of metal primer. [The interior portion of the stands, including mechanisms, shall be cleaned and re-lubricated.] The switch stand staff shall be painted with two coats of black enamel paint. Switch targets shall be similarly prepared and painted with two coats of red or white enamel paint to indicate switch position in accordance with normal railroad practice.

2.14.6. Rail Braces

Rail braces shall be either the fixed or adjustable type and shall be of standard manufacture.

2.15. GRADE CROSSINGS

Premanufactured, precast concrete panels for grade crossings shall be constructed of reinforced concrete having a minimum 28-day compressive strength of 34.5 MPa 5,000 psi. Each panel shall be manufactured to meet HS20-44 loading in accordance with AASHTO HB-17, with 30 percent impact increment. Loading

SECTION 34 11 00 Page 114 shall be based on single axle loads of 32,000 lbs. Precast crossing panels shall be the product of a company regularly engaged in the manufacture of such panels, and whose products have been successfully used in the commercial railroad industry for at least 2 years. Flange protection must be installed.

Crossings shall be new and shall be fabricated to match existing. Rail weight and section shall be 110RE.

2.15.1. Rail

Rail within the road crossing and for at least 20 ft on either side of the crossing shall be 110RE as specified in paragraph Rail and Joint Bars. Welded joints or long 78 feet rail for the crossing area will be used to eliminate any joints in the crossing area.

2.14.5. Track Crossings

2.15.2. Ties within the road crossing and for at least 20 ft on either side of the crossing shall be replaced with hardwood or polymer composite and shall be as specified in paragraphs Crossties and Switch Ties. Ties will be specified by the government, Directorate of Public Works. Tie layout shall match existing crossing Ties unless otherwise specified.

2.15.3. Track Materials

For premanufactured crossing surfaces or systems, tie plates, spikes or other rail fasteners, rail anchors, and other track materials shall conform to the manufacturer's recommendations. Unless specified by the crossing manufacturer, track materials shall be as specified in paragraph MISCELLANEOUS TRACK

MATERIALS.

2.16. Screw Spikes

Screw spikes shall have a minimum ultimate tensile strength of 60,000 psi and shall be galvanized for corrosion protection.

2.17. MISCELLANEOUS TRACK MATERIALS

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

Miscellaneous track materials shall be as follows:

2.17.1. Track Spikes

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

2.17.2. Bolts, Nuts, and Spring Washers

New track bolts, nuts, and spring washers shall be used throughout the project for both new and relay rail. Bolts shall be used in both steel and timber bridge connections. The various rail, joint bars, and rail drillings require various lengths and diameters of bolt assemblies. Determine the number of bolt assemblies of each size required.

All bolt diameters shall be the largest possible for a given rail drilling and joint bar punching. Track bolts and nuts shall conform to Chapter 4, Part 2 of AREMA Eng Man. Track bolts shall be long enough to leave at least two threads exposed after the nut is tightened. Steel bridge connections shall use ASTM A325M ASTM A325 or ASTM A490M ASTM A490 bolts. Timber bridge connections shall use hot dip galvanized steel bolts, minimum 3/4 in diameter with lengths as required.

SECTION 34 11 00 Page 115

Spring washers and nuts shall be sized to ensure that the spring washer develops its full reactive force and does not jam into the joint bar hole. Spring washers shall be of the size to fit the bolt and nut used and shall conform to Chapter 4, Part 2 and Section M12 of AREMA Eng Man.

2.17.3. Rail Anchors

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

Anchors may be either drive-on or spring type.

2.17.4. Salvaged Rail Anchors

Rail anchors salvaged from the track being removed shall become the property of the Contractor and shall be removed from the site. No used anchors shall be reinstalled unless they have been repinched.

2.17.5. Rail Clips and Fasteners

Provide single tight fit clips with fillers as necessary to fit rail section furnished. Clip or fastener design shall anchor rail against longitudinal movement.

