metropolitan transit authority of harris county, texas · hrt or metro, provide the construction...

Metropolitan Transit Authority Of Harris County, Texas

METRO SOLUTIONS TRANSIT PROJECT

Contract Number: CT00800120 Project Number: 532132

Specifications Volume 2 of 3

Trackwork

Rail Operations Center (ROC) Phase 2

Storage Track Expansion

April 2, 2014

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January 13, 2014

DIVISION 34 - TRANSPORTATION

Trackwork

Doc. No. Document Title Doc.Date

34 14 00 Rail 1-23-2014

34 14 05 Special Trackwork Material 1-23-2014

34 14 10 Ballast 1-23-2014

34 14 15 Other Track Material 1-23-2014

34 14 20 Ballasted Track Construction 1-23-2014

34 14 36 Concrete Crossties 1-23-2014

34 14 37 Special Trackwork Ties 1-23-2014

34 14 40 General Track Construction 1-23-2014

34 14 50 Grade Crossings 1-23-2014

34 14 75 Rail Welding 1-23-2014

Section 34 14 00 – Rail

34 14 00 - 1 01/23/2014

SECTION 34 14 00

RAIL PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the furnishing, fabricating, treating, testing, inspecting, shipping, and delivering standard and high strength 115 RE rail and precurved rail.

B. The Supplier shall furnish all labor, tools, materials, equipment, facilities

and transportation to supply and deliver rail. C. All work shall be in accordance with AREMA Specifications except as

modified herein.

1.02 DEFINITIONS

A. The term “Contractor” and “Construction Manager” as used in this Section shall mean the Houston Rapid Transit (HRT) Joint Venture.

B. The term “Supplier” shall mean the entity which that undertakes the

furnishing rail as specified in this Section. C. The terms “Fabricator” or “Manufacturer” shall mean the entity that

manufactures rail as specified in this Section.

1.03 RELATED WORK

A. Section 34 14 15 Other Track Material

1.04 QUALITY CONTROL Comply with the Supplier’s Quality Plan. 1.05 REFERENCED STANDARDS

A. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the Work included in this Section.


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B. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the Work included in this Section.

C. Rail shall be in accordance with the American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, except as modified herein.

1.06 SUBMITTALS

A. Submit the following to the Construction Manager, for review and approval, at least four weeks prior to the manufacture of rail: 1. Schedule showing dates of rail production, testing, inspection,

shipment, and final delivery. 2. A document explaining the Quality Control program of the

Manufacturer. 3. Testing facility information. 4. Description of the test method for verification of mechanical

properties to achieve the required rail hardness. 5. Manufacturing process. 6. Casting process. 7. Method used for hydrogen elimination. 8. Chemical composition of alloy high-strength rail, if to be supplied,

including the average Brinell hardness attained. 9. Ultrasonic testing work plan, method, equipment and records,

certification of testing personnel. Construction Manager approval of the ultrasonic instrumentation systems calibration will be based on the system's ability to repeatedly identify the known internal defects in the calibration reference rail. The Construction Manager shall be notified at least 72 hours in advance to witness each calibration.

10. The method of handling, shipping, unloading and stacking rail.


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B. Submit the following to the Construction Manager, for review and approval, at least two weeks prior to delivery: 1. Result of rail steel chemical analysis. 2. Completed Rail Inspection Forms or equivalent. 3. Control cooling and heat treating process records. 4. Brinell hardness test reports.

PART 2 - PRODUCTS 2.01 MATERIALS

A. Provide new 115 RE rail in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 1 Design, Figure 4-1-1 115 RE Rail Section, subject to tolerances as specified in, and in accordance with, AREMA Chapter 4, Part 2 Specifications.

B. Provide standard and high strength rail as specified. C. High strength rail shall be head-hardened rail. Only one type of high

strength rail shall be used throughout the contract. D. Precurved rail for radii equal to or less than 300 ft.

2.02 MANUFACTURE

A. Rail shall be manufactured in accordance with AREMA Manual, Volume 1

Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.2 Manufacture.

B. The steel shall be made by one of the following processes: basic oxygen or

electric furnace. C. All rail shall be cast by continuous process. D. Sufficient discard shall be taken from blooms or ingots to ensure freedom

from injurious segregation and pipe.


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2.03 CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES

A. Chemical composition and mechanical properties of the rail shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.3 Chemical Composition and Mechanical Properties.

B. Surface hardness of the rail shall be as specified in Sub-Article 2.1.3.2

Surface Hardness, shall be within the limits found in the AREMA Rail Hardness Tables for the rail steel grade specified.

C. Internal hardness of the high strength rail shall be as specified in Sub-

Article 2.1.3.3 Internal Hardness of High-Strength Rail. D. Tensile properties of the rail shall be as specified in Sub-Article 2.1.3.4

Tensile Properties, for the rail steel grade specified.

2.04 PROPERTIES OF AREMA RAIL GRADES

A. Rail grades shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.4 Properties of AREMA Rail Grades.

B. Phosporous and sulfur contents specified in Table 4-2-1-4-1a

Product/Chemical Analysis Table for Standard Chemistry Rail Steel shall not be exceeded.

C. Minimum percent elongation in two inches specified in Table 4-2-1-4-1c

Tensile Properties Table for Standard Chemistry Rail Steel shall not be exceeded.

2.05 SECTION

A. Steel rail shall conform to rail section in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 1 Design, Section 1.1 Recommended Rail Sections, Figure 4-1-1 115 RE Rail Section.

B. Tolerances on dimensions of the steel rails shall be in accordance with

AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.5 Section, Table 4-2-2 Section Tolerances.


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2.06 BRANDING AND STAMPING

Branding and Stamping shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.6 Branding and Stamping.

2.07 HYDROGEN ELIMINATION

Hydrogen elimination shall be in accordance with the AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.7 Hydrogen Elimination, and Article 2.1.18 Appendix 1.

2.08 ULTRASONIC TESTING

A. Ultrasonic testing shall be in accordance with the AREMA Manual,

Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.8 Ultrasonic Testing.

B. All rails shall be ultrasonically tested by a computerized in-line unit.

2.09 INTERIOR CONDITION/MACROETCH STANDARDS

A. Interior condition/Macroetch standards shall be in accordance with the

AREMA Manual, Volume 1 Track, Chapter 4 Rail , Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.9 Interior Condition/Macroetch Standards.

2.10 SURFACE CLASSIFICATION

A. Surface classification shall be in accordance with the AREMA Manual,

Volume 1 Track, Chapter 4 Rail , Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.10 Surface Classification.

2.11 LENGTH

A. Lengths shall be in accordance with AREMA Manual, Volume 1 Track,

Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.11 Length, except as amended herein.

B. The standard rail length shall be 80 feet.


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2.12 WORKMANSHIP

A. Workmanship shall be in accordance with AREMA Manual Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.13 Workmanship, except as modified below.

B. Precurved Rail

1. Pre-curve rail used for track curves having less than 300-foot radius for continuously welded rail (CWR).

2. Pre-curved rail may be cropped at 36-foot lengths if at no

additional cost.

3. All rails shall be straight before pre-curving.

4. Uniformly curve rail, such that the deviation of the interior mid-ordinate offset from the theoretical offset is within the tolerances for straight rail using the appropriate chord distance required by the straight rail Specification. Pre-curved rail bases shall be level when laid out on a flat surface and distortion to laying flat in pre-curved rail base will not be acceptable.

5. Curved rails shall be pre-curved in the shop by either gag press or

roller bending methods.

6. Identify pre-curved rail with painted identity numbering per approved Shop Drawing code at the end of each rail, and paint identity numbers so that they are visible from both the top and the side of the rails.

2.13 ACCEPTANCE

A. Acceptance shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.14 Acceptance.

B. Rail which does not comply with the accepatance criteria or which, not withstanding tests, inspection or acceptance at any previous time or location, is found to contain deficiencies, will be rejected.

C. The Construction Manager will have authority to reject any material, work

in progress or finished work that fails to meet the requirements of these


34 14 00 - 7 01/23/2014

Specifications, and will have authority to specify corrective work necessary to meet the requirements.

2.14 MARKINGS

A. Markings shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.15 Markings.

PART 3 - EXECUTION 3.01 QUALITY ASSURANCE

A. The Supplier shall have in effect a recognized quality control program.

This program shall be submitted to the Construction Manager for review and approval.

B. All testing and inspection shall be at the expense of the Supplier, and may

be performed at the Manufacturer’s facility. In any case, the testing facility shall meet the requirements of AREMA and shall be approved by the Construction Manager.

3.02 INSPECTION

A. Provide the Construction Manager free entry at all times to the Supplier's shop to inspect the processing and manufacture of rail while work on this contract is being performed. Have the Supplier, at no additional cost to HRT or METRO, provide the Construction Manager with all labor, machinery, material, tools and equipment necessary to inspect test specimens to satisfy the Construction Manager that the rail is being furnished in accordance with this Specification. Perform all rail tests and inspections at the shop and provide certified test results for all chemical, physical and mechanical tests prior to shipment at no additional cost to HRT or METRO.

B. Schedule in-shop inspections at a time agreeable to the Construction

Manager. Provide the inspection schedule to the Construction Manager at least 30 days in advance of the initial in-shop inspection and 10 days in advance for subsequent in-shop inspections.

C. The Supplier shall furnish to the Construction Manager computerized rail

inspection reports.


34 14 00 - 8 01/23/2014

3.03 LOADING

A. Loading shall be in accordance with AREMA Manual, Volume 1 Track, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.16 Loading.

3.04 STORAGE AND HANDLING

A. Stack rail for easy handling and maintain cleanliness for visual inspection. Protect rail ends from physical damage after fabrication. Rails shall not be stored in direct contact with the ground surface. All rail shall be supported by an approved wood or plastic dunnage material. Adequate space between layers of rail shall be maintained to provide free air circulation.

B. Stacking of rails shall be done in such a way as to prevent sagging.

END OF SECTION 34 14 00

Section 34 14 05 – Special Trackwork Material

34 14 05 - 1 01/23/2014

SECTION 34 14 05

SPECIAL TRACKWORK MATERIAL PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the furnishing, fabricating, testing, inspecting, shipping, delivering, and stockpiling of special trackwork material. Special trackwork includes turnouts, crossovers, and track diamond crossings. Special trackwork includes installation in ballasted track with concrete ties.

B. Special trackwork material includes switch points, stock rails, lead rails,

closure rails, frogs, guard rails, switch plates, frog plates, tie plates, brace plates, adjustable filler blocks, concrete ties, manual switch operating mechanisms (switch stands), and other components as necessary to permit a completely functional installation.

1. Insulated rail joint materials will be furnished by others. 2. Power operated switch operating mechanisms will be furnished by

others.

C. The Supplier shall furnish all labor, tools, materials, equipment, facilities and transportation to supply and deliver the special trackwork material. The special trackwork material shall be delivered and stockpiled at the locations in the metropolitan Houston area directed by the Construction Manager.

D. All work shall be in accordance with AREMA specifications except as

modified herein.

1.02 DEFINITIONS

A. The term “Construction Manager” as used in this Section shall mean the Houston Rapid Transit (HRT) Project Joint Venture.

B. The term “Supplier” shall mean the entity which undertakes the

furnishing of special trackwork material as specified in this Section.


34 14 05 - 2 01/23/2014

C. The terms “Fabricator” or “Manufacturer” shall mean the entity that manufactures special trackwork material as specified in this Section.

1.03 RELATED WORK

A. Section 34 14 00 Rail B. Section 34 14 15 Other Track Material C. Section 34 14 36 Concrete Crossties D. Section 34 14 37 Special Trackwork Ties E. Section 34 14 75 Rail Welding

1.04 QUALITY CONTROL

A. Comply with the Supplier’s Quality Plan. B. The quality control plan shall be in conformance with the relevant

provisions of AAR M-1003.

1.05 REFERENCE STANDARDS A. Where a date is given for reference standards, the edition of that date shall

be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the Work included in this Section.

B. American Railway Engineering and Maintenance-of-Way Association

(AREMA)

Manual for Railway Engineering, Volume 1 Track, hereinafter referred to as the AREMA Manual Portfolio of Trackwork Plans, hereinafter referred to as the Portfolio Communications and Signals Manual of Recommended Practice

C. Association of American Railroads (AAR)

Specification for Quality Assurance M-1003


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D. ASTM International (formerly American Society for Testing and Materials) (ASTM)

A36 Standard specification for Carbon structural Steel A325 Standard Specification for structural Bolts, Steel, Heat Treated,

120/105ksi Minimum Tensile Strength A490 Standard Specification for Structural Bolts, Alloy Steel, Heat

Treated, 150 ksi Minimum Tensile Strength D257 Standard Test Methods for DC Resistance or Conductance of

Insulating Materials

1.06 SUBMITTALS

A. All submittals shall be made in conformance with the Submittal’s Exhibit in the contract, except as modified herein.

B. Submit inspection reports and certified material test reports to the

Construction Manager, for review and approval, at least two weeks prior to shipping of special trackwork material.

C. Submit the following to the Construction Manager, for review and

approval, at least 30 days prior to fabrication.

1. Schedule showing dates of special trackwork fabrication, tests, inspection, shipment, delivery, and stockpile.

2. Shop fabrication drawings for each type and size of turnouts,

crossovers and crossings showing complete geometry, locations, dimensions and details of each special trackwork component, including plates and special trackwork ties.

3. Identification System for each special trackwork component. 4. Quality control program. 5. Documentation of coordination with the Fabricators of material

indicated to be furnished by others.

PART 2 - PRODUCTS


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2.01 GENERAL

A. Special trackwork for ballasted track shall be furnished with all required concrete ties. Special trackwork concrete ties shall be as specified in Section 34 14 37 Special Trackwork Ties. Standard concrete ties shall be as specified in Section 34 14 36 Concrete Crossties, except that no rail cant is required for ties within the special trackwork limits.

B. To the extent possible all components of the special trackwork shall be

identical for ballasted track. C. Miscellaneous requirements:

1. Rail connections within yard turnouts shall be bolted standard joints. 2. All special trackwork shall be fully insulated electrically from the

substrate. 3. All rails, frogs and other special trackwork materials, including frog

guardrails, shall conform to the AREMA dimensional requirements for 115 RE rail section as specified in the AREMA Manual, Chapter 4 Rail, Part 1 Design, Section 1.1 Recommended Rail Sections, and Figure 4-1-1.

4. All rails shall be pre-cut to the required lengths. Rail cutting shall be

in accordance with the AREMA specifications. 5. Holes drilled in rails for bonded insulated, bonded standard, and

bolted standard joints shall be as specified in Section 34 14 15 Other Track Material.

6. Field kits shall be provided as to provide a complete electrical

isolated installation. 2.02 SPECIAL TRACKWORK RAIL

A. General:

1. Special trackwork rail shall be in accordance with Section 34 14 00 Rail.


34 14 05 - 5 01/23/2014

2. Special trackwork rails shall be heat treated in accordance with Portfolio Plan No. 100, Specifications for Special Trackwork, Part M1 Steel Rails, Article M1.4 Heat Treatment, and Section 34 14 00 Rail.

B. Drilling and Beveling

1. All rail ends specified to be bonded standard and bonded insulated joints shall be beveled in accordance with Portfolio Plan No. 1005.

2. Holes in rails for bonded insulated, bonded standard, and bolted

standard joint installation shall be predrilled. Rail drilling shall be for 6-hole joint bar assemblies in accordance with the AREMA Manual, Chapter 4 Rail, Part 1 Design, Section 1.3 Rail Drillings, Bar Punchings and Bolts. Hole spacing shall be as directed by the Construction Manager. All drilled bolt holes shall be ground to remove all sharp edges.

3. Rail ends to be welded shall be left blank and shall not be beveled.

C. Precurved Rail

1. All rails in special trackwork with radii of 500 feet or less shall be

precurved to the required radius and length.

a. After precurving, the rail base shall be within 0.090 inch of a uniform plane at both edges of the rail base along the full length of each rail.

b. All precurved closure rail shall be paint marked on the rail

head to show length and turnout or crossover number.

2. All rails to be precurved shall be supplied with blank ends for welding, except that where bonded insulated and bonded standard joints are shown, rail ends shall be drilled after curving.

3. Rail Alignment

a. The deviations of the lateral (horizontal) line shall be in

accordance with the AREMA Manual, Chapter 4 Rail, Part 2 Specifications, Section 2.1 Specifications for Steel Rails, Article 2.1.13 Workmanship, and Sub-Article 2.1.13.1 Rail Straightness, and as modified below:


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1) The uniform surface upsweep at the rail ends shall not exceed a maximum ordinate of 0.012 in 3 feet using a 3 foot straight edge. The 0.012 inch maximum shall not occur at a point closer than 18 inches from the rail end.

2) The uniform surface upsweep of the rail between

points 3 feet from each rail end shall be in accordance with AREMA Specifications for new rail, i.e., 3/4 inch in 39 feet, adjusted to the actual rail length.

3) Surface downsweep or droop will not be acceptable. 4) Post-Rolling Rail Treatments

a) Treatments to the rail after initial rolling shall be

conducted prior to precurving the rail. b) Treatments which are location specific on the

rail surface, such as hardening weldments, shall be placed on the rail such that the required hardness is obtained at the surfaces where wheel contact occurs.

2.03 SWITCHES

A. All switch point rails and stock rails shall be Samson type construction in accordance with Portfolio Plan No. 221, Point Detail 5100. Thick web switch point rails are acceptable in lieu of rail with reinforcing bars.

B. Boltless adjustable rail braces shall be provided on all switches. C. Switch points and rods shall have a throw of 4-3/4 inches.

2.04 FROGS

A. All frogs shall be either of the following:

1. Railbound manganese steel construction in accordance with

Portfolio Specifications for Special Trackwork, Part M2 Manganese Steel Castings. Manganese inserts shall be depth hardened in accordance with Portfolio Specifications for Special Trackwork, Article M2.7 Depth Hardening.


34 14 05 - 7 01/23/2014

2. Solid block machined cast manganese steel with shop welded rail extensions. Welds shall be electric flash butt welds.

B. All frogs shall have a flangeway width of 1-7/8”. C. Frogs in yard tracks shall be Rail Bound Manganese and may have bolted

joints.

