RAILROAD PROVISIONS SECTION 1 GENERAL REQUIREMENTS

Transcription

1 RAILROAD PROVISIONS SECTION 1 GENERAL REQUIREMENTS 1.01 CONTRACTOR'S RESPONSIBILITY By acceptance of the contract, the Contractor assumes complete responsibility for construction of the work. The Contractor shall understand that any work not specifically mentioned in the written specifications, but which is necessary, either directly or indirectly, for the proper carrying out of the intent thereof, shall be required and applied, and will perform all such work just as though it were particularly delineated or described. Contractor shall also understand that final approval of the track for service is the prerogative of Sound Transit and close contact with Contracting Agency's Representative is required. No work is to be performed on Sound Transit's right-of-way, or in such proximity as to interfere with tracks or roadbed, without advance permission by Sound Transit, including insurance and if necessary, flagging protection INSURANCE REQUIREMENTS Prior to construction, the Contractor is required at his own expense to obtain railroad insurance as specified in Section of the Special Provisions CONSTRUCTION UNDER TRAFFIC Construction and demolition of the tracked crossing of Berkeley Street will require closure of the railway tracks and roadway traffic along Berkeley Street between Interstate 5 and Union Avenue. Full roadway closures for Berkeley Street are authorized between the hours of Fridays at 7:00 P.M. until Mondays at 4:00 A.M. The Contractor shall follow the requirements of Section of the special provisions for closures of the roadway. The Contractor shall coordinate the rail closure with BNSF and Tacoma Rail. Work requiring any disruption of the rail service shall not commence without authorization of BNSF and Tacoma Rail. Prior to work disrupting rail service commencing, the Contractor shall forward to the Contracting Agency, a written authorization from BNSF and Tacoma Rail documenting the approved start and duration of rail closure. For bidding purposes, the Contractor shall assume that the authorized hours of closure are Friday 7:00 P.M. until Monday at 4:00 A.M LIQUIDATED DAMAGES In the event that railway work requiring disruption of the railway extends beyond the authorized duration from BNSF and Tacoma Rail, the Contractor shall be imposed liquidated damages of $31,000 per day for each day that railway service remains interrupted beyond the authorized duration. The damages shall be assessed fully commencing one minute beyond the authorized duration of closure and successive damages will compound every 24 hours thereafter. Proration of damages will not be accommodated under this contract COORDINATION WITH OTHER CONTRACTORS It is anticipated that a separate bid for construction of the rail adjoining each end of the project limits will be let in late spring of The Contractor is hereby notified that construction of the tracked crossing of North Thorne Lane as a portion of this separate bid will require a closure of North Thorne Lane with the detour across Berkeley Street. Coordination with the closures of Berkeley Street required under this contract and the closures of North Thorne Lane let under a separate contract will be the responsibility of the Contractor SALVAGING EXISTING MATERIAL The existing rail signal equipment for the at grade crossing of Berkeley Street will remain property of Sound Transit. Once demolished, the Contractor shall deliver all existing rail signal equipment to the Sound Transit storage area located at the intersection of 108 th Street and Halcyon Road in Lakewood,