2.18. Insulated Joints

Insulated joints shall conform to applicable portions of Chapter 4, Part 2 of AREMA Eng Man. Conventional continuous insulated joints with fibre insulation shall not be used. Unless otherwise directed by the Contracting Officer, insulated joints shall be for the following rail sections, rail drilling, and number of joints:

RAIL SECTION DRILLING NO. JOINTS

110RE 2 ½” – 5” 8

2.19. Bumping Posts and Cushion Heads

Bumping posts and cushion heads, and shall be new and shall be of a standard design that has been in use by commercial railroad industry or match existing.

Bumping posts and cushion heads shall be manufactured by a company regularly engaged in the manufacture of these products.

2.20. Bumping Posts

Bumping posts shall be of all-steel construction, shall bolt firmly onto the rail, and shall be of a type designed for general service. Bumping posts shall have tension with 6 sq inch cross-sectional area and compression members with a moment of inertia not less than 37 inch4 of A36 steel. Bumping post shall be capable of withstanding a yield load of 550,000 pounds.

2.21. Cushion Heads

Cushion heads shall be of all steel construction, shall firmly bolt, attach, or clamp onto the bumper or end dock (platform or ramp). Cushion heads shall resist 80,000 lbs of compression.

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2.22. Inner Guard Rail

Inner guard rail shall be Class IV or better used rails as indicated in Part 2, Chapter 4, "Inspection Classification of Second Hand Rail for Welding", of AREMA Eng Man. Rail shall be 80 lbs/yd or greater. All rails used at any one inner guard rail location shall be the same weight and section. Joint bars shall match the rail provided and shall be in good condition.

2.23. Gage Rods

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

2.24. Derails

A derail shall be installed where potential runaway protection is present and provided by the contractor.

2.25. Salvaged Materials

2.25.1. Marking Paint

Marking paint shall be a good quality oil-based spray marking paint or a good quality oil-based paint marker.

2.25.2. Salvaging Rail

Salvage rail as directed; the Government will make available salvaged rail to the Contractor subject to the following:

Nondefective and reclaimable rails salvaged from existing tracks may be used to execute spot rail replacement work at other locations of the project, subject to review and approval of the materials by the Contracting Officer.

Reclaimable defective rails may be used to construct inner guard rails provided all defects can be cropped off. Detailed inspection shall be made of such rails to ensure that rails which contain critical defects such as transverse defects, head-web separations, vertical split heads, pipe, split webs, etc., are not incorporated in the work. Loose rails located along the right-of-way shall be inspected and used as directed.

2.25.3. Joint Bars

Non-defective joint bars salvaged from existing tracks may be used to execute spot replacement work at other locations of the project, subject to review and approval of the material by the Contracting Officer.

2.25.4. Tie Plates

Tie plates salvaged from existing tracks, which are not either broken, cracked, or severely corroded or worn, may be used to execute the work subject to review and approval of the material by the Contracting Officer.

2.26. RAIL BONDING AND GROUNDING

2.26.1. Rail Bonds

SECTION 34 11 00 Page 117

Rail bonds shall be exothermic type ("Cadweld") bonds applied to the field side of the rail head, or 46 inch bonds welded to the rail web. The bond cables shall be flexible bare copper stranded 1/0 AWG cables with preformed ends. Bond cables shall be flexible bare copper stranded cables with preformed ends and shall conform to applicable requirements of AREMA Eng Man Vol. 3.

2.26.2. Grounding Rods

Grounding rods shall be 3/4 in diameter copper clad steel rods 1 inch diameter zinc-coated steel rods. The minimum length of ground rods shall be 8 ft.

Ground Connection Cables

Connections between the grounding system or ground rods and rails shall be made with a bare flexible copper stranded 2/0 AWG cable.

Electrical Connecting Hardware

Electrical connecting hardware shall be bronze pressure bar type materials having no rotating parts coming in direct contact with conductors.