2.05 GUARD RAILS

A. Frog guard rails and accessories shall be manufactured in accordance with Portfolio Plan No. 504 or equivalent.

B. Frog guard rails shall be 115 RE section machined and drilled as shown. C. Frog guard rails shall be furnished with the accessories as shown.

Separator blocks and end blocks shall be malleable or ductile iron. D. Frog guard rails shall provide a flangeway width of 1 7/8” when installed

adjacent to new rails and shall be adjustable in increments of a maximum of 1/8 inch. The flangeway adjustment range shall permit 1/2 inch inward adjustment to compensate for worn running rails. End block and separator blocks shall be designed so as to allow for the adjustment of the flangeway width.

E. Frog guard rail bolts shall be high strength type conforming to the

requirements of ASTM Designations A325 or A490 and shall have Class 2A and 2B thread fit. Thread length may vary as required from that specified for structural bolts. Bolts shall include a positive means of preventing the loosening of the element due to in-service vibrations. A double coil steel spring washer, elastomeric rebound washer or equivalent spring device shall be used.

2.06 SPECIAL TRACKWORK PLATES

A. Special trackwork fasteners on concrete ties shall consist of steel plates with weld-on shoulders, Pandrol Type e-2055 rail clips or approved equal, and anchor inserts embedded into the concrete switch ties. Special trackwork plates shall have at least four holes in each plate for bolted connection to concrete switch ties.

B. Special trackwork plates shall conform to current AREMA specifications for

low-carbon steel tie plates with copper.


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C. Rail stops as required for adjustable braces and shoulders for non-threaded

resilient clips shall be welded to their respective plates. All welds shall conform to American Welding Society Standards.

D. Special trackwork fasteners shall conform to ASTM A36. Holes in steel

plates shall be punched or drilled through each plate perpendicular to its face and shall be clean cut without torn or ragged edges. Plates shall conform to the listed tolerances and tolerances shall not be cumulative. 1. The thickness of the plate shall be to a tolerance of ± 1/32 inch. 2. The special trackwork plate, when placed on a horizontal support,

shall not have a middle ordinate greater than 0.001 inch per inch of length when wire stringline or straight edge is placed from one end of the fastener to the other end on the concave side and the middle ordinate is determined by measuring the distance between the plate surface and the stringline or straight edge. Surface downsweep or upsweep shall be uniform.

3. Hole dimensions shall be within ± 1/32 inch. 4. Hole centerline locations shall be within a tolerance of ± 1/16 inch. 5. The thickness of plate rail stops and riser plates shall be to a

tolerance of ± 1/32 inch. 6. The edge of rail stops and riser plates parallel and adjacent to the

base of the running rail shall be straight to a tolerance of ± 1/32 inch.

7. The transverse dimensions of rail stops shall be to a tolerance of ±

1/32 inch. 8. Dimensions, except those listed above, shall be to a tolerance of ±

1/8 inch.

E. Rail braces for special trackwork concrete ties shall be boltless and adjustable for use with non-threaded resilient clips.

F. Rail braces for special trackwork fasteners on direct-fixation concrete slabs

shall be bolted and adjustable for use with non-threaded resilient clips.


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G. Gauge Plates and Switch Plates

1. Insulation for gauge plates and switch plates on concrete switch ties shall be a flat cross ply non-woven fiberglass reinforced epoxy resin as manufactured by 3-M or equivalent. The assembly shall use a 3/4 inch swage fastener collar. The insulation shall not cover the tie in the area reserved for extension plates for switch operating mechanism attachment.

2.07 SWITCH RODS

A. Switch rods and clips shall be of vertical design, such as an ABC Racor Type "SMJ" or approved equal. The position of all nuts shall be maintained by ¼ inch cotter pins. All switch rods shall be fabricated, insulated, assembled and tested in accordance with Part 8.5.1 of the AREMA Communications and Signals Manual, Recommended Instructions for Assembly and Electrical Testing of Insulated Track Fittings.

B. Switch rods shall be 1-1/4 inch by 2-1/2 inch bar stock of sufficient length

for each rod to extend under the stock rail in either thrown position. C. Switch rod No. 1 shall be designed to attach a conventional connecting rod,

as well as the basket for machine thrown switches. The connecting rod bolt shall be vertical in the installed position. Switch rods shall be drilled to accept a 1-1/8 inch diameter connecting rod bolt.

D. The clearance gap between the top of the vertical switch rod and the base of

stock rail shall be 1/16 to 3/16 inch. E. Switch rod No. 1 shall be designed to permit interchange of the insulation

assembly with a conventional power operated switch rod basket connection.

F. Point and drilling per Portfolio Plan No. 221, shall allow for future

conventional front rod and detector rod lug connections.

2.08 IDENTIFICATION MARKING

A. Special trackwork plate identification markings shall be plainly stamped or embossed with letters and figures not less than 1/2 inch in height, located on the top surface, plainly visible when assembled and not subject to wear.


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B. Markings shall be made in a permanent manner that will ensure their complete legibility. Markings shall include the manufacturer's name or trademark, and component identification code.

C. Each turnout component, switch point rails, frog, guard rails and cartons of

packages containing loose fastenings shall be individually identified to show specific turnout identification number.

D. To assist in the installation of turnouts, rail ends shall be identified by joint

number as shown on the shop drawings. Joint number shall incorporate the specific turnout identification number.

PART 3 - EXECUTION 3.01 SHOP INSPECTION

A. All material furnished in this Contract shall be presented for inspection at

the place of manufacture. For the inspection of material under this Contract, the terms set forth in Portfolio Plan No. 100, Specifications for Special Trackwork, shall control.

B. The Supplier shall provide the Construction Manager, without charge, all

necessary facilities to examine the Work during its progress as well as after completion of the finished product to satisfy the Construction Manager that the materials comply with this Specification. The Supplier shall provide measuring tools, track gauges, and templates to check flangeways, rail end drilling and switch rail planing. The design of the templates shall be such that using the templates will be easy and quick, requiring only one person for the operation.

C. Material for inspection shall be presented in a safe area away from

excessive noise and manufacturing activities. The Supplier shall provide labor to facilitate inspection of the top, side and bottom of frogs, switches and special crossing frogs.

D. One type of each turnout and each crossing shall be completely assembled

by the Supplier for inspection. After inspection, the components shall be match-marked in a manner acceptable to the Construction Manager. The match-marking scheme shall be a part of the shop drawings and shall have prior approval of the Construction Manager.


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E. The Supplier shall give the Construction Manager written notice for inspection at least ten working days in advance of availability for inspection.

3.02 ACCEPTANCE A. The Construction Manager will have authority to reject any material, work

in progress or finished work that fails to meet the requirements of these Specifications, and will have authority to specify corrective work necessary to meet the requirements.

3.03 SHIPPING/PACKAGING/STACKING

A. Band or package together the following special trackwork materials for each turnout:

1. Frog: Frog, frog plates, guard rails and guard rail plates. Guard rails

and guard rail plates may be bolted to the rail for shipping. 2. Switch: Switch points, stock rails, switch rods, straps, gauge plates,

slide plates, switch plates and heel block assemblies.

B. Mark all switch packages to identify the switch direction (right hand, equilateral or left hand), switch length, type of operation, and type of construction (ballasted, embedded, direct fixation).

C. Mark all frog packages to identify frog type, frog number, and type of

construction.


Section 34 14 10 – Ballast

34 14 10 - 1 01/23/2014

SECTION 34 14 10

BALLAST PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the furnishing, testing, storage, and delivery of ballast material for track construction. Ballast shall be either delivered and stockpiled or delivered directly to the construction sites as directed by the Construction Manager.

B. The Supplier shall furnish all labor, tools, materials, equipment, facilities,

and transportation to furnish and deliver the ballast material in the quantity required.

C. All materials and procedures shall be in accordance with the relevant

AREMA Specifications except as modified herein. 1.02 DEFINITIONS

A. The term “Contractor” and “Construction Manager” as used in this Section shall mean the Houston Rail Transit (HRT) Project Joint Venture.

B. The term “Supplier” shall mean the entity that undertakes the furnishing

of ballast material as specified in this Section. C. The term “Producer” shall mean the entity that processes raw material to

produce ballast.

1.03 RELATED WORK

Not Used.


Comply with the Supplier’s Quality Plan. 1.05 REFERENCE STANDARDS

A. Where a date is given for reference standards, the edition of that date shall

be used. Where no date is given for reference standards, the latest edition


34 14 10 - 2 01/23/2014

in effect on the bid due date shall apply to all Work in this Section.

B. Ballast shall be in accordance with the American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Volume I Track, Chapter 1 Roadway and Ballast, Part 2 Ballast, except as modified herein.

C. ASTM International (formerly American Society for Testing and

Materials) (ASTM)

C25 Standard Test Methods for Chemical Analysis of Limestone, Quicklime, and Hydrated Lime

C29 Standard Test Method for Bulk Density (“Unit Weight”) and

Voids in Aggregate C88 Standard Test Method for Soundness of Aggregates by Use

of Sodium Sulfate or Magnesium Sulfate

C117 Standard Test Method for Materials Finer than 75-mm (No.

200) Sieve in Mineral Aggregates by Washing C127 Standard Test Method for Density, Relative Density (Specific

Gravity), and Absorption of Coarse Aggregate C136 Standard Test Method for Sieve Analysis of Fine and Coarse

Aggregates C142 Standard Test Method for Clay Lumps and Friable Particles

in Aggregates C535 Standard Test Method for Resistance to Degradation of

Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

C702 Standard Practice for Reducing Samples of Aggregate to

Testing Size D75 Standard Practice for Sampling Aggregates D4791 Standard Test Method for Flat Particles Elongated Particles,

or Flat and Elongated Particles in Coarse Aggregate


34 14 10 - 3 01/23/2014

1.06 SUBMITTALS

Submittals shall be in accordance with the requirements of the Submittal’s Exhibit in the contract, except as modified herein. A. The following shall be submitted to the Construction Manager, for review

and approval, at least ten day prior to start of production of material for use on this project.

1. Ballast source, identification of testing service, testing program and

procedures, and copy of agreement between the Supplier and the testing service.

2. Plan for handling and stockpiling of ballast. This plan shall include

type of equipment to be used, locations of stockpiles and method of distribution.

B. Quarry qualification test reports shall be submitted to the Construction Manager, for review and approval, at least five days prior to start of production.

C. Production test reports shall be submitted to the Construction Manager,

for review and approval, at least five days prior to delivery of ballast material.

1.07 LABORATORY TESTING

A. All laboratory testing shall be performed at the expense of the Supplier. B. The Supplier shall submit a copy of the Supplier’s agreement with the

Independent Testing Laboratory prior to testing. The agreement shall specify that the testing agency is directly responsible to the Construction Manager and that all subsequent communication between the Independent Testing Laboratory and the Supplier regarding the work under this contract shall be only through the Construction Manager. The agreement shall run for the duration of the contract and can be terminated for cause by the Construction Manager at any time. If so terminated, no material will be accepted until a satisfactory alternative testing arrangement has been approved by the Construction Manager.

C. The Independent Testing Laboratory shall submit in a timely manner, test

reports containing a description of each test; identification of test equipment used along with current calibration certificates; an explanation of all deviations of test procedures; tabulations and/or plots of test results;


34 14 10 - 4 01/23/2014

the testing service's evaluation of the results; and sketches or diagrams necessary to clarify the test or results.

D. The Independent Testing Laboratory shall submit at least five copies of

each test report to the Construction Manager. The Construction Manager will forward two copies to the Supplier.

E. Qualification Testing

1. Qualification tests for ballast material are required prior to

production of material for this project. The Supplier shall have representative samples taken, tested for quality and gradation and certified by the approved testing laboratory.

2. Each stratum or portion of the quarry containing a variation in

quality of stone shall be separately tested. Tests of a single stratum or portion shall not be averaged with any other stratum or portion of the quarry. Two samples shall be taken from each ledge or different quality of stone used in the preparation of the ballast.

3. Certificates shall be submitted not less than five working days prior

to start of production of ballast. Additional sampling and testing shall be performed at the expense of the Supplier if, in the Construction Manager's opinion, there are significant changes in the quarry operation.

F. Quality Control Testing

1. The approved testing lab will sample ballast at the time of delivery

and perform a minimum of one gradation test for every 1,000 cubic yards of ballast delivered to the job site to ensure uniformity and conformance with the gradation requirements.

2. The Construction Manager may order additional samples of

delivered ballast to be tested. The Supplier shall assist and cooperate with the Construction Manager in taking the samples.

3. Soundness tests will be performed in accordance with ASTM C88

as required.


34 14 10 - 5 01/23/2014

PART 2 - PRODUCTS 2.01 BALLAST

A. General: Ballast shall be crushed rock with fractured faces composed of hard, strong angular, durable particles, free from injurious amounts of deleterious substances and conforming to the requirements of the following paragraphs. Crushed blast furnace slag or crushed limestone ballast will not be accepted.

B. Ballast Source

The Supplier shall select a ballast source to produce ballast in accordance with this specification. The ballast source shall be submitted to the Construction Manager for review and approval. Ballast material and source of supply shall not be changed without prior approval of the Construction Manager.

C. Quality

1. Deleterious material in the ballast shall not exceed the following

amounts, as determined by the appropriate testing method listed:

a. Material passing No. 200 Sieve when tested in accordance with ASTM C117 shall not exceed 1.0 percent.

b. Clay Lumps and Friable Particles when tested in accordance

with ASTM C142 shall not exceed 0.5 percent.

2. Percentage of wear of the material when tested in accordance with ASTM C535 shall not exceed 35 percent.

3. Weighted average loss when tested in accordance with ASTM C88

for sodium sulfate soundness shall not exceed 5 percent after 5 cycles.

4. Bulk specific gravity when tested in accordance with ASTM C127

shall not be less than 2.60 5. Absorption when tested in accordance with ASTM C127 shall not

exceed 1.0 percent. 6. Flat and elongated particles when tested in accordance with ASTM

D4791 shall not exceed a weighted average of 5 percent by weight.


34 14 10 - 6 01/23/2014

7. Limestone, slag, river gravel or any material containing metallic ore or metallic residues will not be accepted.

8. Sampling shall be done in accordance with ASTM D75. Test

samples shall be reduced from field samples in accordance with ASTM C702.

9. Determination of weight per cubic yard shall be in accordance with

ASTM C29. 10. Determine the magnesium carbonate content in accordance with

ASTM C25. Material containing measurable carbonates will not be accepted.

D. Gradation Requirements

1. Gradation of ballast shall be determined by testing in accordance

with ASTM C136. All gradation tests shall include minus 200-sieve particle analysis in accordance with ASTM C117.

2. Ballast for mainline and yard tracks shall conform to AREMA Size

No. 4 with the following gradation requirements:

Sieve Size, Inches

Percent by Weight Passing Sieve

2 100 1 1/2 90 – 100 1 20 – 55 3/4 0 - 15 3/8 0 - 5

3. Ballast for walkways shall conform to AREMA Size No. 5 with the

following gradation requirements:

Sieve Size, Inches

Percent by Weight Passing Sieve

1 1/2 100 1 90 – 100 3/4 40 – 75 1/2 15 - 35 3/8 0 - 15 No. 4 0 - 5


34 14 10 - 7 01/23/2014

PART 3 - EXECUTION 3.01 HANDLING

A. Handling of ballast during blending, stockpiling, and other production

and handling operations shall be managed to minimize segregation, degradation, breakage or contamination of the finished product. Movement of wheeled vehicles over stockpiled material shall be limited. Ballast shall be kept clean and free from segregation during handling and placing operations. Wash and/or re-screen processed ballast as necessary to correct fine particle contamination prior to delivery.

B. Storage sites for ballast are the responsibility of the Supplier.

3.02 INSPECTION

A. Ballast is subject to inspection and testing (gradation and quality) as often as considered necessary by the Construction Manager at any time between quarry production and delivery of material. Ballast which does not conform to this specification shall not be used and the Construction Manager will notify the Supplier to stop further ballast delivery until the fault has been corrected.

B. The Construction Manager shall have free entry to the producing plants

and the storage sites at all times while the work of this Contract is being executed.

C. The Supplier shall arrange for all reasonable access by the Construction

Manager to production facilities and stockpile sites to permit verification that ballast is being prepared and loaded without segregation in accordance with the specifications.

3.03 DEFECTIVE BALLAST MATERIALS

Unless otherwise permitted by the Construction Manager, the Supplier shall remove defective materials from the site within 48 hours of notification. Materials shall be removed at Supplier’s expense.


Section 34 14 15 – Other Track Material

34 14 15 - 1 01/23/2014

SECTION 34 14 15

OTHER TRACK MATERIAL

PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies furnishing, fabricating, testing, inspecting, delivering, unloading and stockpiling of Other Track Material (OTM). OTM shall be stockpiled at the location(s) directed by the Construction Manager.

B. Other Track Material to be supplied are as follows:

1. Bonded Insulated Joints, complete 2. Bonded Standard Joints, complete 3. Unbonded Standard Joints, complete 4. Track Bolts, Nuts and Lockwashers

C. The Supplier shall furnish all labor, tools, materials, equipment, facilities and transportation to supply and deliver the OTM necessary for the complete installation of the Work specified.

1.02 DEFINITIONS

A. The term “Contractor” and “Construction Manager” as used in this

Section shall mean the Houston Rail Transit (HRT) Project Joint Venture. B. The term “Supplier” shall mean the entity that produces or furnishes

Other Track Material as specified in this Section. C. The terms “Fabricator” or “Manufacturer” shall mean the entity that

manufactures the OTM as specified in this Section. 1.03 RELATED WORK

A. Section 34 14 00 Rail B. Section 34 14 05 Special Trackwork Material


34 14 15 - 2 01/23/2014

C. Section 34 14 20 Ballasted Track Construction D. Section 34 14 40 General Track Construction


Comply with the Supplier’s Quality Plan.

1.05 REFERENCE STANDARDS

A. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to all the Work in this Section.