2 2.03 MATERIAL Contracting Agency representative should inspect all track materials prior to placement to avoid removal of sub-standard material. Contracting Agency representatives will also inspect the track before placing it into service. Anchors: Rail anchors shall be new or reconditioned, sized to fit the rail section. Ties: Hardwood ties shall be new 7 X 9 (No. 5) Douglas Fir, with length and spacing as shown on the plans. Concrete ties shall be pre-stressed, measure 11 wide at the bottom and 9 high with length and spacing as shown on the plans. Tie Plates: Tie plates for 136 lb. rail over wooden ties shall be new and secured with Panderol e-clip fasteners and contain matching plate sand screw spikes. Plates for all rail transitions from 136 lb. to worn 85 lb. may be new or secondhand, free of injurious defects and foreign material, conforming to AREMA Specifications, and shall fit rail being used. For rail 110# section and greater, all plates will be double-shouldered. Joints: Joints shall only be completed in the transition between the 136 lb rail and the worn 85 lb. rail. The contractor shall not drill outer holes in the 136 lb. rail at the comp joints. New or secondhand joints, free of foreign material and without injurious defects, and with 4 or 6 bolt holes, conforming to AREMA requirements, may be furnished to fit rail section for which they are designed. Bolt holes must be drilled with proper equipment. Torch-cutting of bolt holes is not allowed. New or secondhand compromise joints of manufactured type (welded or homemade are not acceptable), free of foreign material and without injurious defects, shall be furnished and used where rail section (weight or design) changes. Rail section by weight shall not be compromised where difference in weight is in excess of 25 lbs. When this becomes necessary, a rail of some weight between the two different rail sections, in excess of 25 lbs., shall be used and the compromise made in two steps. The length of the medium-weight rail shall be 39 feet where practical. Spikes: 5/8" x 6" cut track spikes shall be installed. All spikes shall conform to AREMA requirements. Track Bolts & Nuts: Track bolts and nuts shall be installed conforming to AREMA Specifications. Bolts will be correct size and length to fit rail. Lock Washers: One lock washer conforming to AREMA Specifications shall be installed on each track bolt. Ballast: Track ballast shall be AREMA No. 4A. Ballast shall be free from loam, dust, and other foreign articles and shall not have less than 75% crushed particles with two or more fractured faces. Processed ballast shall be hard, dense, of angular particle structure, providing sharp corners and cubicle fragments and free of deleterious materials. Ballast materials shall provide high resistance to temperature changes, chemical attack, have high electrical resistance, low absorption properties and free

3 be tightened to a range of 20,000 to 30,000 ft-lbs. tension. If a bolt tightening machine is not used, a standard track wrench with a 42" long handle may be used. At the time of installation, rail expansion shims of softwood not over 1" width shall be placed between the ends of adjacent rails to insure proper space allowance for expansion required by the rail temperatures in the following table, and shall be left in place: 39-ft Rail Temperature Deg. F Expansion Over 85 None 66 to 85 1/16 46 to 65 1/8 26 to 45 3/16 6 to 25 1/4 Below 6 5/16 Bending Stock Rails: Use approved rail bending equipment. Make bends uniform and accurate for all stock rails. Spiking to Wood Ties: Rails shall be spiked to every tie, using not less than 2 spikes for each rail at each tie. Drive spikes through tie plate holes into ties, located diagonally opposite each other but not less than 2" from edge of tie. Start and drive spikes vertically and square with rail. Take care to avoid slanting, bending, or causing sideways movement of spike. Each rail will be spiked with two spikes per tie plate on tangent track staggered with inside spikes to the east or north and outside spikes to the west or south. On curves a third spike is required on the gage side of the rail. Spikes shall not be placed in the slots on skirted joint bars when such practice can be avoided by providing other plates with a hole pattern that will clear the skirts. When spikes are driven by machine, work shall be closely supervised to see that they are driven with hammer centered exactly over each spike head and drive spike vertically. Set stop bolt on the machine to prevent over-driving. Withdraw spikes that are incorrectly driven and fill hole by driving a tie plug to full depth of hole. Locate replacement spike at another hole in tie plate and tie. Unloading and Tamping Ballast: Unload and level down ballast by most practical means, taking care not to disturb grade stakes. Perform tamping, using power tamping machines with a minimum 16 tool squeeze-type tamper, using approved AREMA tamping tools appropriate for type of ballast being placed. Distribute 6 minimum depth ballast prior to placing ties and compact with smooth drum non-vibratory roller. Tamp each layer of ballast from a line 15" inside each rail, on both sides of and to the ends of ties. Center area between these limits shall be filled lightly with ballast but not tamped. At turnouts and crossovers, tamp ballast uniformly for full length of ties. Tamping shall proceed simultaneously at both ends of same tie, making sure ballast is forced directly under the ties and against sides and ends of ties. Finishing and Dressing: Dress ballast in conformance with dimensions shown on drawings, placing additional ballast material as necessary. When placing pavement up to the track and flush with top of rail it is important to make sure water drains away from the track. This will prevent pooling and freezing which create hazardous walking conditions. Lines shall be painted 10 feet parallel to the centerline of track on both sides to serve as visual reminder of the track s foul zone. Crushed rock or fabric shall be placed over the ties to