2.27. WELDING

2.27.1. Electrodes

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

Provide electrodes of the smallest practical diameter worked at the lowest compatible current. Coating on low-hydrogen type electrodes shall be thoroughly dry when the electrode is provided. Use electrodes taken from hermetically sealed packages within one hour of the time the package is opened. Electrodes not used within this one-hour period and electrodes taken from non-hermetically sealed packages shall be dried for at least one hour between 371 and 427 degrees C 700 and 800 degrees F. Electrodes so dried may be stored at temperatures between 107 and 205 degrees C 225 and 400 degrees F until used, or, if not stored and not used within one hour after this drying is completed, shall be re-dried before use. Do not use electrodes which have been wet.

2.28. Vegetation removal

Removal of vegetation for safe site clearance along installation railroad system. 30 foot off center of rail bed shall be 100% clear of vegetation.

Vegetation off 30 foot mark to boundary mark shall be cut to a 6 inch height where possible.

2.29. Ditching

Ditching to maintain unobstructed water flow and prevent erosion along installation railroad system.

PART 3 EXECUTION

2.30. REMOVAL, SALVAGE, AND DISPOSITION OF MATERIALS

Tracks and segments of track shall not be dismantled until approved to do so by the Certified Track Inspector. Salvage the following materials for later use by the Government. Some of these items will be used in the repair of tracks as indicated.

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2.30.1. Materials to be salvaged for later use by the Government are:

a. 90RA rail & joint bars

b. 100RE rail & joint bars

c. 110RE rail & joint bars

Other materials shall become the property of the Contractor and shall be removed from the project.

2.30.2. Dunnage

Pallets, sills, and other material used for packaging and stacking salvaged track items shall be clean, free of decay or other defect, and sufficiently sturdy for the service intended.

2.30.3. Methods and Procedures

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

2.30.4. Inventory of Track Materials

Keep a detailed inventory of excess and salvaged track materials stockpiled for the Government. Detailed inventory shall be recorded in appropriate format and furnished to the Contracting Officer.

2.30.5. Inspection and Reconditioning of Used Track Materials

Salvaged track materials shall be cleaned and inspected by a DPW Certified Army Track Inspector for defects to determine their suitability for further use.

2.30.6. Cleaning By Hand or Mechanical Means

Rail, joint bars, gage rods, tie plates, rail anchors, and other materials shall be cleaned by hand or mechanical means to remove all adhering dirt and heavy rusting so that the bare steel can be examined by DPW Certified Army Track Inspector.

2.30.7. Visual Examination of Rails

Rails shall be visually examined for evidence of defects such as those illustrated on Form 402-A found in Chapter 4 Part 3 of AREMA Eng Man. Such defects shall be brought to the attention of the DPW Certified Army Track Inspector who will be the final judge as to the serviceability of the rail.

Rails having bolt hole cracks or end batter under paragraph TRACK REPAIR that can be reconditioned for use by cropping and redrilling shall be marked at the location of the defect with yellow paint. Rails with other defects or which cannot be reconditioned shall be rejected as scrap and shall be marked with bright red paint and stacked separately.

2.30.8. Visual Examination of Joint Bars

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Existing joint bars and compromise joint bars which are removed and no longer required at that location due to rail replacement or other work may be cleaned and reused at other locations, subject to review and approval of the Contracting Officer. Joint bars and compromise joints that are not reused shall be salvaged or scrapped. Joint bars shall be visually examined for defects and wear. Joint bars with bolt hole or spike slot cracks shall be scrapped. Bars which do not fit tightly against the rail or bars in which the bolt holes are excessively corroded or worn shall be scrapped. The DPW Certified Army Track Inspector will be the final judge of the serviceability of joint bars. Scrapped bars shall be marked with bright red paint and stacked separately.