B. American Railway Engineering and Maintenance-of-Way-Association (AREMA):

1. AREMA Manual for Railway Engineering (Manual)

2. AREMA Portfolio of Trackwork Plans (Portfolio)

C. ASTM International (formerly known as American Society for Testing and Materials) (ASTM)

A90 Standard Test method for Weight (Mass) of Coating on Iron

and Steel Articles with Zinc or Zinc – Alloy Coatings

A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

A325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi. Minimum Tensile Strength

D1002 Standard Test Method for Apparent Shear Strength of Single-

Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal)

E10 Standard Test Method for Brinell Hardness of Metallic

Materials E1248 Standard Practice for Shedder Explosion Protection


34 14 15 - 3 01/23/2014

1.06 SUBMITTALS

A. Submittals shall be in accordance with the requirements of the Submittal’s Exhibit in the contract.

B. Submit the following to the Construction Manager, for review and

approval, at least 30 days prior to fabrication:

1. Schedule showing dates of OTM fabrication, tests, inspection, shipment, delivery and stockpile.

2. Shop drawings for each OTM items showing complete geometry,

dimensions and details of each component. 3. Certified material test reports showing physical properties and

chemical composition, including steel chemical analysis from ladle samples.

4. Description of the method and verification testing to achieve the

required steel hardness including Brinell hardness test reports.

C. Submit to the Construction Manager, for review and approval, at least 30 days prior to delivery, the method of handling, shipping, unloading and stockpiling of each OTM items.

PART 2 - PRODUCTS 2.01 BONDED INSULATED JOINTS

A. Bonded insulated joints shall be assembled in the field using complete bonded insulated joint kits.

B. Bonded insulated joints shall be in accordance with the AREMA, Chapter 4

Rail, Part 2 Specifications, and Section 2.11 Specifications for Bonded Insulated Rail Joints

C. Bonded insulated joints shall be as supplied by Allegheny Rail Products,

Co., American Track Systems, Inc., Atlantic Track and Turnout Co., Portec Inc., or approved equal. Supplier shall submit documentations that the proposed bonded insulated joints meets or exceeds the AREMA Specifications for Bonded Insulated Rail Joints and as amended by this specification.


34 14 15 - 4 01/23/2014

D. Bonded insulated joint bars shall be 36 inches long with six-holes and shall be new, smooth, straight bars providing full face contact such as the “Metro D bar”, conforming to the configuration of 115 RE rail.

E. Bonded insulated joint bars shall be fabricated from micro alloyed steel or

quenched carbon-steel as specified in AREMA, "Specification for Quenched Carbon Steel Joint Bars, Micro-alloyed Joint Bars, and Forged Compromised Joint Bars".

F. Bonded insulated joint bars shall be manufactured with the following

tolerances: 1. Fishing height: Plus or minus 1/64 inch of the dimensions shown on

the approved shop drawings. 2. Length: Within plus or minus 1/8 inch of the dimensions shown on

the approved shop drawings. 3. Straightness: That portion of the bar adjacent to the rail: within plus

or minus 1/32 inch, when using a 36 inch straight edge.

G. Bonded insulated joint bolts shall be 1-inch diameter high strength bolts, insulated collar to fit the bolt diameter.

H. Bonded insulated joint bolts, nuts and washers shall conform to the

chemical and mechanical requirements of ASTMA A90 or A325, as applicable and have Class 2A and 2B thread fits.

I. End post shall be 3/16 inch in thickness. J Bonded insulated joint assembly shall be suitable for installation without

altering the structural integrity or mechanical performance of the rail. K. Bonded insulated joint electrical resistance shall be in accordance with the

AREMA Specifications for Bonded Rail Joints. L. Bonded insulated joint adhesives shall have a minimum shelf life of one

calendar year from the time of purchase when stored in accordance with the manufacturer's recommendations where the room temperature may vary from 40°F to 90°F Adhesive shall produce minimum lap shear strength of 3,500 psi at 75°F when tested in accordance with ASTM D1002.

M. Bonded insulated joints shall be tested in accordance with the AREMA

Specifications for Bonded Insulated Rail Joints. As an alternate to the tests


34 14 15 - 5 01/23/2014

specified in the AREMA Manual, the Supplier may submit, for review and approval, other methods of testing the bonded joint. Test results shall be certified and shall have been performed within 12 months of the request for approval. Approval of alternate test method and results will be approved by the construction manager.

N. Bonded insulated joints shall be capable for installation on curves with radii

of 125 feet. O. For curves with radii less than 125 feet, 24 inch pre-curved joint bars shall

be used. P. Four appropriate modified e-clips shall be supplied with each joint.

2.02 BONDED STANDARD JOINTS

Bonded standard joints shall be similar in material and configurations as the bonded insulated joints except that insulating properties will not be required. However, chemical and mechanical requirement as specified in the AREMA Specifications for Bonded Insulated Rail Joints and as amended by this Specification shall apply. Four appropriate modified e-clips shall be supplied with each joint.

2.03 UNBONDED STANDARD JOINT BARS, BOLTS AND SPRING WASHERS

A. Unbonded standard joint bars shall be fabricated of quenched carbon steel for 36-inch, six-hole joint toeless bars in accordance with the AREMA Specifications for Quenched Carbon Steel Joint Bars, Micro-alloyed Joint Bars, and Forged Compromise Joint Bars.

A. Bolts and Nuts be new and shall be in accordance with the AREMA

Specifications for Rail Drilling, Bar Punching, and Track Bolts, and Design for Track Bolts and Nuts. Track bolts and nuts shall be in accordance with the AREMA "Specifications for Heat Treated Carbon Steel Track Bolts and Carbon Steel Nuts.”

B. Spring Washers shall be new and in accordance with AREMA Specifications for Spring Washers.

C. Four appropriate modified e-clips shall be supplied with each joint.


34 14 15 - 6 01/23/2014

2.04 TRACK BOLTS, NUTS AND LOCK WASHERS

A. Track bolts and nuts shall conform to AREMA Standard Specification for heat-treated carbon steel track bolts and nuts, Chapter 4, Section 3.5 for Grade 8 steel. Track bolts shall have oval neck design, one inch diameter and six inches in length with rolled or cut threads. The nut shall be square and heavy duty for wrench turn fit.

B. Lock washers shall follow AREMA Standard Specification for Spring

Washers, Chapter 4, Section 3.6. PART 3 - EXECUTION NOT USED


Section 34 14 20 – Ballasted Track Construction

34 14 20 - 1 1/23/2014

SECTION 34 14 20

BALLASTED TRACK CONSTRUCTION PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the construction of new ballasted mainline and yard tracks, and new rail grinding, as shown on the Contract Drawings and as specified herein.

B. The track to be constructed is for an electrified Light Rail Transit (LRT)

system with an overhead contact system (OCS). The rail in the track is the ground return for the OCS. Care shall be taken by the Contractor to reduce the possibility of stray currents.

C. Mainline track shall be constructed with new 115 RE Continuous Welded

Rail (CWR). Yard track shall be constructed with new 115 RE welded and jointed rail. The minimum length of any rail installed in track shall be 12 feet.

1.02 RELATED WORK

A. Section 34 14 00 Rail B. Section 34 14 05 Special Trackwork Material C. Section 34 14 10 Ballast D. Section 34 14 15 Other Track Material E. Section 34 14 36 Concrete Crossties F. Section 34 14 37 Special Trackwork Ties G. Section 34 14 40 General Track Construction H. Section 34 14 75 Rail Welding


Comply with the Contractor’s Quality Plan.


34 14 20 - 2 1/23/2014


A. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the Work included in this Section.

B. American Railway Engineering and Maintenance-of-Way-Association (AREMA):

1. AREMA Manual for Railway Engineering (Manual)

2. AREMA Portfolio of Trackwork Plans (Portfolio)

1.05 SUBMITTALS

Submittals shall be made in accordance with the requirements of the Construction Quality Management Plan, except as modified herein.

A. A Sequence of Work Plan with detailed description of installation

procedures required for the work specified in this Section. B. Working Drawings, including the following:

1. Complete details for loading, storing and distributing CWR and

stick rail, including a rail schedule with rail stations for fully heat-treated rail.

2. Complete details of the proposed methods, including equipment, of

laying and fastening stick rail and CWR. 3. Location of proposed field cuts and field welds in CWR on the rail

schedule.

C. Installation procedure for bonded insulated joint. D. Continuous Welded Rail (CWR) rail anchoring temperature records. E. Records and measurement of rail. F. Ballast tamping procedure, including proposed production tamper

specifications. G. Other Track Material (OTM): comply with Section 34 14 15 Other Track

Material.


34 14 20 - 3 1/23/2014

H. Rail grinding equipment performance specifications.

I. Rail Train Furnished by the Contractor, if used

1. The Contractor shall submit to the Construction Manager an equipment list for the rail train consisting of the following:

a. The locomotive or equipment to move the rail train.

b. The rail train must comply with the clearance envelope for

operation on METRO tracks.

c. The type of rail train including braking system.

d. Safety cable to be attached to each rail train member and to the locomotive.

e. End plates at each end of the rail train to prevent movement

of rails during transport.

f. Rail skates to be used for chocking the rail train members while the rail train is stopped.

g. Equipment to secure rail to rail train members.

2. The Contractor shall also submit calculations by a registered professional engineer certifying the size and types of rail train brakes that will stop the loaded rail train and locomotive on wet rail within a distance of 40 feet from a speed of 5 MPH on a negative 6 percent slope.

3. The Contractor shall also submit calculations by a registered

professional engineer certifying that the size and type of the safety cable and end plates will prevent rail movement or separation of rail train members during rail train movement and stopping or starting.

4. Rail trains are subject to inspection at any time. Correction of

defects requested by the Construction Manager shall be made promptly. No equipment shall remain in service after defects have been identified. The Construction Manager shall be notified and shall inspect all repaired equipment prior to the equipment being placed back in service.


34 14 20 - 4 1/23/2014

J. Traffic Management System: The rail train must not be insulated against being tracked by the signal system.

PART 2 - PRODUCTS 2.01 MATERIALS

All material shall be furnished by the Contractor. A. Rail: Comply with Section 34 14 00 Rail. B. Precurved Rail: Comply with Section 34 14 05 Special Trackwork

Material. C. Other Track Material: Comply with Section 34 14 15 Other Track Material.

1. Yard Track: Rail anchors, and joint bars.

D. Concrete Crossties: Comply with Section 34 14 36 Concrete Crossties.

E. Special Trackwork Ties: Comply with Section 34 14 37 Special Trackwork

Ties. F. Insulated joints: Comply with Section 34 14 15 Other Track Material.

G. Any and all material necessary to complete the work.

PART 3 - EXECUTION 3.01 GENERAL

Track construction shall conform to AREMA Specifications for Track Construction except as modified herein.

3.02 TRACK TYPES

The Contractor shall construct the following types of track as shown on the Contract Drawings and as specified herein: A. Yard Track, 115 RE Welded and Jointed


34 14 20 - 5 1/23/2014

3.03 EXISTING FACILITIES

The Contractor shall conduct his trackwork operations to avoid damage to subballast surface, ditches, drainage structures, fences and existing utilities. The Contractor shall be responsible for coordinating his work with the other contractors in the area. All damages to existing facilities shall be repaired by the Contractor.

3.04 TOLERANCES

A. Tie Spacing: Distance between centerline on adjacent ties shall not vary more than plus or minus one inch from the indicated spacing. There shall be 32 concrete crossties per 80 feet of rail length for mainline tracks. Ties shall not be placed closer than three inches from any field rail weld.

B. Minimum depth of ballast shall be 12 inches below the bottom of tie on

the mainline and yard tracks, unless otherwise noted on the Contract Drawings. Measurement will be from the bottom surface of the crosstie to the top surface of the subballast, taken at the location of the low rail.

3.05 PLACEMENT OF INITIAL BALLAST

A. Initial layer of ballast shall be uniformly distributed over the finished subballast and individually compacted with vibratory rollers to a level surface before tie distribution. Subballast fouled or disturbed by the Contractor's operations shall be repaired by the Contractor. The initial layer of ballast shall be limited to a total compacted depth of 4 or 8 inches measured below the bottom of the tie beneath the low rail that will establish the track surface at least four inches below final grade.

B. Each lift of ballast shall be uniformly spread and compacted with not less

than four passes of a vibratory compactor with the following characteristics:

Gross weight 5,000 pounds minimum Drum width 58 inches minimum Drum diameter 42 inches minimum

Each compacted lift shall not exceed a compacted depth of four or eight inches.

C. The vibratory compactor shall have a weight of not less than 5,000 pounds

and shall be capable of applying a dynamic load of not less than 18,000 pounds at a frequency between 1100 to 2000 vibrations per minute. The


34 14 20 - 6 1/23/2014

compacting equipment selected by the Contractor shall be subject to inspection and acceptance by the Construction Manager.

D. In addition to the requirements specified:

1. Place the track in good alignment before the finishing lift is made.

2. Follow immediately behind the finishing lift with a mechanical means of lining the track and line to accurate alignment. Typically line and surface in the same operation, but the finishing lift may include adjustments to ''accurate alignment''.

3.06 CROSSTIE DISTRIBUTION

A. Except as modified herein, crossties shall be handled, transported and stored in accordance with the current AREMA standards.

1. Only approved lifting devices shall be used which will not damage

the tie. 2. Crossties and switch ties shall be transported in a horizontal

position and braced to prevent any movement that could cause damage.

B. The Contractor shall transport the ties from the storage area to the job site,

where the ties shall be distributed and properly lined and spaced on the compacted layers of ballast.

C. Crossties

1. Ties shall be placed on a smooth, compacted surface as specified

herein, spaced as shown within specified tolerances, and laid normal to the centerline of track.

2. Line ends of concrete ties shall be aligned uniformly.

D. All ties shall be lifted and supported during storage, transportation, and placing in such a manner as to prevent damage. Ties damaged as a result of improper handling by the Contractor will be rejected by the Construction Manager and removed and replaced by the Contractor with undamaged ties meeting specifications. The cost of the replacement tie and the cost of removing the damaged tie and transporting and installing the undamaged tie shall be borne by the Contractor.


34 14 20 - 7 1/23/2014

3.07 SURFACING AND LINING

A. Track shall be surfaced and aligned as soon as possible after installing rail. B. Lifts: Track shall be lifted a maximum of two inches by automated

methods and equipment subject to approval of the Construction Manager. Undue bending of rail shall be prevented. Both rails shall be raised at one time and as uniformly as possible. Track shall be lifted so that it will be necessary to give it a final lift of two inches nominal to bring it up to final line and grade. Ties that have been pulled loose shall be restored to proper position, have a bearing against the rail and be secured. The Contractor shall exercise care during all ballasting operations to prevent center binding and damage to compacted subballast.

C. Alignment: The Contractor shall exercise care to protect track from being

forced out of alignment by heat expansion and shall maintain full cribs at all times. Alignment shall be maintained during the lifting operations.

D. Final surfacing may only be performed when track is within 1/2 inch of final alignment.

3.08 BALLAST COMPACTION

A. General: Vibratory squeeze-type tampers shall be used. Tools shall be maintained to manufacturer's specifications.

B. Requirements: Ballast shall be packed tightly under and around the tie

from a point 18 inches inside each rail on both sides of the tie to the ends of the tie. Ballast around the center of the tie between the above limits shall not be compacted.

C. Procedure Specification: The Contractor shall prepare for the Construction

Manager's review a detailed tamping procedure specification covering tamping equipment and method. The Procedure shall include a complete description of equipment to be used and variables that can be adjusted such as:

1. Number of insertions of tamping tools per tie 2. Number of passes of tamping machine 3. Depth of penetration


34 14 20 - 8 1/23/2014

4. Length of time tools remain down 5. Tamping special trackwork 6. Tamping at transition slabs

D. Procedure Qualification: The Contractor shall qualify his tamping procedure specified herein as follows:

1. In the presence of the Construction Manager, the Contractor shall

tamp 100 feet of track in accordance with his Procedure Specification.

2. The Contractor shall then remove three ties if requested by the

Construction Manager to enable the Construction Manager to observe the tamped ballast under the tie and determine conformance with requirements herein.

3. After inspection and approval by the Construction Manager, the

Contractor shall replace the three ties and retamp.

4. Rejected Procedures: If tamping does not produce ballast compaction meeting the criteria stated herein, tamping variables shall be adjusted and the Procedures Qualification repeated until criteria is met.

5. Production Compaction: The Contractor shall perform all

production compaction in accordance with a Procedure Specification approved by the Construction Manager in accordance with requirements herein.

E. Spot Checks: The Construction Manager may spot check production

compacting. The Contractor shall remove and reinsert two crossties per every 2500 feet of track if directed by the Construction Manager.

3.09 BALLAST CONSOLIDATION

A. General: After final surface and line is achieved, ballast shall be

consolidated to the sections shown. The top of ballast shall be: 1. Yard Track: 1 inch below the top of tie.


34 14 20 - 9 1/23/2014

B. In areas of track where no sloped shoulders exist, ballast is level between tracks, or the shoulder is contained by ballast curbs, shoulder compaction is not required.

C. Equipment Requirements: Equipment used shall be rail mounted railroad

maintenance of way equipment specifically designed for consolidation of the crib and shoulder portions of the track ballast section. Equipment shall be capable of consolidating two cribs and both ballast shoulder simultaneously. Each crib consolidating set shall consist of four tools, one on each side of each rail. Shoulder consolidators shall be centered above the centerline of the two crib compacting tool sets. Crib consolidating tools shall be adjustable to accommodate the tie spacing as specified. The shoulder consolidating tool shall be a minimum of 60 inches in length with trailing and leading edges contoured to prevent flowing of ballast. Horizontal shoulder tools shall provide for the consolidation of the 18-inch wide shoulder with one inch nominal clearance between the tool and tie end. Shoulder slope tools shall be adjusted to maintain the specified 2 to 1 slopes and shall be a minimum of 12 inches wide.

D. Compactive Effort: Ballast crib and shoulder tools shall operate in the

range of 2100 to 3500 vibrations per minute. Vibration amplitude shall be between 0.04 and 0.2 inches. Duration of the cycles shall be between three to five seconds automatically timed. Consolidating tools shall be statically loaded sufficiently to prevent lifting off ballast during compaction. Compactive energy shall be regulated to prevent crushing or degradation of ballast.

E. Ballast Shoulders: The Contractor shall dress the ballast shoulders and

cribs by means of an approved ballast regulator. Equipment and vehicles shall not operate on ballast shoulders after dressing and consolidation. Any damage to shoulders by the Contractor's forces shall be dressed and reconsolidated at the Contractor's expense.

3.10 TRACTION ELECTRIFICATION AND SIGNAL BONDING

Traction Power Bonds and Signals: Traction power and signal bonds shall be installed as shown on Contract Drawings. Prior to performing this work the Contractor to submit detailed shop drawings for approval.