4 serve as visual reminder of the track s foul zone. Crushed rock or fabric shall be placed over the ties to keep the pavement from adhering to them. Flange ways need to be kept clean to allow wheels to contact top of rail at all times. Shoulders on each side of the tie shall be 12 minimum. Final Inspection: After ballasting and surfacing are completed, inspect track to see that joints are tight and rail attachments to ties are secure. The Contractor will notify the Sound Transit representative that the trackwork is complete and ready for inspection. The Sound Transit representative will arrange an on-site inspection with the Roadmaster, or designate, who will inspect the finished trackwork. The Contractor will provide a copy of the Record of Neutral Temp of Welded Rail as Laid form to the Roadmaster prior to or during inspection RAIL ANCHORING REQUIREMENTS Where the anchoring function is otherwise provided, rail anchors may be omitted. Anchors may not be applied where they will interfere with signal or other track appliances, where they are inaccessible for adjustment or inspection, or on rail opposite a joint. Anchor pattern may be varied as reasonable to avoid placing anchors against deteriorated ties. When installing CWR, box anchor every other tie.

5 SECTION 4 CONCRETE CROSSTIES AND RAIL FASTENER ASSEMBLIES PART 1 - GENERAL 1.1 DESCRIPTION Concrete Crossties shall be CXT 200S-13 tie type or approved equivalent. A. Section includes specifications for furnishing and installing new prestressed, pretension monoblock concrete crossties and rail fastener assemblies for use with 136 RE rail. B. The concrete crossties (standard crossties and grade crossing ties) shall be as shown on the Drawings, and as specified in this Section. C. The concrete crossties shall be compatible to the specified rail fastener assemblies. 1.2 REFERENCE STANDARDS A. American Railway Engineering and Maintenance-of Way Association (AREMA): 1. Manual for Railway Engineering (Manual) B. American Society for Testing and Materials (ASTM International): 1. A536 Specification for Ductile Iron Castings 2. A881 Specification for Steel Wire, Deformed, Stress-Relieved or Low- Relaxation for Prestressed Concrete Railroad Ties 3. C31 Practice for Making and Curing Concrete Test Specimens in the Field 4. C33 Specification for Concrete Aggregates 5. C39 Test Method for Compressive Strength of Cylindrical Concrete Specimens 6. C78 Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading) 7. C109 Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-inch Cube Specimens) 8. C150 Specification for Portland Cement 9. C172 Standard Practice for Sampling Freshly Mixed Concrete 10. C260 Specification for Air-Entraining Admixtures for Concrete 11. C359 Test Method for Early Stiffening of Hydraulic Cement (Mortar Method)

6 SECTION 5 THERMITE RAIL WELDING PART 1 - GENERAL 1.01 DESCRIPTION A. Section includes specifications for welding rails together by the Thermite process at the project site for the purpose of joining rail strings and for other intrack welds. B. Refer to Section 3, Flash Butt Rail Welding, for additional requirements for thermite welds REFERENCE STANDARDS A. American Railway Engineering and Maintenance of Way Association (AREMA): 1. Manual for Railway Engineering (Manual), Volume 1, Chapter 4, Rail B. American Society for Testing and Materials (ASTM International): 1. E164 Standard Practice for Ultrasonic Contact Examination of 2. E709 Weldments Standard Guide for Magnetic Particle Examination C. Federal Railroad Administration (FRA): 1.03 SUBMITTALS 1. CFR 49 Part Track Safety Standards A. Submit detailed procedure specification of the step-by-step methods to be employed in making the welds for Engineer s approval. Include complete description of each of the following items, as applicable: 1. Manufacturer s trade name for the welding process. 2. Method used for cutting and cleaning the rail ends. Refer to Section 1, Track Construction for allowable means of cutting rail. 3. Minimum and maximum allowable gap between rail ends prior to welding. 4. Methods used for cleaning multiple-use crucibles and removing moisture, and the procedures for tracking the number of welds made. If single- use crucibles are used, the above mentioned procedure will not be required. 5. Method used for preheating, including time and temperature.