2.30.9. Visual Examination of Tie Plates and Rail Anchors

Tie plates and rail anchors shall be visually examined for cracks, breaks, excessive wear, and excessive corrosion. Track material with these defects shall be considered scrap, marked with bright red paint and stacked separately by a DPW Certified Army Track Inspector

2.30.10. Grade Crossing Materials

Existing premanufactured grade crossing panels, rail and other track materials shall be salvaged as indicated, or as designated by the DPW Certified Army Track Inspector. All salvaged materials shall remain the property of the Government, and shall be reinstalled as indicated or shall be transported to the military installation storage yard. Grade crossing materials to be salvaged shall be removed, cleaned as required for proper reinstallation, marked or labeled as necessary for proper reinstallation, and transported to the reinstallation location or to the storage yard.

2.30.11. Transport and Stack Excess and Salvaged Materials

Excess and salvaged materials which are not used in track repair work shall be stacked at a site on the military installation designated by the DPW Certified Army Track Inspector.

2.30.12. Stacking of Rails

Rails shall be stacked on approved sills a minimum of 6 inch above the ground.

Rails shall be stacked with the heads up and with the ends even. Each layer shall be separated by at least three 2 by 4 inch wood strips evenly spaced along the length of the rail. Rail shall be grouped by weight, section, drilling, condition, length, and amount of wear. The weight, section, drilling, and length shall be marked on one of the rails near the mid-height of the stack. These markings shall be painted neatly near one end of the rail.

2.30.13. Stacking of Joint Bars, Gage Rods, and Tie Plates

Joint bars, gage rods, and tie plates shall be sorted by section, punching and condition and shall be stacked on pallets. Each pallet stack shall be steel banded for forklift handling. The maximum weight on any pallet shall be 1,500 lbs. Compromise joint bars shall be wired together in pairs and stacked on pallets, separate from other bars.

2.30.14. Containers

Rail anchors shall be sorted by type and size and placed in kegs, steel drums, or other approved containers. Containers shall be labeled with the rail weight and section. Containers provided by the contractor.

SECTION 34 11 00 Page 120

2.30.15. Stacking of Special Track work Materials

Special track work materials shall be palletized and stacked as directed by the DPW Certified Army Track Inspector. The rail weight, rail section, and length shall be marked on each switch point. The weight, section, and frog number shall be marked on the side of each frog casting. Other switch materials salvaged shall be placed in steel drums and labeled as to rail weight, section, length of points, and turnout size.

2.30.16. Material to be scrapped

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

2.31. PLACEMENT OF BALLAST AND SUBBALLAST

Place ballast and subballast to the lines and grades indicated. The average thickness shall be within 0.25 inch of the thickness indicated. Subgrade must conform to the requirements of Section 31 00 00 EARTHWORK. Do not place ballast and subballast on soft, muddy, or frozen areas. Where the prepared subgrade (roadbed) is soft, muddy, rutted, exhibits severe depressions, or is otherwise damaged, the ballast and subballast shall not be placed until the damaged subgrade has been repaired and the area has been approved by the Contracting Officer.

2.31.1. Compaction

Finish compaction by sheep foot rollers, pneumatic-tired rollers, steel-wheeled rollers, vibratory compactors, or other approved equipment.

2.31.2. Subgrade for Railroads

Compact subgrade for railroads to at least 90 percent laboratory maximum density for cohesive materials or 95 percent laboratory maximum density for cohesionless materials.

2.31.3. Subballast

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

2.31.4. Subballast Compaction

Each subballast lift shall be compacted using approved compaction equipment. The roller weights, vibration frequencies (where applicable), tire pressures (where applicable), and number of passes shall be sufficient to obtain in-place densities across the full width of the subballast and throughout the entire depth of the layer of not less than 95 percent of the ASTM D1557 laboratory maximum dry density for the subballast material. Prior to placement of subsequent subballast layers the top of the previous layer shall be scarified to a depth of approximately 2 inch to insure proper bond of the layers. Density shall be field measured in accordance with ASTM D1556/D1556M(base plate, as shown in the drawing shall be used or ASTM D6938. The calibration curves shall be checked and adjusted, if necessary, using only the sand cone method as described in paragraph Calibration, of the ASTM publication. Tests performed in accordance with ASTM D6938 result in a wet unit weight of soil and ASTM D6938 shall be used to determine the moisture content of the soil.