Section 34 14 36 – Concrete Crossties

34 14 36 - 1 1/23/2014

SECTION 34 14 36

CONCRETE CROSSTIES PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the design, manufacture, fabrication, testing, inspection, handling, loading, and shipment of new prestressed, pretensioned, monoblock concrete standard ties and restraining rail ties, complete with rail fastening assemblies consisting of rail clips, shoulders, insulators and rail seat pads.

B. The Supplier shall furnish all parts, labor, tools, materials, equipment,

facility, and transportation to design, manufacture, test, and ship prestressed concrete crossties and associated hardware.

C. All materials and procedures shall be in accordance with the relevant

AREMA Specifications except as modified herein. 1.02 DEFINITIONS

A. The term “Construction Manager” as used in this Section shall mean the Houston Rail Transit (HRT) Project Joint Venture.


of concrete crossties as specified in this Section. C. The term “Manufacturer” shall mean the entity that fabricates the

crossties. D. Where the terms approval, approved, or other similar words are used in

this specification, the approving authority will be the Construction Manager.

1.03 RELATED WORK

NOT USED.


A. Quality control procedures shall be in conformance with the Supplier’s


34 14 36 - 2 1/23/2014

Quality Plan. B. Quality Control Program:

1. A complete description of the quality control program shall be submitted no later than 45 calendar days following issuance of Notice to Proceed.

2. The quality control program shall describe step-by-step procedures

and controls in producing concrete crossties with embedded shoulders and inserts and in fabrication of rail fasteners as required in PCI MNL-116.

3. Production shall not proceed until approval is received. 4. Include the following requirements in the program:

a. Crossties:

(1) Material specifications and certificates of compliance

for said materials. (2) Formwork. (3) Setting of embedded inserts for running rails. (4) Placing prestressing steel tendons. (5) Application of prestressing force and transfer details. (6) Proportioning of concrete mix. (7) Mixing, transporting, placing, consolidating, and

surface finishing. (8) Curing details. (9) Identification marking. (10) Quality control production testing and frequency. (11) Inspection procedures. (12) Vendor (sub-supplier) surveillance.


34 14 36 - 3 1/23/2014

(13) Corrective action and disposition of defective or rejected crossties.

(14) Delivery protection and handling.

b. Weekly written reports documenting a strict adherence to

the Quality Control Program. The written reports shall be submitted to the Construction Manager prior to delivery of finished items.

C. Shop Inspection by Construction Manager:

1. The Construction Manager reserves the right to inspect all products

at the Manufacturer’s facilities during manufacturing or testing, and prior to shipment. Materials shall not be prepared for shipment before the Construction Manager has either inspected the materials or waived inspection. Any deficiencies found shall be corrected prior to shipment. Any inspection or waiver of inspection shall in no way relieve the Supplier of the responsibility of furnishing materials in accordance with these Specifications.

2. All materials shall be presented for inspection at the place of

manufacture. The Supplier shall provide the Construction Manager free entry at all times to the Manufacturer’s plant to inspect the manufacture of the concrete crossties and rail fastener assemblies while work on this contract is being performed.

3. The Supplier shall afford the Construction Manager with all labor,

material, tools, measuring instruments, testing equipment and other equipment necessary to examine the work during its progress, as well as the finished product specifications.

4. All material for inspection shall be presented in a safe area away

from excessive noise and manufacturing activities. The Supplier shall provide all labor, material tools and equipment required to facilitate inspection of the top, bottom and sides of the crossties.

5. Regular examinations of the product will take place during normal

working hours. 6. The Construction Manager will give the Supplier written notice for

inspection at least seven days in advance of the initial in-shop inspection and seven days in advance for subsequent in-shop inspections.


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7. All material is subject to inspection by the Construction Manager at

any time up to and including the time of delivery. 8. After material has been delivered and unloaded, an inspection will

be conducted by the Construction Manager.


A. Where a date is given for the below reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the date of the final procurement agreement shall apply to the requirements of this Section.

B. American Concrete Institute (ACI)

ACI 305R Hot Weather Concreting ACI 318/318R Building Code Requirements for Structural Concrete

and Commentary C. American Railway Engineering and Maintenance-of-Way Association

(AREMA)

Manual for Railway Engineering (Manual) D. ASTM International (ASTM)

A416 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete

A421 Standard Specification for Uncoated Stress-Relieved Steel

Wire for Prestressed Concrete A536 Standard Specification for Ductile Iron Castings A881 Standard Specification for Steel Wire, Deformed, Stress-

Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties

A886 Standard Specification for Steel Strand, Indented, Seven-

Wire Stress-Relieved for Prestressed Concrete


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C31 Standard Practice for Making and Curing Concrete Test

Specimens in the Field C33 Standard Specification for Concrete Aggregates C39 Standard Test Method for Compressive Strength of

Cylindrical Concrete Specimens C78 Standard Test Method for Flexural Strength of Concrete

(Using Simple Beam with Third-Point Loading)

C114 Standard Test Methods for Chemical Analysis of Hydraulic Cement

C150 Standard Specification for Portland Cement C172 Standard Practice for Sampling Freshly Mixed Concrete C231 Standard Test Method for Air Content of Freshly Mixed

Concrete by the Pressure Method C260 Standard Specification for Air-Entraining Admixtures for

Concrete C265 Standard Test Method for Water-Extractable Sulfate in

Hydrated Hydraulic Cement Mortar

C295 Standard Guide for Petrographic Examination of Aggregates for Concrete

C309 Standard Specification for Liquid Membrane-Forming

Compounds for Curing Concrete C359 Standard Test Method for Early Stiffening of Hydraulic

Cement (Mortar Method)

C403 Standard Test Method for Time of Setting of Concrete Mixtures by Penetration Resistance

C457 Standard Test Method for Microscopical Determination of

Parameters of the Air-Void System in Hardened Concrete C494 Standard Specification for Chemical Admixtures for


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Concrete C586 Standard Test Method for Potential Alkali Reactivity of

Carbonate Rocks as Concrete Aggregates (Rock-Cylinder Method)

C617 Standard Practice for Capping Cylindrical Concrete Specimens

C618 Standard Specification for Coal Fly Ash and Raw or

Calcined Natural Pozzolan for Use in Concrete C666 Standard Test Method for Resistance of Concrete to Rapid

Freezing and Thawing

C917 Standard Test Method for Evaluation of Cement Strength Uniformity From a Single Source

D257 Standard Test Methods for DC Resistance or Conductance of

Insulating Materials

D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers – Tension

D2240 Standard Test Method for Rubber Property – Durometer

Hardness. E. Precast/Prestressed Concrete Institute (PCI)

MNL-116 Manual for Quality Control for Plants and Production of Structural Precast Concrete Products

1.06 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of the Submittal’s Exhibit in the contract, except as modified herein.

B. All submittals shall be made to the Construction Manager. C. The following shall be submitted for review and approval.

1. Qualification of Concrete Crosstie Manufacturer.


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2. Structural design of concrete crossties shall be submitted no later than 28 calendar days following issuance of Notice to Proceed. a. Include all structural calculations based upon state-of-the-art

methods for prestressed concrete design and ACI standard requirements.

b. Structural analysis shall include shear and moment analysis

of the ties and references to applicable sections of AREMA Chapter 30, Part 4.

c. Include the effects of the acceptable tolerances on the

placement of the centroid of the prestressing tendons. d. The concrete tie design will not receive final approval until

successful completion of the qualification testing as specified below.

3. Shop Drawings shall be submitted no later than 28 calendar days

following Notice to Proceed. Shop drawings shall include:

a. Dimensional details of crossties showing plan, elevation, and cross sections. Include concrete strength and material specifications.

b. Location and spacing of prestressing tendons with

specifications and initial prestress force. c. Dimensions, tolerances, and location of rail fastening

components and restraining rail inserts. d. Details of proposed handling, transporting, and stacking of

ties.

D. Certificates: 1. Submit ISO 9001 or PCI Plant certification for the production

facility. 2. Submit documentation that the Manufacturer’s QA and

Engineering personnel have passed ACI Concrete Field Testing Technician Grade 1 and PCI Quality Control Personnel Certification Levels I and II.


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3. Manufacturers' certifications of compliance to this specification with each shipment of material.

4. Proof of specified qualification of testing laboratories to be used.

E. Submit mix design no later than 45 calendar days following issuance of Notice to Proceed. The mix design shall conform to all requirements in this specification including test results, curves, and information concerning concrete tie material, production, and strength tests.

1.07 SUPPLIER/MANUFACTURER QUALIFICATIONS

A. Except as otherwise specified below, concrete crossties shall be produced in a production facility by a Manufacturer who has regularly and continuously engaged in the fabrication of precast, prestressed concrete crossties similar to the ties required for a minimum of five years using the long line process (20 forms minimum). If the production facility where the ties are to be produced has not been in production for at least five years, special review and approval of the facility and its material, equipment, and procedures by the Construction Manager will be required to qualify the Manufacturer.

B. The Manufacturer shall have sufficient production capacity to produce the

required number of ties in accordance with the quality requirements and within the required time. The Manufacturer shall demonstrate to the Construction Manager that he has the necessary and proper equipment, tools, facilities and means, including the ability and financial resources, to perform the specified work.

C. The Manufacturer shall furnish certification that all aspects of the

production and yard operations, including materials testing, storage, and handling, conform to the quality control requirements herein, and certification either to ISO 9001 or PCI Plant Certification.

D. ISO 9001 or PCI certification must be maintained throughout the

fabrication period.

1.08 QUALIFICATION TESTING

A. Qualification Testing Location: 1. Testing shall be performed by a certified testing agency approved

by the Construction Manager in accordance with PCI MNL-116. The Supplier may either employ an independent testing laboratory


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or perform testing in the Manufacturer's laboratory, provided it possesses the required certification.

2. The Supplier shall deliver all samples used in testing to the

Construction Manager within 30 days after acceptance of the final qualification test report unless otherwise directed by the Construction Manager.

B. Qualification Tests for Crossties: 1. Upon acceptance of shop drawings, the Manufacturer shall

fabricate at least five prototype concrete crossties in the same manner as is planned for production crossties, and according to the approved shop drawings. The Supplier shall notify the Construction Manager at least 14 days in advance of the manufacture of the prototype ties.

2. From a lot of not less than five ties produced in accordance with

these Specifications, three ties will be selected at random by the Construction Manager for laboratory testing. The age of test ties at time of testing shall be at least seven days but not more than 28 days. a. If required for design testing of the fastening system, the

Manufacturer shall also furnish a section of a tie or a concrete block with rail seat and fastening system identical to the ties furnished for testing. The age of test ties or concrete block at time of testing shall be at least seven days but not more than 28 days.

b. Each of the three ties and, if required, the tie block submitted

for testing shall be carefully measured and examined to determine their compliance with the specified dimensions and tolerances. Upon satisfactory completion of the examination two ties, designated as Tie No. 1 and Tie No. 2, shall be subjected to performance tests as specified below. The remaining tie, which will be designated as Tie No. 3, shall be retained by the Construction Manager for further test use and as a control for dimensional tolerances and surface appearance of ties subsequently produced.

3. Sequence of Tests (Tie No. 1): a. Rail Seat Vertical Load Test as described in Article 4.9.1.4,


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Chapter 30 of the AREMA Manual, shall be performed on the two rail seats designated "A" and "B". This includes the following: (1) Rail Seat Positive Bending Moment Test. (2) Rail Seat Negative Bending Moment Test.

b. Center Negative Bending Moment Test as described in Article 4.9.1.6, Chapter 30 of the AREMA Manual.

c. Rail Seat Repeated-Load Test as described in Article 4.9.1.5,

Chapter 30 of the AREMA Manual shall be performed on rail seat B.

d. Bond Development, Tendon Anchorage, and Ultimate Load

Test as described in Article 4.9.1.8, Chapter 30 of the AREMA Manual shall be performed on rail seat A. The load for the bond development and tendon anchorage test shall be 1.5 times the load used for the Rail Seat Positive Bending Moment test and shall be held for not less than three minutes.

C. Qualification Tests for Fastening Systems: 1. Qualification testing of the fastening system consists of testing of

components cast into the concrete tie in addition to tests conducted on the external components.

2. Sequence of qualification tests using Tie No. 2 shall be as follows:

a. Fastening Insert Test as described in Article 4.9.1.9, Chapter

30 of the AREMA Manual shall be performed on all shoulders.

b. Fastening Uplift Test as described in Article 4.9.1.10, Chapter

30 of the AREMA Manual shall be performed on one rail seat.

c. Electrical Impedance Test as described in Article 4.9.1.14,

Chapter 30 of the AREMA manual. The passing value shall be greater than 40,000 ohms.

3. Sequence of qualification tests using Tie Block shall be as follows:


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a. Tie Pad Test as described in Article 4.9.1.15, Chapter 30 of

the AREMA Manual. (1) Tie pad test shall be conducted on three pads. The

highest and lowest spring rate values cannot vary by more than 25 percent.

(2) Of the three pads tested for spring rate, the median

pad shall be used for tests in articles b through e below.

(3) See item e. below for continuation of this test.

b. Fastening Repeated-Load Test as described in Article

4.9.1.11, Chapter 30 of the AREMA Manual. In addition to this test, perform an Electrical Resistance and Impedance Test on the rail fastener assembly as follows:

(1) After the rail fastener assemblies have satisfied the

Fastening Repeated-Load Test, the rail fasteners, in dry condition, shall have not less than 10 megohm insulation resistance between the rail and the anchor bolts or rail shoulder in contact with the crosstie, when measured with a 500 volt “Megger” Insulator Tester. Rail fastener shall provide minimum fastener impedance of 10,000 ohms to all frequencies from 20 cycles to 10 kilocycles with maximum of 50 volts alternating current.

c. Fastening Longitudinal Restraint Test as described in Article

4.9.1.12, Chapter 30 of the AREMA Manual. d. Lateral Load Restraint Test as described in Article 4.9.1.13,

Chapter 30 of the AREMA Manual. e. Tie Pad Test as described in Article 4.9.1.15, Chapter 30 of

the AREMA Manual (continuation). When rail fastening tests are completed, the median pad shall have its spring rate value measured again. If this value does not vary from the initial test on that pad by more than 25 percent, the pads meet the requirements of this section.

D. Qualification Failure:


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1. Should a concrete crosstie or fastener component fail a qualification

test, the entire sequence of tests in which the failed test is included shall be performed on another concrete crosstie and fastener component.

2. If the crossties are modified to pass tests, shop drawings of the new

design shall be submitted for approval prior to testing. 3. Following approval of the shop drawings of the new design, a new

lot of not less than five of the new design shall be produced and tests performed on the new design. This cycle shall be continued until the testing is successfully performed and documented, or for a period of not more than 100 days from the commencement of the initial qualification testing. If more than 100 days elapses from start of initial qualification testing and no tie design is qualified, the Manufacturer will be disqualified and the Supplier shall seek to qualify another Manufacturer.

E. Qualification Waiver: 1. For designs that have previously met tests equal to or more severe

than those specified, a waiver of the specified qualification testing may be given. For a waiver to be given, certified laboratory test reports must be submitted in sufficient detail so that the Construction Manager may make the determination that the testing program performed was satisfactory and the test results are acceptable.

PART 2 - PRODUCTS 2.01 TYPES OF CROSSTIES

The following types of concrete crossties shall be provided under this Contract:

A. Standard concrete tie.

2.02 GENERAL REQUIREMENTS FOR CONCRETE CROSSTIES

A. Concrete crossties shall be suitable for use in the following conditions:

1. Track Configuration:


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a. Ballasted track with 115RE continuously welded rail or

bolted rail in yards.

b. Standard gauge is 4 feet 8-1/2 inches. Gauge at curves requiring gauge widening is 4 feet 8-3/4 inches.

2. Installation Conditions: The compaction of ballast under and

around the crosstie will be accomplished by using properly adjusted hydraulic or electro-mechanical tamping tools on a production ballast tamper. The crossties shall resist these forces without spalling of concrete on the sides and bottom corners.

3. Environmental Conditions: The ambient temperature range is 0°F

to 125°F and average annual rainfall is 50 inches.

B. Design Parameters for Concrete Crossties:

1. Maximum tie spacing is 30 inches. 2. Multiple unit electrically propelled trains of up to three cars per

consist will operate at speeds of up to 66 mph. 3. The design axle load is 27,500 pounds subject to a nominal 200

percent impact factor. 4. Minimum flexural strength values shall be calculated in accordance

with AREMA Manual Chapter 30, Section 4.4 as follows:

a. Rail Seat Positive (in-kips). b. Rail Seat Negative (in-kips). c. Center Negative (in-kips).

C. Rail Clip Toe Loads: The tolerances of the ties, shoulders, rail clips,

insulators, and rail seat pads shall be established to prevent excessive variations in the rail clip toe loads. Tolerances which affect the rail clip toe loads shall be submitted by the rail clip manufacturer for approval by the Construction Manager.

D. Crosstie Components and Dimensions:

1. Concrete crossties shall be of prestressed design, provided with


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steel prestressing tendons, rail fastenings consisting of embedded cast iron shoulders, threadless, detachable spring clips, plastic insulators, and rail seat pads.

2. Location and tolerances of rail fastener shoulders shall be in

accordance with the rail fastener manufacturer's drawings and specifications.

3. Dimensions and Tolerances:

a. Length: Nominal 8 feet 3 inches plus or minus 1/4 inch,

exclusive of prestressing tendons. b. Width of Bottom: 10 inches minimum, 13 inches maximum,

plus or minus 1/8 inch. c. Width of Top at Center of Rail Seat: 6 inches minimum,

including chamfer, plus or minus 1/8 inch.

d. Maximum chamfer: 3/4 inch, at 45 degrees. e. Depth of Tie: 7 1/2 inches minimum, 10 inches maximum,

plus 1/4 inch, minus 1/8 inch. f. The concrete tie and fastening system shall hold track gauge

to plus or minus 1/16 inch exclusive of rail mill tolerances. The centerline of the tie shall be within 1/8 inch of the centerline of track gauge.

g. Rail Cant: The rail seat shall provide for a cant of 1 in 40,

plus or minus 5 toward the centerline of the tie. h. Differential Tilt of Rail Seat: A differential tilt in the direction

of the rail of one rail seat to the other shall not exceed 1/16 inch in a width of 6 inches.

i. Rail Seat Plane: The rail seat shall be a flat smooth surface,

plus or minus 1/32 inch. j. Protrusion of Pretensioning Tendons: Strands or wires shall

not project more than 1/4 inch beyond the ends of ties. k. Concrete Cover for Prestressing Tendons, Ducts, and

Prestresssing End Fittings: Design 3/4 inch minimum cover


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measured from outside of embedded items to surface of concrete. Tolerances on tendon placement shall be as needed to provide minimum cover and minimum required bending strengths.