7 6. Method used for removing the upset metal and finishing the weld to the final contour, including a description of special tools and equipment. 7. Quality control procedures to be followed. B. Submit welder qualifications and certification from weld-kit manufacturer for Engineer s approval DELIVERABLES A. Prepare welding testing record in a form acceptable to the Engineer. Submit signed original form to the Engineer within 14 days of completion of the weld testing. B. Submit a weld record for each weld indicating weld number, location, rail temperature, date and time of weld, and name of welder within 72 hours of completing the weld QUALITY ASSURANCE A. Perform welding under the direct supervision of an experienced welding supervisor or foreman. Welding supervisors and foremen shall be familiar with FRA parts , , and B. Welders shall be certified by weld kit manufacturer C. Verify that weld kits have not expired. D. Test weld prior to allowing revenue train traffic over DELIVERY, STORAGE, AND HANDLING A. Handle weld kits with care from receipt to installation to ensure high quality welds. B. Identify weld kits by brand name in the original Manufacturer s container. Store weld kits in a moisture-proof container. C. Use weld kits prior to the expiration date. Remove expired weld kits from Owner s property. PART 2 - PRODUCTS 2.01 RAIL WELDING KITS A. The following rail welding kits are approved. 1. Calorite, limited or standard preheat, by Calorite Inc. 2. Boutet, distributed by Esco.

8 PART 3 - EXECUTION 3.01 GENERAL 3. Orgo-Thermit, by Orgo-Thermit, Inc. A. Perform welding in accordance with the requirements of the AREMA Manual, Chapter 4, Section 3.13, Specification for the Quality Assurance of Thermite Welding of Rail and Section 3.11, Specifications for Fabrication of Continuous Welded Rail, except as modified or amended by this Section. B. Weld second hand rail according to the requirements of the AREMA Manual, Chapter 4, Section 3.12, Inspection and Classification of Secondhand Rail for Welding, for Class 1 Rail. C. Position weld in the crib between two ties. Do not place weld on a tie. Field welds are not permitted in road crossings. D. Weld compromise joints using in track thermite welds for compromise joints END PREPARATION 3.03 GAP E. Do not weld in rain, or other inclement weather without adequate protection from the elements. A. Clean the rails to be welded of grease, oil, dirt, loose scale, and moisture to a minimum of 6 inches back from the rail ends, including the railhead surface. Use a wire brush to completely remove dirt and loose oxide, and use oxygenacetylene torch to remove grease, oil and moisture. B. Align the rail ends using a rail beam specifically designed for this purpose or a 36-inch straight edge. C. Use a power grinder with an abrasive wheel to remove scale, rust, burrs, lipped metal and mill brands which would interfere with the fit of the mold for two (2) inches on each side of the ends. Rail ends shall show no steel defects, dents, or porosity before welding. D. Cut rail square using approved rail saws. E. Field welds shall be no closer than 8 inches from any existing bolt hole. A. The minimum and maximum spacing between rail ends shall be as specified by the rail welding kit manufacturer and the approved procedure specification. Wide gap welds will not be permitted unless approved by the Engineer ALIGNMENT

9 A. Properly gap and align the ends of the rails to be welded to produce a weld which shall conform to the alignment tolerances below. Hold the rail gap and alignment without change during the complete welding cycle. 1. Alignment of rail shall be done on the head, web, and base of the rail. 2. Vertical alignment shall provide for a flat running surface. Any difference of height of the rails shall be in the base. 3. Horizontal alignment shall be done in such a manner that any difference in the width of heads of rails shall occur on the field side. 4. Maximum horizontal offsets: 1/25 inches in the head and/or 1/16 inches in the base. 5. Surface Misalignment Tolerances: 3.05 THERMITE WELD PREHEATING a. Maximum combined vertical offset and crown camber: 1/40 inches per foot at 600 degrees F. b. Maximum combined vertical offset and dip camber: 1/50 inches per foot at 600 degrees F. 6. Gage Misalignment Tolerance: Maximum combined horizontal offset and horizontal kink camber is 1/50 inches per foot at 600 degrees F. A. Preheat the rail ends prior to welding to the temperature and for the time specified in the approved welding procedure specification to ensure full fusion of the weld metal to the rail ends without cracking of the rail or weld. Engineer will reject welds that were made without the rail first properly preheated in accordance with the manufacturer s recommendations POST HEATING TREATMENT A. Leave the moulds in place, after tapping per manufacturer s recommendation to permit complete solidification of the molten metal, in order to allow proper slow cooling in order to prevent cracking and to provide a complete weld with proper hardness and ductility WELD FINISHING AND TOLERANCES A. Bring welded joints in the finished track to a true surface and align by means of an approved grinding or planning machine (shear). Use a hand grinder for the final smoothing and for areas not accessible to a track grinder. Perform finish grinding with an approved grinder operated by a skilled workman. Take care to grind evenly and leave the joints in a satisfactory condition. Finishing shall eliminate all cracks. Complete the completed weld by mechanically controlled grinding in conformance with the following requirements:

10 3.08 WELD QUALITY 3.09 WELD NUMBERING 1. Tolerances: A finishing deviation of not more than plus or minus 1/100 inches of parent section of the rail will be allowed. 2. Welds produced by welding kits which are specially designed to produce reinforced welds need not be ground in the fishing area except as necessary to remove fins, burrs, cracks, etc. A. Each completed weld shall have full penetration and complete fusion and be entirely free of cracks or fissures. A. Semi-permanently mark a sequential weld number, rail temperature, and date on the rail immediately adjacent to the weld using a quality paint marker at the time the weld is made. B. Number the welds sequentially in the order in which they are made. C. Obtain the initial weld number from the Engineer. D. When defective welds are replaced, assign a new sequential number by adding a letter to the defective weld number (e.g. defective weld 109 would be replaced by 109A) FIELD QUALITY CONTROL AND TESTING A. Visually inspect all welds at the time of welding and during the grinding operation. B. Prior to completion of welding operation, visually inspect all welds to verify the base riser break off area has been smoothed. C. Visually inspect and check welds in accordance with approved procedures to ensure there are no surface defects such as cracks and to verify that the welds conform to the alignment and finishing tolerances specified in this Section. D. Each completed field weld shall be marked with the date, name of welder, air temperature, and rail temperature or with date, name, and free weld for welds not used to control CWR thermal adjustment. E. Verify that each completed weld has full penetration and complete fusion and is entirely free of cracks or fissures. F. Perform the following tests on all welds. All testing shall be performed by a qualified Independent Testing Agency (ITA) hired by the Contractor and approved by the Engineer. The testing agency shall provide test results directly to the Engineer. 1. Ultrasonic testing shall be performed after the weld has been ground and finished to specified tolerances. Ultrasonic testing shall be performed in accordance with ASTM E164. Equipment used shall be

11 capable of detecting a 3/64-inch discontinuity, 6-1/2 inches below the top of rail. G. The weld quality, finishing and alignment requirements specified in this Section shall also apply as requirements of acceptance. H. Perform testing of welds in active tracks within 96 hours after placing the track back in service. Perform testing of welds in other tracks prior to placing the track in service. Replace unacceptable welds in accordance the requirements of this Section. I. The Engineer may randomly select any welds to be retested at any time within the period of the Contract. Such testing shall be performed by Contractorhired ITA REPLACEMENT OF DEFECTIVE WELDS A. Welds made outside of the track which the Engineer determines to be unacceptable prior to rail installation shall be cut out, rails pulled together to the indicated rail gap, and re-welded. B. Cut unacceptable welds and replace with a section of rail and 2 new welds. The minimum length of the new rail used shall be 15 feet. C. Saw cuts shall be made at least 6 inches from the centerline of the faulty weld. In-track welds shall be made in accordance with the requirements specified in this Section. D. Ultrasonically test the replacement welds as specified in this Section CLEAN UP E. Install joint bars on defective welds in active track immediately upon completion of testing, and under no circumstances later than 8 hours after testing in accordance with FRA Standards Part 213. A. Inspect areas where welding operation performed. Collect and dispose any remaining scrap sections of cropped rail daily after completion of welding operation.