E. Identification Marking:

1. Markings must be such that they will remain legible for the design life of the ties.

2. Permanently label concrete crossties by indented or raised

numerals or letters on the top surface to identify the following: a. Manufacturer’s Identification b. Form Number c. Line Number d. Tie Number e. Restraining Rail Tie f. Gauge: 4 feet 8-1/2 inches, or 4 feet 8-3/4 inches g. Year of Manufacture h. Date Code traceable to day of manufacture

3. “METRO” shall be cast on the line end of each tie. 4. In addition to 2.f above, ties with wide gage shall have a “W”

painted in black on the end above the word “METRO” described above. Letter shall be at least two inches in height.

2.03 RAIL HOLD-DOWN COMPONENTS

A. Rail hold-down assemblies shall be the Pandrol ‘e’ clip system, or

approved equal, with Type e-2055 rail clips, embedded cast shoulders, nylon insulators, and 6.5 mm tie pads. The assemblies may, with the Construction Manager’s approval, be a captive, pre-installed system such as Pandrol Fastclip or approved equal. The system shall have a successful service record in the United States for a minimum of five years.


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B. Insulators between Fastener Hardware and Rails:

1. Configuration: a. Provide keys between the insulators and the fastener

hardware to prevent relative motion in any direction. b. The insulators shall cover the full widths of the shoulders. c. Except for surfaces in contact with the rail, the surfaces of

the insulators shall be smooth, clearly finished, and free of flash. Insulators shall be free of internal defects and cavities.

2. An insulator shall be used between the rail clip, shoulder insert,

and the rail to provide electrical insulation, reduce abrasion, prevent shoulder wear and transfer the rail loading to the rail clip and shoulder insert. The insulator shall be held in correct position by the shoulder insert and shall be easily removed upon removal of the rail clip. As an alternate, captive systems with all fastening components pre-assembled onto the tie may be acceptable.

3. Restraining rail flangeway widths shall be controlled by adding

and removing shims and rail seat width shall vary with flangeway width. The Manufacturer shall design the insulator on the retraining rail side for varying rail seat widths in 1/16 inch increments. The Manufacturer shall provide the insulator per curve requirements.

4. Insulators shall comply with standard material tests as described in

Article 4.2.6.1, Chapter 30 of the AREMA Manual with the following tolerances to selected tests: a. ASTM D257: Volume resistivity shall be a minimum of 1 x

1013 ohm-cm. b. ASTM D570: Absorption over 24 hours shall be four percent

maximum.

5. Insulators shall be capable of withstanding temperatures in the range of -20°F to +160°F without having a detrimental effect on the performance of the insulator.

6. The insulator shall be capable of withstanding ozone, water, alkali,

petroleum oils, synthetic lubricants, and sunlight without


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detrimental effect on the performance of the insulator. 7. The insulator shall be designed to withstand the rigors of

application and reapplication of the rail clips and other components without breaking, cracking, or other detrimental effects of the performance of the insulator.

8. Recycled material shall not be used.

C. Tie Pads:

1. Tie pads shall be compatible with the rail fastening system, 6.5

millimeters thick, designed to fit between the shoulders of a rail seat. Pads shall be made from high quality polyurethane, rubber, EVA, or specialty compounds. Pads shall be supplied by Pandrol, Inc. or an approved equal. The tie pad material shall meet the following requirements: a. Material shall be capable of withstanding temperatures of –

20°F to +160°F and other dynamic forces generated by trains without a detrimental effect on their performance.

b. Hardness, measured in accordance with ASTM D2240:

Between 50 and 80 durometer value, Shore A. c. Tensile Strength, measured by ASTM D412: 1,500 psi,

minimum. d. Volume Resistivity, measured in accordance with ASTM

D257: 1 x 1012 ohm-cm, minimum. e. Material shall be resistant to ozone.

D. Shoulders:

1. Cast ductile iron conforming to ASTM A536 Grade 65-45-12, or 80-

55-06. 2. Shoulders shall be threadless and shall be designed to provide and

maintain proper position and alignment of the rail clip, insulator, tie pad, and running rail or guardrail base. The shoulder shall also be designed to provide function of the clip, insulator, and tie pad.

3. The shoulder shall not be directly anchored to or come in contact


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with the prestressing steel. 4. The shoulder shall provide pull-out and torque resistance as

required in Article 4.9.1.9, Chapter 30 of the AREMA Manual. 5. The shoulder shall have a continuous vertical gauge face to prevent

the rail from hooking or catching between the shoulders and tie during rail placement, removal or transportation.

2.04 CONCRETE TIE MATERIALS

A. Portland Cement:

1. Portland cement shall comply with ASTM C150, Type II or Type III, low alkali (having not more than 0.60 percent alkali content per Table 2, “Optional Chemical Requirements”).

2. Fly ash, silica fume, slag or other pozzolanic materials shall not be

used as a cement replacement. 3. Use no more than two clinker sources for Portland cement in this

work. The clinker for this work shall have been used in the production concrete crossties for at least five years.

4. Conduct false set penetration tests per ASTM C359. False set

penetration values shall not be less than 50 mm initially, 35 mm at intermediate times, and 40 mm after remix. Conduct tests at 3, 5, 8, and 11 minutes, and after remix.

5. At the beginning of production and at a frequency of not greater

than three months, analyze a randomly chosen sample of cement for alkali content in accordance with ASTM C114.

6. The cement manufacturing plant shall conduct tests, in accordance

with ASTM C265, at sufficient frequency to produce consistent control of clinker sulfate levels. The maximum allowable SO3 content in clinker shall be 0.5 grams per liter when tested in accordance with ASTM C265. The ratio of SO3 to Al2O3 shall not be greater than 1.0.

7. Monitor uniformity of cement using methods described in ASTM

C917. Cement shall be sampled at the rate of one sample per 1000 tons received at the precast plant.


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B. Retain and submit mill test reports, including alkali content, of the cement as supplied by the cement Manufacturer to ensure consistency in chemical ingredients. Under no circumstances shall substitution of cement be permitted unless it has been pre-qualified through the tests listed in this section and approved by the Construction Manager.

C. Concrete Aggregates: Fine and coarse aggregates shall be hard, strong,

and durable crushed stone or gravel, clean and free of deleterious materials. The Manufacturer shall provide evidence that concrete containing aggregate from the proposed source with cement content and alkali burden similar to the job mix has a satisfactory service history of at least five years. New sources will be considered acceptable, pending Manufacturer and Construction Manager agreement on service acceptability.

1. Coarse Aggregate: ASTM C33, clean and uniformly graded from

No. 4 to 3/4-inch maximum size (Size No. 67). 2. Fine Aggregate: ASTM C33, uniformly graded from 1/4 inch to

fines, washed clean. 3. Certificate of Compliance: Submit evidence which indicates that the

aggregates proposed for use meet, and will continue to meet, the requirements of ASTM C33 for gradation, deleterious substances, and soundness. Attention shall be given to the requirements of Sections 5.4 and 10.2 of ASTM C33.

4. Aggregate shall comply with the petrographic analysis test, as

described in Article 4.2.2.2.b, Chapter 30 of the AREMA Manual and ASTM C295.

5. Aggregates containing carbonate shall be tested in accordance with

ASTM C586 every six months. 6. Aggregate shall meet durability requirements as defined in Article

4.2.2.2, Chapter 30 of the AREMA Manual.

D. The composition of the cement, fine aggregate and coarse aggregate shall be analyzed and tested in accordance with the requirements defined in Chapter 30, Part 4 of the AREMA Manual, so as to ensure that the resulting combination does not produce a concrete subject to deleterious expansion resulting from an alkali-silica reaction.


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E. Mixing Water: Water for mixing concrete shall be potable and free from harmful amounts of oils, acids, alkalis, salts, organic materials, or other substances which may be deleterious to concrete or steel. Chloride ion content in the mixing water shall not be in excess of 100 ppm.

F. Concrete Admixtures:

1. Acceptable concrete admixtures may be included in the concrete

mix to improve the water-cement ratio or workability of the concrete, providing the strengths specified and other desirable characteristics of the concrete can be achieved and maintained. Admixtures require the Construction Manager’s approval before they may be used.

2. If used, concrete admixtures shall conform to the following

requirements: a. Only liquid admixtures shall be used. b. Air Entraining Admixtures: ASTM C260. c. Accelerating, Retarding, and Water-Reducing Agents: ASTM

C494. d. Other Pozzolanic Admixtures: ASTM C618, or other mineral

admixtures may not be used without written approval of the Construction Manager.

3. Admixtures containing chlorides, fluorides, sulphites, nitrates, or aluminum powder shall not be used.

G. Entrained Air: When measured in accordance with ASTM C231, the air

content of the freshly mixed concrete shall not be less than 4.5 percent. H. Prestressing Steel Tendons:

1. Wire: Uncoated, stress-relieved or low-relaxation steel wire shall

conform to ASTM A421 or ASTM A881. 2. Strand: Uncoated, seven-wire, stress-relieved or low-relaxation

steel strand shall conform to ASTM A416 or ASTM A886. 3. Minimum prestress working force after long term losses shall be as

required to ensure minimum bending requirements are achieved.


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I. Flexural Strength Pre-Qualification Testing:

1. Flexural strength tests shall be performed to check the adequacy of

the mix design. Samples from which flexural test specimens are molded shall be obtained in accordance with ASTM C31.

2. Test Procedure: Flexural strength tests shall be performed on 6 by 6

by 30 inch beams in accordance with ASTM C78. 3. The 28-day flexural strength shall be at least 700 psi when tested in

accordance with ASTM C78. 4. A minimum of six separate beam tests shall be performed to

establish mix design flexural strength. 2.05 PRODUCTION OF CONCRETE

A. Concrete Quality:

1. Water content shall be kept to a minimum consistent with the strength requirements and placement needs. Concrete mixes shall be proportioned to produce a compressive strength of at least 7,000 psi when tested at 28 days in accordance with ASTM C39.

2. Concrete strength at stress transfer shall be adequate for the

requirements of anchorage and for the transfer of stress through bond. Compressive strength at the time prestress is transferred to the concrete shall be not less than 4,500 psi. Calculated concrete stresses shall be in accordance with ACI 318, Chapter 18 Prestressed Concrete, Section 18.4 Permissible Stresses in Concrete-Flexural Members.

B. Concrete Mix Proportions:

1. Unless previous data are accepted by the Construction Manager to show that a concrete mix will be satisfactory for the production of concrete ties, concrete mix designs shall be established by tests on trial batches to achieve the required specified strengths and properties.

2. Cement content shall be 600 pounds per cubic yard, minimum. 3. Water-cement ratio shall not exceed 0.40 by weight and shall be


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calculated on the basis of the weight of cement. 4. Using materials that will be used in the work, establish proportions

of Portland cement, aggregates, water, and admixtures to produce the specified properties based on field experience or trial batch method described in ACI 318. Substantiate attainment of all specified properties by designated ASTM test methods. Provide concrete that has 28-day compressive strengths that exceed the specified design strength in accordance with ACI 318. Acceptability of concrete strength will be based on requirements for ultimate strength design.

5. The proportions of aggregate to cement shall produce a mixture

which will work readily into corners and angles of the forms and around the prestressing tendons with the assistance of specified vibration, but without permitting the materials to segregate or excess free water to collect on the surface.

6. The Manufacturer shall assure that the air content is as specified

above while producing a minimum 28 day compressive strength of 7,000 psi. At least one measurement of air content of the freshly mixed concrete shall be made on separate batches from each bed cast, or each 50 cubic yards of concrete, whichever is less volume of concrete.

PART 3 - EXECUTION 3.01 FABRICATION OF TIES

A. Production and Production Testing: Upon the Construction Manager’s

approval of the qualification testing, the Manufacturer shall begin production of the concrete crossties and fastener components. During production, the Supplier shall submit to the Construction Manager the certified test results of the production tests. Upon acceptance of the production test results and certification requirements for each lot, that lot will be released by the Construction Manager for shipment from the fabrication facility.

B. Conform with applicable requirements of the AREMA Manual Chapter

30, Part 4, and PCI MNL-116. C. Ties shall be manufactured by the long-line process.


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D. Forms:

1. Forms shall be rigid and shall be constructed of material that will result in finished ties conforming to the shape, lines and dimensions indicated. Tolerances in excess of those indicated or specified will not be permitted.

2. Forms for concrete crossties shall be constructed to permit

movement of the tie without damage during transfer of the prestressing force.

3. Forms shall provide proper markings as specified above.

E. Placement of Prestressing Steel:

1. Prestressing tendons in the concrete crosstie shall be accurately

placed and adequately secured in position. Prior to placing concrete, the dimensional accuracy of the position of prestressing tendons, bulkheads, inserts, and anchorage devices shall be verified. Prestressing tendons shall be inspected for proper surface condition. Tendons contaminated with form release agents and other substances that will reduce bond with concrete shall be cleaned.

2. Tolerances for placing reinforcement shall conform to Article


F. Application and Measurement of Prestressing Force: 1. Initial prestressing force in each of the tendons shall not exceed the

tendon manufacturer's recommendation and shall not exceed 75 percent of the ultimate strength for stress relieved strand and stress relieved wire and 70 percent of ultimate strength for direct drawn wire.

2. The force shall be applied in two increments. An initial force shall

be applied to the tendons to straighten them, eliminate slack, and provide a starting or reference point for measuring elongation.

3. Prestressing force shall be determined by reading hydraulic ram

pressure on a calibrated gauge or by the use of a calibrated dynamometer. Elongation measurements shall be taken from average load-elongation curves for the steel used. Actual elongation shall agree with the elongation calculated, using the


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force determined from the pressure gauge within plus or minus five percent.

4. Tendons may be stretched either individually or simultaneously. If

tendons are stretched simultaneously, provision shall be made to induce approximately equal stress in each.

5. Transfer of force from the abutments of the pretensioning bed to

the concrete shall be carefully accomplished by gradual and simultaneous detensioning of all tendons. Exposed tendons shall be cut near the tie end. The projection of tendons beyond the ends of the ties shall not exceed 1/8 inch.

G. Mixing, Placing, and Curing of Concrete:

1. Preparation for Placing Concrete: Prior to placing concrete,

equipment for mixing the concrete shall be clean, debris shall be removed from spaces to be occupied by the concrete, forms shall be oiled, and the tendons shall be cleaned of deleterious coatings. Forms shall be inspected for alignment and tightness of joints, and the dimensional accuracy of the position of bulkheads, prestressing tendons, inserts, and other embedments shall be verified.

2. Proportioning of Concrete Materials:

a. 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.

b. Water and liquid admixtures may be measured by weight or

volume. c. The accuracy of measurement of the concrete ingredients

shall be as required to produce consistent concrete capable of meeting minimum strength and air entrainment requirements.

3. Mixing of Concrete:

a. Mixing equipment shall be capable of combining specified

materials, within the time specified by the equipment manufacturer, into a thoroughly mixed and homogeneous mass, and discharging the mixture without segregation.


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b. Concrete shall be mixed until there is a uniform distribution of the materials, and shall be discharged completely before the mixer is recharged.

c. Optimum mixing time shall be established by the equipment

manufacturer's specifications. Generally, minimum mixing time shall be four minutes for batches of one cubic yard or less, this mixing time shall be increased by at least fifteen seconds for each cubic yard, or fraction thereof, of capacity in excess of one cubic yard. Mixing time shall be established for the concrete mix in order to produce batch-to-batch uniformity. Both under-mixing and over-mixing shall be avoided.

4. Conveying:

a. Concrete shall be conveyed from the mixer to the place of final deposit in the shortest practicable time by methods which will prevent segregation or loss of materials.

b. Equipment for chuting, pumping, and pneumatic conveying

of concrete shall be of size and design to assure flow of concrete at the delivery end without segregation of materials.

5. Depositing:

a. Concrete shall be deposited as nearly as practical in its final position to avoid segregation due to rehandling or flowing. Concrete which has partially hardened or has been contaminated by foreign materials shall not be used.

b. Concrete shall have a minimum temperature of 50°F, and a

maximum temperature of 90°F when placed. When concrete is placed at an ambient temperature of 90°F or greater, special precautions to prevent rapid drying shall be employed. Comply with applicable requirements of ACI 305R. When concrete is placed at ambient air temperatures below 40°F, precautions should be employed to keep the concrete from freezing.

6. Consolidating:

a. Concrete shall be thoroughly consolidated by vibration


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during placement, and shall be thoroughly worked around the prestressing tendons, embedded inserts, and into corners of the forms.

b. External form vibration, internal concrete vibration, or a

combination of both shall be used to obtain uniform mix, and shall be sufficient to yield concrete with a density in compliance with qualified mix design density, taking into account allowable air content variation.

c. Forms shall not be damaged during consolidation.

7. Curing:

a. Immediately after placement and consolidation, all exposed surfaces shall be covered with impermeable sheeting or an ASTM C309 compliant curing compound.

b. Concrete crosstie shall be heat cured by low pressure steam,

radiant heat, conduction heat, or other accepted curing process to accelerate strength gain so that removal of forms and transfer of the prestressing force may be accomplished at an early age.

c. Curing shall be performed in accordance with procedures

established by the Precast/Prestressed Concrete Institute to produce the required concrete strengths. The temperature gradient shall not exceed 36°F per hour. Maximum curing temperature shall not exceed 158°F. Heat curing of concrete shall not be started until after concrete initial set (ASTM C403) has occurred. Referenced temperatures are center of concrete cross-section, not ambient.

8. Crossties shall be removed from forms in a manner which will prevent damage to the forms or crossties.

9. Finishing:

a. Formed surfaces of the finished crossties shall have a smooth

and dense uniform surface. The surface of the rail seat shall have a smooth finish and shall be free from surface irregularities and excessive air holes. Other surfaces shall have a smooth finish which may contain honeycomb not to exceed two percent of the surface and a maximum void


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diameter and depth of 3/8 inch. b. The bottom surface of the ties shall have a rough or coarse

finish such as may be obtained with a medium coarse broom or wood float.

3.02 PRODUCTION TESTING

A. One tie selected at random from each production day shall be subjected to the following tests:

1. Shoulder adjacent spacing and shoulder outer-to-outer spacing

shall be verified. 2. The rail seat vertical load test, rail seat positive bending moment

test and rail seat negative bending moment test, as specified above for qualification testing, shall be performed on one rail seat. Ties that pass testing requirements and have no visible cracks after testing or are not otherwise damaged will be accepted. Selected tests may be waived at the discretion of the Construction Manager based upon historically demonstrated interrelation between these tests.

3. If cracking occurs in any of the tests, two additional ties from the

same lot shall be subjected to the same tests, and acceptance of the lot shall be based on the following conditions: a. If both retest ties meet the requirement, the lot will be

accepted. b. If either of the retest ties fails to meet the test requirement,

the remaining ties of the lot shall be tested in accordance with a statistical sampling plan to be reviewed and accepted by the Construction Manager.

B. Bond Development and Ultimate Load Test: In addition to the

requirements specified above, the following tests shall be performed: 1. One tie selected at random each production day shall be tested for

bond development and ultimate strength as specified above for qualification testing.

2. If strand slippage exceeds 0.001 inch for bond development with

bond load held for not less than three minutes, three additional ties


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shall be tested. If any of the three ties does not meet the requirements of the test, the remaining ties in the lot shall be rejected.

C. An electrical test shall be performed to check for shoulder to shoulder

direct electrical shorts at between 10 and 13 volts DC using a digital multi-meter. The resistance shall not be less than 100 ohms, calculated as measured voltage divided by measured current.

3.03 STRENGTH TESTS OF CONCRETE

A. Compressive Strength Testing:

1. Compressive strength tests of concrete shall be performed to check the adequacy of mix proportions and as a basis for acceptance.

2. Test Specimens: Samples for compressive-strength test specimens

shall be obtained in accordance with ASTM C172. 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 under production conditions. Concrete temperature shall be recorded during curing.

3. Test Procedures: Strength tests shall be performed on standard

cylinders, 6 by 12 inch or 4 by 8 inch in size, in accordance with ASTM C39. For each day of production at least eight cylinders shall be prepared and capped per ASTM C617 for each production line: three for 28 day strength tests, three for checking strength at prestress transfer, and two for spares.

B. Durability:

1. One tie shall be selected by the Construction Manager at the start of production and thereafter every three months, for air void content and durability factor tests. This test requirement will be waived if the Manufacturer has previously performed durability test on similar ties and can demonstrate to the Construction Manager that ties are satisfactorily similar and meet requirements.

2. The air void content shall be measured in accordance with ASTM

C457 on the top, center, and bottom of a cross section slice cut from the rail seat of a tie. The measured air void content shall not be less than 3.5 percent and the air void spacing factor shall not exceed 0.008 inch.


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3. The durability factor shall be measured in accordance with ASTM

C666, Procedure A, on a minimum of four prisms of concrete taken adjacent to the air void samples. The durability factor shall be not less than 90 percent at 300 cycles.

3.04 HANDLING AND STORAGE OF TIES

A. Handling: Ties shall be lifted and supported during manufacture, storage, transportation, and installation operations in a way which will prevent chipping, spalling, cracking, or other damage.

B. Storage: When stacked in multiple tiers, each tier shall be separated with

dunnage having sufficient thickness to clear fastening shoulder inserts. Ties shall be stacked by type in separate rows with access alleys. Fastening system components, if not a pre-installed captive system, shall be packaged and stored independently of the crossties, clearly marked, and protected against corrosive environment.

3.05 DELIVERY

A. The Supplier shall deliver all materials in accordance with the delivery schedule. All material shall be delivered by truck to locations designated by the Construction Manager. The Construction Manager will make arrangements for the unloading of material by others.

B. The Supplier shall have on hand at the unloading area, for each delivery, a

representative for the verification of condition of packaged items. C. The Supplier shall replace all concrete ties and rail fastener assemblies

damaged during loading and shipping with new concrete ties and rail fastener assemblies.

3.06 WARRANTY

A. The Supplier shall warranty the crossties and all related components to be free of faulty materials and workmanship for five years after final acceptance of the delivered ties by the Construction Manager.

B. Concrete crossties and other materials supplied under this specification

found to be defective in materials and/or workmanship prior to the end of the warranty period shall be replaced.

C. Any material failures due to manufacturing defects between acceptance


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and end of the warranty period shall be remedied. Damage caused by the construction and maintenance activity, or operational accidents is excluded.

D. Replacement material shall carry the same warranty as the original

materials, starting with the date of final acceptance of the replacement items.


Section 34 14 37 – Special Trackwork Ties

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SECTION 34 14 37

SPECIAL TRACKWORK TIES

PART 1 - GENERAL 1.01 INTRODUCTION

A. This Section specifies the design, manufacture, fabrication, testing, inspection, handling, loading, and shipment of new prestressed, pretensioned monoblock concrete special trackwork ties complete with rail fastening assemblies consisting of rail clips, embedded shoulders, insulators, special trackwork plates, special trackwork plate pads, embedded threaded inserts, plate fastening hardware, and rail seat pads.

B. The Supplier shall furnish all parts, labor, tools, materials, equipment,

facility, and transportation to design, manufacture, test, and ship prestressed concrete special trackwork ties and associated hardware.

C. Ties shall be furnished for use in turnouts and roadway grade crossings.

1.02 DEFINITIONS

A. The term “Construction Manager” as used in this Section shall mean the

Houston Rail Transit (HRT) Project Joint Venture. B. The term “Supplier” shall mean the entity that undertakes the furnishing

of special trackwork ties as specified in this Section. C. The term “Manufacturer” shall mean the entity that fabricates the special

trackwork ties. D. Where the terms approval, approved, or other similar words are used in

this specification, the approving authority will be the Construction Manager.

1.03 RELATED WORK

A. Section 34 14 36 Concrete Crossties


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A. Quality control procedures shall be in conformance with the Supplier’s Quality Plan.

B. Quality Control Program:

1. A complete description of the quality control program shall be submitted no later than 45 calendar days following issuance of Notice to Proceed.

2. The quality control program shall describe step-by-step procedures

and controls in producing concrete crossties with embedded shoulders and inserts and in fabrication of rail fasteners as required in PCI MNL-116.

3. Production shall not proceed until approval is received. 4. Include the following requirements in the program:

a. Special Trackwork Ties:

(1) Material specifications and certificates of compliance for said materials.

(2) Formwork. (3) Setting of embedded inserts for running rails. (4) Placing prestressing steel tendons. (5) Application of prestressing force and transfer details. (6) Proportioning of concrete mix. (7) Mixing, transporting, placing, consolidating, and

surface finishing. (8) Curing details. (9) Identification marking. (10) Quality control production testing and frequency.


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(11) Inspection procedures. (12) Vendor (sub-supplier) surveillance. (13) Corrective action and disposition of defective or

rejected ties. (14) Delivery protection and handling.

b. Weekly written reports documenting a strict adherence to the Quality Control Program. The written reports shall be submitted to the Construction Manager prior to delivery of finished items.

C. Shop Inspection by Construction Manager:

1. The Construction Manager reserves the right to inspect all products

at the Manufacturer’s facilities during manufacturing or testing, and prior to shipment. Materials shall not be prepared for shipment before the Construction Manager has either inspected the materials or waived inspection. Any deficiencies found shall be corrected prior to shipment. Any inspection or waiver of inspection shall in no way relieve the Supplier of the responsibility of furnishing materials in accordance with these Specifications.

2. All materials shall be presented for inspection at the place of

manufacture. The Supplier shall provide the Construction Manager free entry at all times to the Manufacturer’s plant to inspect the manufacture of the special trackwork ties and rail fastener assemblies while work on this contract is being performed.

3. The Supplier shall afford the Construction Manager with all labor,

material, tools, measuring instruments, testing equipment and other equipment necessary to examine the work during its progress, as well as the finished product.

4. All material for inspection shall be presented in a safe area away

from excessive noise and manufacturing activities. The Supplier shall provide all labor, material tools and equipment required to facilitate inspection of the top, bottom and sides of the ties.

5. Regular examinations of the product will take place during normal

working hours.


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6. The Construction Manager will give the Supplier written notice for inspection at least seven days in advance of the initial in-shop inspection and seven days in advance for subsequent in-shop inspections.

7. All material is subject to inspection by the Construction Manager at

any time up to and including the time of delivery. 8. After material has been delivered and unloaded, an inspection will

be conducted by the Construction Manager.


A. Where a date is given for the below reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the date of the final procurement agreement shall apply to the requirements of this Section.

B. American Concrete Institute (ACI):

305R Hot Weather Concreting

ACI 318/318 R Building Code Requirements for Structural Concrete and Commentary

C. American Railway Engineering and Maintenance-of-Way Association

(AREMA):

Manual for Railway Engineering, Volume 1, Track, hereinafter referred to as the AREMA Manual.

D. ASTM International (ASTM):

A82 Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

A325 Standard Specification for Structural Bolts, Steel, Heat

Treated, 120/105 ksi Minimum Tensile Strength A416 Standard Specification for Steel Strand, Uncoated Seven-

Wire for Prestressed Concrete


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A421 Standard Specification for Uncoated Stress-Relieved Steel Wire for Prestressed Concrete

A449 Standard Specification for Hex Cap Screws, Bolts and Studs,

Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

A536 Standard Specification for Ductile Iron Castings A881 Standard Specification for Steel Wire, Deformed, Stress-

Relieved or Low-Relaxation for Prestressed Concrete Railroad Ties

A886 Standard Specification for Steel Strand, Indented, Seven-

Wire Stress-Relieved for Prestressed Concrete C31 Standard Practice for Making and Curing Concrete Test

Specimens in the Field C33 Standard Specification for Concrete Aggregates C39 Standard Test Method for Compressive Strength of

Cylindrical Concrete Specimens C78 Standard Test Method for Flexural Strength of Concrete

(Using Simple Beam with Third-Point Loading) C114 Standard Test Methods for Chemical Analysis of Hydraulic

Cement C150 Standard Specification for Portland Cement C172 Standard Practice for Sampling Freshly Mixed Concrete C173 Standard Test Method for Air Content of Freshly Mixed

Concrete by the Volumetric Method C231 Standard Test Method for Air Content of Freshly Mixed

Concrete by the Pressure Method C260 Standard Specification for Air-Entraining Admixtures for

Concrete C265 Standard Test Method for Water-Extractable Sulfate in


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Hydrated Hydraulic Cement Mortar C295 Standard Guide for Petrographic Examination of Aggregates

for Concrete C359 Standard Test Method for Early Stiffening of Hydraulic

Cement (Mortar Method) C403 Standard Test Method for Time of Setting of Concrete

Mixtures by Penetration Resistance C457 Standard Test Method for Microscopical Determination of

Parameters of the Air-Void System in Hardened Concrete C494 Standard Specification for Chemical Admixtures for

Concrete C618 Standard Specification for Coal Fly Ash and Raw or

Calcined Natural Pozzolan for Use in Concrete C666 Standard Test Method for Resistance of Concrete to Rapid

Freezing and Thawing C917 Standard Test Method for Evaluation of Cement Strength

Uniformity From a Single Source D257 Standard Test Methods for DC Resistance or Conductance of

Insulating Materials D412 Standard Test Methods for Vulcanized Rubber and

Thermoplastic Elastomers -- Tension D570 Standard Test Method for Water Absorption of Plastics D2240 Standard Test Method for Rubber Property -- Durometer

Hardness

E. Precast/Prestressed Concrete Institute (PCI):

MNL-116 Manual for Quality Control for Plants and Production of Structural Precast Concrete Products


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1.06 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of the Submittal’s Exhibit in the contract, except as modified herein.

B. All submittals shall be made to the Construction Manager. C. The following shall be submitted for review and approval.

1. Qualification of Concrete Special Trackwork Tie Manufacturer. 2. Structural design of special trackwork ties shall be submitted no

later than 28 calendar days following issuance of Notice to Proceed.

a. Include all structural calculations. These shall be based upon state-of-the-art methods for prestressed concrete design and ACI standard requirements.

b. Structural analysis shall include shear and moment analysis

and references to applicable sections of AREMA Chapter 30, Part 4.

c. Include the effects of the acceptable tolerances on the

placement of the centroid of the prestressing tendons. d. The concrete tie design will not receive final approval until

successful completion of the qualification testing as specified below.

3. Shop Drawings shall be submitted no later than 28 calendar days following Notice to Proceed. Shop drawings shall include: a. Dimensional details of special trackwork ties showing plan,

elevation, and cross sections. Include concrete strength and material specifications.

b. Location and spacing of prestressing tendons with

specifications and initial prestress force. c. Dimensions, tolerances, location, and orientation of all rail

fastening components and threaded inserts. d. Details of proposed, handling, transporting, and stacking of

ties.


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e. Tie identification marking system.

D. Certificates:

1. Submit ISO 9001 or PCI Plant certification for the production

facility. 2. Submit documentation that the Manufacturer’s QA and

Engineering personnel have passed ACI Concrete Field Testing Technician Grade 1 and PCI Quality Control Personnel Certification Levels I and II.

3. Manufacturers' certifications of compliance to this specification

with each shipment of material. 4. Proof of specified qualification of testing laboratories to be used.

E. Submit mix design no later than 45 calendar days following issuance of

Notice to Proceed. The mix design shall conform to all requirements in this specification including test results, curves, and information concerning concrete tie material, production, and strength tests.

1.07 SUPPLIER/MANUFACTURER QUALIFICATIONS

A. Except as otherwise specified below, concrete special trackwork ties shall

be produced in a production facility by a Manufacturer who has regularly and continuously engaged in the fabrication of precast, prestressed concrete ties similar to the ties required. If the production facility where the ties are to be produced has not been in production for at least five years, special review and approval of the facility and its material, equipment, and procedures by the Construction Manager will be required to qualify the Manufacturer. Such special review will require thorough documentation of production procedures, history of material sources, and qualifications of technical supervisory personnel to the extent necessary to satisfy the Construction Manager.

B. The Manufacturer shall have sufficient production capacity to produce the required ties in accordance with the quality requirements within the required time. The Manufacturer shall demonstrate to the Construction Manager that he has the necessary and proper equipment, tools, facilities and means, including the ability and financial resources, to perform the specified work.


34 14 37 - 9 1/23/2014

C. The Manufacturer shall furnish certification that all aspects of the production and yard operations, including materials testing, storage and handling, conform to the quality control requirements herein, and certification either to ISO 9001 or PCI Plant Certification.

D. ISO 9001 or PCI certification must be maintained throughout the

fabrication period. E. Qualification Tests:

1. The Manufacturer shall notify the Construction Manager at least 14 days in advance of the manufacture of the prototype ties.

2. Upon acceptance of shop drawings, the Manufacturer shall

fabricate at least four prototype concrete special trackwork ties, two with embedded shoulders and two with embedded inserts in the same manner as is planned for production special trackwork ties, and according to the approved shop drawings. These four special trackwork ties are to be provided for testing as specified below in “Qualification Testing”.

F. Production and Production Testing: Upon the Construction Manager’s approval of the qualification testing described, the Manufacturer may begin production of the concrete special trackwork ties and fastener components. During production, the Supplier shall submit to the Construction Manager the certified test results of the production tests as specified below. Upon acceptance of the production test results and certification requirements for each lot, that lot will be released by the Construction Manager for shipment from the fabrication facility.

1.08 QUALIFICATION TESTING

A. Qualification Testing Location:

1. Testing shall be performed by a certified testing agency approved by the Construction Manager in accordance with PCI MNL-116. The Supplier may either employ an independent testing laboratory or perform testing in the Manufacturer's laboratory, provided it possesses the required certification.

2. The Supplier shall maintain samples used in testing in a secure

location until at least 30 days after acceptance of the final qualification test report. The samples shall not be disposed of until permitted by the Construction Manager.


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B. Qualification Tests for special trackwork ties:

1. From a lot of not less than four special trackwork ties, two with

embedded shoulders and two with embedded inserts, produced in accordance with these Specifications, three ties, will be selected at random by the Construction Manager for laboratory testing. The age of test ties at time of testing shall be at least seven days but not more than 28 days. The special trackwork ties selected shall be carefully measured and examined to determine its compliance with the specified dimensions and tolerances. Upon satisfactory completion of the examination two ties, one of each type, designated as Tie No. 1 and Tie No. 2, shall be subjected to performance tests as specified below. The remaining tie, which will be designated as Tie No. 3, shall be retained by the Construction Manager for further test use and as a control for dimensional tolerances and surface appearance of ties subsequently produced.

2. Sequence of Tests (Tie No. 1):

a. Rail Seat Vertical Load Test as described in Article 4.9.1.4, Chapter 30 of the AREMA Manual, shall be performed on the two rail seats designated "A" and "B". This includes the following:

(1) Rail Seat Positive Bending Moment Test. (2) Rail Seat Negative Bending Moment Test.

b. Rail Seat Repeated-Load Test as described in Article 4.9.1.5,

Chapter 30 of the AREMA Manual shall be performed on rail seat B.

c. Bond Development, Tendon Anchorage, and Ultimate Load

Test as described in Article 4.9.1.8, Chapter 30 of the AREMA Manual shall be performed on rail seat A. The load for the bond development and tendon anchorage test shall be 1.5 times the load used for the Rail Seat Positive Bending Moment test as and shall be held for not less than three minutes.

C. Qualification Tests for Fastening Systems:

1. Qualification testing of the fastening system consists of testing of


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components cast into the concrete tie in addition to tests conducted on the external components.

2. Sequence of qualification tests using Tie No. 1, rail seat A, and Tie

No. 2, rail seat A or B, shall be as follows: a. Fastening Insert Test as described in Article 4.9.1.9, Chapter

30 of the AREMA Manual shall be performed on both shoulders or inserts.

b. Fastening Uplift Test as described in Article 4.9.1.10, Chapter

30 of the AREMA Manual shall be performed on one rail seat.

c. Electrical Impedance Test as described in Article 4.9.1.14,

Chapter 30 of the AREMA manual. The passing value shall be greater than 40,000 ohms.

d. Tie Pad Test as described in Article 4.9.1.15, Chapter 30 of

the AREMA Manual. The tie pad test shall be conducted on three pads. The highest and lowest spring rate values cannot vary by more than 25%.

D. Qualification Failure:

1. Should a concrete special trackwork tie or fastener component fail a

qualification test, the entire sequence of tests in which the failed test is included shall be performed on another concrete special trackwork tie of the same length and with the same type of fastener component.

2. If the special trackwork ties are modified to pass tests, shop

drawings of the new design shall be submitted for approval prior to testing.

3. Following approval of the shop drawings of the new design, a new

lot of not less than four ties, two with embedded shoulders and two with embedded inserts, of the new design, shall be produced and tests performed on the new design. This cycle shall be continued until the testing is successfully performed and documented, or for a period of not more than 100 days from the commencement of the initial qualification testing. If more than 100 days elapses from start of initial qualification testing and no tie design is qualified, the Manufacturer shall be disqualified and the Supplier shall seek to


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qualify another Manufacturer.

E. Qualification Waiver: 1. For designs that have previously met tests equal to or more severe

than those specified, a waiver of the specified qualification testing may be given. For a waiver to be given, certified laboratory test reports must be submitted in sufficient detail so that the Construction Manager may make the determination that the testing program performed was satisfactory and the test results are acceptable.

PART 2 - PRODUCTS 2.01 GENERAL REQUIREMENTS FOR CONCRETE SPECIAL TRACKWORK

TIES

A. Concrete special trackwork ties shall be suitable for use in the following conditions:

1. Track Configuration: Ballasted track with 115RE continuously

welded rail and bolted rail in yards. Gauge is 4 feet 8-1/2 inches. 2. Installation Conditions: The compaction of ballast under and

around the special trackwork ties will be accomplished by using properly adjusted hydraulic or electro-mechanical tamping tools on a production ballast tamper. The special trackwork ties must resist these forces without spalling of concrete on the sides and bottom corners.

3. Environmental Conditions: The ambient temperature range is 0°F

to 125°F and average annual rainfall is 50 inches.

B. Design Parameters for Concrete Special Trackwork Ties:

1. Maximum spacing of the concrete special trackwork ties shall be 30 inches.

2. Multiple unit electrically propelled trains of up to three cars per

consist will operate at speeds of up to 66 mph on these ties. 3. The design axle load is 27,500 pounds subject to a nominal 200

percent impact factor.


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4. Minimum flexural strength values shall be as follows, calculated in

accordance with AREMA Manual Chapter 30, Section 4.4.

a. Rail Seat Positive: 191 in-kips. b. Rail Seat Negative: 110 in-kips.

c. Center Negative: 110 in-kips.

5. The minimum end to end tie clearance shall be 2 inches. 6. All ties shall be consecutively numbered. 7. The centerline of the first switch tie shall be placed 4-1/2 inches

behind the point of switch and shall be designated as Tie Number 1.

C. Switch machine ties shall be configured with embedded fastener inserts for attachment of switch machines or switch stands.

D. Concrete Special Trackwork Tie Components and Dimensions:

1. Concrete special trackwork ties shall be of prestressed design,

provided with steel prestressing tendons, rail fastenings consisting of embedded cast iron shoulders, threaded fastener inserts, detachable spring clips, nylon insulators, rail seat pads, and plate pads.

2. Location and tolerances of rail fastener shoulders shall be in

accordance with the rail fastener manufacturer's drawings and specifications and individual turnout geometry requirements.

3. Dimensions and Tolerances:

a. Nominal Length: end of tie to rail centerline 21” minimum with overall length plus or minus 1/2 inch, exclusive of prestressing tendons, except that ties for roadway grade crossings shall be 10 feet long configured for installation centered on the track centerline.

b. Width of Bottom: 10 inches minimum, 12 inches maximum,

plus or minus 1/8 inch.


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c. Width of Top; Center of rail seat: 7-1/2 inches minimum, plus or minus 1/8 inch. Maximum chamfer: 1 inch at 45 degrees.

d. Depth of Tie: 7-1/2 inches minimum, 10 inches maximum,

plus 1/4 inch, minus 1/8 inch. Ties for roadway crossings shall have a constant depth with a top plane surface in the areas outside the rail seats.

e. Track Gauge: The concrete tie and rail fastening system shall

hold track gauge to plus or minus 1/16 inch exclusive of rail mill tolerances.

f. Rail Cant: The rail seat shall provide for a zero cant within

turnouts and track crossing diamonds and 1 in 80 cant for any transition ties at the start and ends of the turnout. Rail seats for roadway grade crossing ties shall provide for a 1 in 40 cant.

g. Differential Tilt of Rail Seat: The differential tilt in the

longitudinal direction of the rail of one rail seat to the other companion rail seat shall not exceed 1/16 inch in a width of 6 inches.

h. Rail Seat Plane: The rail seat shall be a flat smooth surface,

plus or minus 1/32 inch. i. Protrusion of Pretensioning Tendons: Strands or wires shall

not project more than 1/4 inch beyond the ends of ties. j. Concrete Cover for Prestressing Tendons, Ducts, and

Prestressing End Fittings: Design one inch minimum cover measured from outside of embedded items to surface of concrete. Tolerances on tendon placement shall be as needed to provide minimum cover and minimum required flexural strength.

k. Surface Finish on top and sides 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.


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E. Identification Marking:

1. Markings must be such that they will remain legible for the design life of the ties.

2. Permanently label concrete special trackwork ties by indented or

raised numerals or letters on the top surface to identify the following: a. Manufacturer’s Identification b. Form Number c. Tie Number d. Frog No. and Hand of Turnout e. Year of Manufacture f. Date Code traceable to day of manufacture

3. “METRO” shall be cast on the line end of each tie.

2.02 RAIL HOLD-DOWN COMPONENTS

A. Rail hold-down assemblies for concrete special trackwork ties shall be the Pandrol ‘e’ clip system, or approved equal, consisting of Type e-2055 rail clips with special trackwork plates, plate pads, and threaded fastener inserts at switches and frogs. Embedded shoulders, nylon insulators, and rail seat pads shall be used at other locations.

B. Special Trackwork Plates:

1. Special trackwork plates shall have weld-on shoulders designed to

provide and maintain proper position and alignment of the rail clip, and running rail or guardrail base.

2. Special trackwork plates shall be in accordance with Section 19405. Location of special trackwork plates shall be in accordance with Manufacturer’s drawings and yield the specified tolerances provided herein.


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C. Threaded Fastener Inserts:

1. Threaded fastener inserts shall be provided for the attachment of special trackwork plates and switch machines or switch stands to the concrete ties. Inserts shall be ductile iron housings conforming to ASTM A536 grade 65-45-12 or 80-55-06 with removable nylon threaded cores to prevent stray current or signal leakage paths from the bolt into the concrete. a. Inserts shall be threaded to ensure at least 3 inches thread

engagement in the final assembly. b. Each insert shall be furnished with a firmly fixed and easily

removable plug of nylon or plastic material to exclude concrete or other materials from entry during and after production. Plugs shall be capable of re-insertion and, if re-inserted, shall still exclude concrete or other materials from entry.

c. Inserts shall provide pull-out and torque resistance as

required in Article 4.9.1.9, Chapter 30 of the AREMA Manual.

d. Location of inserts shall be in accordance with

Manufacturer’s drawings and yield the specified tolerances provided herein.

D. Embedded Shoulders:

1. Cast ductile iron conforming to ASTM A536 Grade 65-45-12 or 80-

55-06. 2. Shoulders shall be threadless and shall be designed to provide and

maintain proper position and alignment of the rail clip, insulator, tie pad, and running rail or guardrail base. The shoulder shall also be designed to provide function of the clip, insulator, and tie pad.

3. The shoulder shall not be directly anchored to the prestressing

steel. The shoulder shall not come in contact with prestressing steel.

4. The shoulder shall provide pull-out and torque resistance as

required in Article 4.9.1.9, Chapter 30 of the AREMA Manual.


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5. The shoulder shall have a continuous vertical gauge face to prevent the rail from hooking or catching between the shoulders and tie during rail placement, removal or transportation.

E. Insulators between Fastener Hardware and Rails:

1. Configuration:

a. Provide keys between the insulators and the fastener

hardware to prevent relative motion in any direction. b. The insulators shall cover the full widths of the shoulders. c. Except for surfaces in contact with the rail, the surfaces of

the insulators shall be smooth, clearly finished, and free of flash. Insulators shall be free of internal defects and cavities.

2. An insulator shall be used between the rail clip, shoulder insert,

and the rail to provide electrical insulation, reduce abrasion, prevent shoulder wear and transfer the rail loading to the rail clip and shoulder insert. The insulator shall be held in correct position by the shoulder insert and shall be easily removed upon removal of the rail clip.

3. Insulators shall comply with standard material tests as described in

Article 4.2.6.1, Chapter 30 of the AREMA Manual with the following tolerances to selected tests: a. ASTM D257, Electrical Resistivity: Volume resistivity shall

be a minimum of 1x1013 ohm-cm. b. ASTM D570, Water Absorption: Absorption over 24 hours

shall be four percent maximum.

4. Insulators shall be capable of withstanding temperatures from -20°F to +160°F without detrimental effect on the performance of the insulator.

5. The insulator shall be capable of withstanding degradation from

oxidation, water, alkali, petroleum oils, synthetic lubricants, and sunlight without having detrimental effects on the performance of the insulator.

6. The insulator shall be designed to withstand the rigors of


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application and reapplication of the rail clips and other components without breaking, cracking, or any other detrimental effect of the performance of the insulator.

7. Recycled material shall not be used.

F. Plate Pads and Rail Seat Pads:

1. Special trackwork plate pads shall have a minimum thickness of 9.0 millimeters and shall extend beyond all edges of plates by at least 1/2 inch. The hole diameters and locations shall match the plates they are under. The pads shall be permanently marked to identify manufacturer, year manufactured, pad identification number and installation orientation if required by design. Rail seat pads shall be compatible with the rail fastening system, 6.5 millimeters thick, designed to fit between the shoulders of a rail seat. All pads shall be of standard “off-the-shelf” design and made from high quality polyurethane, rubber, EVA, or specialty compounds. Pads shall be supplied by Pandrol, Airboss, Nortrak, or approved equal. All pads shall be approved by the Engineer.

2. The spring rate for special trackwork plate pads shall provide a

uniform track modulus in combination with rail seat pads on adjoining ties. The spring rate for pads shall be determined in accordance with the qualification testing specified above.

3. Pads shall meet the following material requirements:

a. Material shall be capable of withstanding temperatures of -20° F to +160° F and other dynamic forces generated by trains without a detrimental effect on their performance.

b. Hardness measured in accordance with ASTM D2240:

Between 50 and 80 durometer value, Shore A. c. Tensile Strength, measured by ASTM D412: 1,500 psi,

minimum. d. Volume Resistivity, measured in accordance with ASTM

D257: 1 x 1012 ohm-cm, minimum. e. Material shall be resistant to ozone.


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2.03 CONCRETE TIE MATERIALS

A. Portland Cement:

1. Portland cement shall comply with ASTM C150, Type II or Type III, low alkali (having not more than 0.60 percent alkali content per Table 2, “Optional Chemical Requirements”).

2. Use no more than two clinker sources for Portland cement in this

work. 3. Use no more than two suppliers for Portland cement for this work. 4. Conduct false set penetration tests per ASTM C359. False set

penetration values shall not be less than 50 mm initially, 35 mm at intermediate times, and 40 mm after remix. Conduct tests at 3, 5, 8, and 11 minutes and after remix.

5. At the beginning of production and at a frequency of not greater

than three months, analyze a randomly chosen sample of cement for alkali content in accordance with ASTM C114.

6. The ratio of SO3 to Al2O3 shall not be greater than 1.0 and the

manufacturer shall conduct and report tests in accordance with ASTM C917.

7. The maximum allowable SO3 content in clinker shall be 0.5 grams

per liter when tested in accordance with ASTM C265. This test must be with sufficient frequency to produce consistent control of clinker sulfate levels.

B. Retain and submit mill test reports, including alkali content, of the cement

as supplied by the cement Manufacturer to ensure consistency in chemical ingredients. Under no circumstances shall substitution of cement be permitted unless it has been pre-qualified through the tests listed in this section and approved by the Construction Manager.

C. Concrete Aggregates: Fine and coarse aggregates shall be hard, strong,

and durable crushed stone or gravel, clean and free of deleterious materials.

1. Coarse Aggregate: ASTM C33, clean and uniformly (ASTM C33,

Size No. 67, No. 57, or No. 7).


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2. Fine Aggregate: ASTM C33, uniformly graded from 1/4 inch to fines, washed clean.

3. Certificate of Compliance: Submit evidence which indicates that the

aggregates proposed for use meet, and will continue to meet, the requirements of ASTM C33 for gradation, deleterious substances, and soundness. Attention shall be given to the requirements of Sections 5.4 and 10.2 of ASTM C33.

4. Aggregate shall comply with the petrographic analysis test, as

described in Article 4.2.2.2.b, Chapter 30 of the AREMA Manual and ASTM C295.

5. Aggregate meet durability requirements as defined in Article


D. The composition of the cement, fine aggregate and coarse aggregate shall be analyzed and tested in accordance with the requirements defined in Section 4.2, Chapter 30 of the AREMA Manual, so as to ensure that the resulting combination does not produce a concrete subject to deleterious expansion resulting from an alkali-silica reaction. In addition to meeting the aforementioned test requirements, the Manufacturer shall take all necessary measures to protect concrete from alkali-reactivity degradation. Past test result may be accepted only if the test has been performed within the last 12 months and the Construction Manager approves.

E. Water: Water for mixing concrete shall be potable and free from harmful

amounts of oils, acids, alkalis, salts, organic materials, or other substances which may be deleterious to concrete or steel. Chloride ion content in the mixing water shall not be in excess of 100 ppm.

F. Concrete Admixtures:

1. Acceptable concrete admixtures may be included in the concrete

mix to improve the water-cement ratio or workability of the concrete, providing the strengths specified and other desirable characteristics of the concrete can be achieved and maintained. Admixtures require the Construction Manager's acceptance before they may be used.

2. If used, concrete admixtures shall conform to the following

requirements: a. Only liquid admixtures shall be used.


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b. Air Entraining Admixtures: ASTM C260. c. Accelerating, Retarding, and Water-Reducing Agents: ASTM

C494. d. Other Pozzolanic Admixtures: ASTM C618, or other mineral

admixtures may not be used without written approval of the Construction Manager.

3. Admixtures containing chlorides, fluorides, sulphites, nitrates, or aluminum powder shall not be used.

G. Cement Content: 600 pounds per cubic yard, minimum. H. Water-Cement Ratio: 0.40 maximum by weight. I. Entrained Air:

1. Measure the air content of the plastic concrete in accordance with

ASTM C173 or ASTM C231. The tested air content of the freshly mixed concrete shall be between 4.5 and 6.5 percent, or as approved by the Construction Manager, to yield an air content in the hardened concrete when tested in accordance with ASTM C457, Linear Traverse Method, of 3.5 to 6.0 percent.

2. Test specimens from the approved concrete mix shall be tested in

accordance with ASTM C666, Procedure A. The durability factor shall be a minimum of 90 percent at 300 cycles. Test for air content on hardened concrete shall be performed on a hardened tie or companion concrete prisms if a properly sized sample cannot be produced from a tie due to tendon placement.

J. Prestressing Steel Tendons:

1. Wire: Uncoated, stress-relieved or low-relaxation steel wire shall conform to ASTM A421 or ASTM A881.

2. Strand: Uncoated, seven-wire, stress-relieved or low-relaxation

steel strand shall conform to ASTM A416 or ASTM A886. 3. Minimum prestress working force after long-term losses shall as

required to ensure minimum bending requirements are achieved.


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K. Supplemental Reinforcement: A minimum of two 0.21 inch to 0.25 inch

diameter closed loop stirrups shall be placed between 1 inch and 3 inches from all tie ends. Material shall conform to ASTM A82 or A881.

L. Flexural Strength Pre-Qualification Testing

1. Flexural strength tests shall be performed to check the adequacy of

the mix proportions design. Samples from which flexural test specimens are molded shall be obtained in accordance with ASTM C31.

2. Test Procedure: Flexural strength test shall be performed on a 6 by

6 by 20 inch beam in accordance with ASTM C78. 3. The 28-day flexural strength shall be at least 700 psi when tested in

accordance with ASTM C78. 4. A minimum of six separate beam tests shall be performed to

establish mix design flexural strength. 2.04 PRODUCTION OF CONCRETE

A. Concrete Quality:

1. Water content shall be kept to a minimum consistent with the

strength requirements and placement needs. Concrete mixes shall be proportioned to produce a compressive strength of at least 7,000 psi when tested at 28 days in accordance with ASTM C39.

2. Concrete strength at stress transfer shall be adequate for the

requirements of anchorages and for the transfer of stress through bond. Strength at the time prestress is transferred to the concrete shall be not less than 4,500 psi. Calculated concrete stresses shall be in accordance with ACI 318, Chapter 18, Prestressed Concrete, Section 18.4.

B. Concrete Mix Proportions:

1. Unless previous data are accepted by the Construction Manager to

show that a concrete mix will be satisfactory for the production of concrete ties, concrete mix designs shall be established by tests on trial batches to achieve the required specified strengths and properties.


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2. Cement content shall be 600 pounds per cubic yard, minimum. 3. Water-cement ratio shall not exceed 0.40 by weight and shall be

calculated on the basis of the weight of cement. 4. Using materials that will be used in the work, establish proportions

of Portland cement, aggregates, water, and admixtures to produce the properties specified based on field experience or trial batch method described in ACI 318. Substantiate attainment of all specified properties by designated ASTM test methods. Provide concrete that has 28-day compressive strengths that exceed the specified design strength (f'c) in accordance with ACI 318. Acceptability of concrete strength will be based on requirements for ultimate strength design.

5. The proportions of aggregate to cement shall produce a mixture

which will work readily into corners and angles of the forms and around the prestressing tendons with the assistance of specified vibration, but without permitting the materials to segregate or excess free water to collect on the surface.

6. The Manufacturer shall assure that the range of air content to be

used in the freshly mixed concrete remains specified while achieving a minimum 28 day compressive strength of 7,000 psi. At least one measurement of air content of the freshly mixed concrete shall be made from each bed cast or each 50 cubic yards of concrete, whichever is less volume of concrete.

PART 3 - EXECUTION 3.01 FABRICATION OF TIES

A. Conform with applicable requirements of the AREMA Manual, Chapter 30, Part 4, and PCI MNL-116.

B. Forms:

1. Forms shall be rigid and shall be constructed of material that will result in finished ties, conforming to the shape, lines and dimensions indicated. Tolerances in excess of those indicated or specified will not be permitted.


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2. Forms for concrete special trackwork ties shall be constructed to permit movement of the tie without damage during transfer of the prestressing force.

3. Forms shall provide proper markings as specified above.

C. Placement of Prestressing Steel:

1. Prestressing tendons in the concrete special trackwork ties shall be

accurately placed and adequately secured in position. Prior to placing concrete, the dimensional accuracy of the position of prestressing tendons, bulkheads, inserts, and anchorage devices shall be verified. Prestressing tendons shall be inspected for proper surface condition. Tendons contaminated with form release agents and other substances that will reduce bond with concrete shall be cleaned.

2. Tolerances for placing reinforcement shall conform to Article


D. Application and Measurement of Prestressing Force: 1. Initial prestressing force in each of the tendons shall not exceed the

Manufacturer's recommendation and shall not exceed 75 percent of the ultimate strength for stress relieved strand and stress relieved wire and 70 percent of ultimate strength for direct drawn wire.

2. The force shall be applied in two increments. An initial force shall

be applied to the tendons to straighten them, eliminate slack, and provide a starting or reference point for measuring elongation.

3. Prestressing force shall be determined by reading hydraulic ram

pressure on a calibrated gauge or by the use of a calibrated dynamometer. Elongation measurements shall be taken from average load-elongation curves for the steel used. Actual elongation shall agree with the elongation calculated, using the force determined from the pressure gauge within plus or minus five percent shall be ascertained and corrected before production may continue.

4. Tendons may be stretched either individually or simultaneously. If

tendons are stretched simultaneously, provision shall be made to induce approximately equal stress in each.


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5. Transfer of force from the abutments of the pretensioning bed to the concrete shall be carefully accomplished by gradual and simultaneous detensioning of all tendons. Exposed tendons shall be cut near the tie end. The projection of tendons beyond the ends of the ties shall not exceed 1/8 inch.

E. Mixing, Placing, and Curing of Concrete:

1. Preparation of Placing Concrete: Prior to placing concrete,

equipment for mixing the concrete shall be clean, debris shall be removed from spaces to be occupied by the concrete, forms shall be oiled, and the tendons shall be cleaned of deleterious coatings. Forms shall be inspected for alignment and tightness of joints, and the dimensional accuracy of the position of bulkheads, prestressing tendons, inserts, and other embedments shall be verified.

2. Proportioning of Concrete Materials:

a. 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.

b. Water and liquid admixtures may be measured by weight or

volume. c. The accuracy of measurement of the concrete ingredients

shall be as required to produce consistent concrete capable of meeting minimum strength and air entrainment requirements.

3. Mixing of Concrete:

a. Mixing equipment shall be capable of combining specified

materials within the time specified by the equipment manufacturer into a thoroughly mixed and homogeneous mass, and discharging the mixture without segregation.

b. Concrete shall be mixed until there is a uniform distribution

of the materials, and shall be discharged completely before the mixer is recharged.

c. Optimum mixing time shall be established by the equipment

manufacturer's specifications. Generally, minimum mixing time shall be four minutes for batches of one cubic yard or


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less, this mixing time shall be increased by at least 15 seconds for each cubic yard, or fraction thereof, of capacity in excess of one cubic yard. Mixing time shall be established for the concrete mix in order to produce batch-to-batch uniformity. Both under mixing and over mixing shall be avoided.

4. Conveying:

a. Concrete shall be conveyed from the mixer to the place of

final deposit in the shortest practicable time by methods which will prevent segregation or loss of materials.

b. Equipment for chuting, pumping, and pneumatic conveying

of concrete shall be of size and design to assure flow of concrete at the delivery end without segregation of materials.

5. Depositing: a. Concrete shall be deposited as nearly as practical in its final

position to avoid segregation due to rehandling or flowing. Concrete which has partially hardened or has been contaminated by foreign materials shall not be used.

b. Concrete shall have a minimum temperature of 50°F, and a

maximum temperature of 90°F when placed. When concrete is placed at an ambient temperature of 90°F or greater, special precautions to prevent rapid drying shall be employed when concrete is placed at ambient air temperatures below 40°F, precautions should be employed to keep the concrete from freezing.

c. Comply with applicable requirements of ACI 305R.

6. Consolidating: a. Concrete shall be thoroughly consolidated by vibration

during placement, and shall be thoroughly worked around the prestressing tendons, embedded inserts, and into corners of the forms.

b. External form vibration, internal concrete vibration, or a

combination of both shall be used to obtain uniform mix,


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and shall be sufficient to yield concrete with a density in compliance with qualified mix design density, taking into account allowable air content variation.

c. Forms shall not be damaged during consolidation.

7. Curing:

a. Concrete special trackwork tie forms shall be heat cured by

low pressure steam, radiant heat, conduction heat, or other accepted curing process to accelerate strength gain so that removal of forms and transfer of the prestressing force may be accomplished at an early age.

b. Curing shall be performed in accordance with procedures

established by PCI to produce the concrete strengths specified. Temperature gradient shall not exceed 36°F per hour. Maximum curing temperature shall not exceed 158°F. Heat curing of concrete shall not be started until after concrete initial set (ASTM C403) has occurred. Referenced temperatures are center of concrete cross section, not ambient.

8. Removal of special trackwork ties from forms: Special trackwork ties shall be removed from forms in a manner which will prevent damage to the forms or special trackwork ties.

9. Finishing:

a. Formed surfaces of the finished special trackwork ties shall

have a smooth and dense uniform surface. Surface of the rail seat shall have a smooth finish and shall be free from surface irregularities and excessive air holes. Other surfaces shall have a smooth finish which may contain honeycomb not to exceed two percent of the surface and a maximum void diameter and depth of 3/8 inch.

b. Two ties that, in the opinion of the Construction Manager,

show the required finishes shall be set aside as comparison standards for acceptance of the concrete special trackwork ties.


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3.02 PRODUCTION TESTING

A. One tie selected at random from each production day shall be subjected to the following tests:

1. Shoulder adjacent spacing and shoulder outer-to-outer spacing

shall be verified. Insert location shall be verified by template. 2. The rail seat vertical load test, rail seat positive moment test and

rail seat negative moment test shall be performed on one rail seat. Ties that pass test requirements and have no visible cracks after testing or are not otherwise damaged will be accepted. Selected tests may be waived at the discretion of the Construction Manager based upon historically demonstrated interrelation between these tests.

3. If cracking occurs in any of the tests, two additional ties from the

same lot shall be subjected to the same tests, and acceptance of the lot shall be based on the following conditions:

a. If both retest ties meet the requirement, the lot will be

accepted. b. If either of the retest ties fails to meet the test requirement,

the remaining ties of the lot shall be tested in accordance with a statistical sampling plan to be reviewed and accepted by the Construction Manager.

B. Bond Development and Ultimate Load Test: In addition to the requirements specified above, the following tests shall be performed:

1. One tie selected at random from each day’s production shall be

tested daily for bond development and ultimate strength as specified above for qualification testing.

2. If strand slippage exceeds 0.001 inch for bond development with

bond load held for a minimum of 3 minutes, three additional ties shall be tested. If any of the three ties do not meet the requirements of the test, the remaining ties in the lot shall be rejected.

C. An electrical test shall be performed to check for shoulder to shoulder

direct electrical shorts at between 10 to 13 volts DC using a digital multi-meter. The resistance shall not be less than 100 ohms, calculated as measured voltage divided by measured current.


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3.03 STRENGTH TESTS OF CONCRETE

A. Compressive Strength Testing

1. Compressive strength tests of concrete shall be performed to check the adequacy of mix proportions and as a basis for acceptance.

2. Test Specimens: Samples for compressive-strength test specimens

shall be obtained in accordance with ASTM C172. 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 under production conditions.

3. Test Procedures: Strength tests shall be performed on standard

cylinders, 6 by 12 inch or 4 by 8 inch in size, in accordance with ASTM C39. For each day of production at least eight cylinders shall be prepared for each production line: three for 28 day strength tests, three for checking strength at prestress transfer, and two for spares.

B. Freeze-Thaw Durability

1. Freeze-thaw durability factor shall be measured in accordance with ASTM C666 Procedure A on a minimum of four prisms of concrete. The durability factor shall be not less than 90 percent. This test shall be performed at the start of production and thereafter every three months.

3.04 HANDLING AND STORAGE OF TIES

A. Handling: Ties shall be lifted and supported during manufacture, storage, transportation, and installation operations in a way which will prevent chipping, spalling, cracking, or other damage.

B. Storage: When stacked in multiple tiers, each tier shall be separated with

dunnage having sufficient thickness to clear fastening shoulder inserts and pre-attached platework. Ties shall be stacked by type in separate rows with access alleys. Fastening system components shall be packaged and stored independently of the special trackwork ties, clearly marked, and protected against corrosive environment.


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3.05 DELIVERY

A. The Supplier shall deliver all materials in accordance with the delivery schedule. All material shall be delivered by truck to locations designated by the Construction Manager. The Construction Manager will make arrangements for the unloading of material by others.

B. The Supplier shall have on hand at the unloading area, for each delivery, a

representative for the verification of condition of packaged items. C. The Supplier shall replace all concrete special trackwork ties and rail

fastener assemblies damaged during loading, shipping, unloading and stockpiling with new concrete special trackwork ties and rail fastener assemblies.

3.06 WARRANTY

A. The Supplier shall warranty the special trackwork ties and all related components to be free of faulty materials and workmanship for five years after final acceptance of the delivered material by the Construction Manager.

B. Concrete special trackwork ties and other materials supplied under this

specification found to be defective in materials and/or workmanship prior to the end of the warranty period shall be replaced at the expense of the Supplier.

C. Any material failures due to manufacturing defects between acceptance

and end of the warranty period shall be remedied. Damage caused by the construction and maintenance activity, or operational accidents is excluded.

D. Replacement material shall carry the same warranty as the original

materials, starting with the date of final acceptance of the replacement material.


Section 34 14 40 – General Track Construction

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SECTION 34 14 40

GENERAL TRACK CONSTRUCTION PART 1 - GENERAL

1.01 DESCRIPTION A. This section specifies general track construction which consists of the

mainline and yard trackwork requirements that are common to standard ballasted track, special trackwork, and track appurtenances, including rail welding, laying CWR, anchoring rail, final alignment and site cleaning.


A. Where a date is given for reference standards, the edition of that date shall

be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the Work included in this Section.

B. American Railway Engineering and Maintenance-of-Way-Association

(AREMA): 1. AREMA Manual for Railway Engineering (Manual) 2. AREMA Portfolio of Trackwork Plans (Portfolio) 3. AREMA Communications and Signal Manual (C&S Manual)

C. ASTM International (formerly known as American Society for Testing and

Materials) (ASTM): D1784 Standard Specification for Rigid Poly (Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds

D1785 Standard Specification for Poly (Vinyl Chloride) (PVC)

Plastic Pipe, Schedules 40, 80, and 120 D3786 Standard Test Method for Hydraulic Bursting Strength of

Textile Fabrics-Diaphragm Bursting Strength Test Method D4491 Standard Test Methods for Water Permeability of Geotextiles

by Permittivity


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D4533 Standard Test Method for Trapezoid Tearing Strength of Geotextiles

D4632 Standard Test Method for Grab Breaking Load and Elongation of Geotextiles

D4751 Standard Test Method for Determining Apparent Opening

Size of a Geotextile D4833 Standard Test Method for Index Puncture Resistance of

Geotextiles, Geomembranes, and Related Products D5199 Standard Test Method for Measuring Nominal Thickness of

Geosynthetics E10 Standard Test Method for Brinell Hardness of Metallic

Materials G165 Standard Practice for Determining Rail-to-Earth Resistance

1.03 RELATED WORK

A. Section 34 14 00 Rail

B. Section 34 14 05 Special Trackwork Material

C. Section 34 14 10 Ballast

D. Section 34 14 15 Other Track Material

E. Section 34 14 36 Concrete Crossties

F. Section 34 14 37 Special Trackwork Ties

G. Section 34 14 75 Rail Welding

1.04 DEFINITIONS A. Ballast: An integral part of the track structure, generally composed of

crushed stone in which ties are embedded. Track ballast includes ballast compacted beneath the ties, in the cribs between the ties, and in the ballast shoulders at the ends of the ties.

B. Closure Rails: The rails between the parts of any special trackwork layout,

such as the rails between the switch and the frog in a turnout; also the rails


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connecting the frogs of a crossing or of adjacent crossings, but not forming parts thereof.

C. Continuous Welded Rail (CWR): A number of rails welded together into a single length.

D. Crossing, Road: The intersection of one or more tracks and a street, road, highway or pedestrian walkway at grade.

E. Crosslevel: The difference in elevation of the tops of heads of opposite rails measured at right angles to the track alignment.

F. Dutchman: A short piece of running rail temporarily placed between the ends of two rails. A Dutchman is placed at the zero thermal stress length before the two rail ends are welded into CWR, to reduce the damage which would occur to the rail ends as a result of rail mounted track equipment passing over those ends.

G. Frog: A device used at the intersection of two running rails to provide support for wheel treads and passageways for their flanges, thus permitting wheels traversing either rail to cross the other.

H. Frog Number: The number used to designate the size of a frog, and being equal to one-half the cotangent of one-half the frog angle.

I. Grade Line: The line on the profile representing the top of the roadbed ready to receive the subballast at the intersection of the roadbed with a vertical plane through the track center line.

J. Guard Rail: A rail or other device laid parallel with the running rails of a track to prevent wheels from being derailed; or to hold wheels in correct alignment to prevent their flanges from striking the points of frogs. A rail or other device laid parallel with the running rails of a track to keep derailed wheels adjacent to running rails.

K. Inside Rail: On curved track, the rail closest to the curve center, the rail with the shorter radius. Sometimes referred to as the "low rail".

L. Joint Bar: A steel member, embodying beam-strength and stiffness in its structural shape and material; commonly used in pairs for the purpose of


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joining rail ends together, and holding them accurately, evenly, and firmly in position with reference to surface and gauge-side alignment.

M. Outside Rail: On curved track, the rail farthest from the curve center; the rail with the longer radius. Sometimes referred to as the "high rail".

N. Profile Grade Line (PGL): The datum line which defines the vertical alignment of the track, applied at the top of the low rail.

O. Rail Fastener - Ballasted Track: A resilient device used to secure the

running rail to the concrete tie at the proper track gauge to provide proper vertical, lateral, and longitudinal restraint of the rail.

P. Rail Joints: A fastening designed to unite the abutting ends of contiguous rails.

Q. Rail Joint, Insulated: A rail joint designed to arrest the flow of electric current from rail to rail by means of insulation so placed as to separate the rail ends and other metal parts connecting them. Commonly called insulated joints or ''IJ's''.

R. Roadbed: The foundation (prepared subgrade) on which the track structure consisting typically of subballast and ballast is placed.

S. Special Trackwork: A generic term referring to turnouts, single and double crossovers, track crossings, and other such items.

T. Standard Rail: A synonymous term to 115 RE rail.

U. Stock Rail: A running rail against which a switch rail bears in a turnout.

V. Stub-up: A conduit temporarily terminated in the roadbed for later use by signal, communication, or traction power installers.

W. Subballast: A material which provides a semi-impervious layer between the finished subgrade of the roadbed and the ballast, to provide better drainage, and better distribute the load over the roadbed.

X. Subgrade: The finished surface of the roadbed below the level of subballast or track slab.


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Y. Superelevation: The vertical distance of the outer rail of a curve above the inner rail. It is provided to overcome or partially overcome the centrifugal forces due to curvature and speed. It is measured in inches, and is applied in 1/4 inch increments.

Z. Switch, Point of: The tip of the tapered end of a switch rail; the end of a switch rail farthest from the frog or heel block.

AA. Switch Point, Undercut: A switch point planed to mate with a stock rail having a planed undercut, in order to provide an effective point width of zero.

BB. Switch Rail (Switch Point): A planed, tapered, movable rail which mates

with a stock rail to enable movement of a train from one track to another.

CC. Switch, Split: The common type of track switch consisting essentially of two planed, movable switch rails.

DD. Top of Rail (T/R): The top surface of the head of the running rail.

EE. Track, Ballasted: Track constructed of rails, crossties, and ballast. It is the predominant form of track constructed at-grade, but it is also used on short bridges.

FF. Track, Gauge: The distance between the inside faces of running rails measured at a point 5/8 inch below the top of each running rail. Standard gauge: 4 feet 8-1/2 inches.

GG. Track, Secondary and Yard: Track constructed for the purpose of switching, storing, or maintaining rail vehicles or connecting such tracks to mainline tracks.

HH. Trackway: The foundation on which the track is constructed. It usually consists of an earthen roadbed, but it may also be one of the following: a concrete roadbed for support of direct fixation track or embedded track; a ballasted bridge deck (designed to receive ballast); or an aerial structure.

II. Turnout: An arrangement of a switch and a frog with stock rails and closure rails, enabling rail vehicles to be diverted from one track to another.


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JJ. Turnout Number: The number corresponding to the number of the frog used in the turnout.

KK. Zero Thermal Stress: The state of uniform stress in CWR, while the rail is unrestrained and free to move longitudinally.

LL. For additional definitions, refer to AREMA Manual and Portfolio. 1.05 SUBMITTALS

A. Shop Drawings, include the following:

1. Complete details for distributing CWR, including a rail schedule showing: a. Designation of line and profile rails. b. Layout of CWR strings by lengths. c. Location of proposed field cuts and field welds in CWR on

the rail schedule. Include locations of any insulated joints fabricated in the field.

2. Complete details of the proposed methods, including equipment, of

laying and fastening CWR. Include method and equipment proposed for achieving zero thermal stress.

3. Description of temperature adjustment and final anchoring procedures for CWR, including charts, tables, and field instructions on heating, cooling and stretching.

4. Charts shall be provided that indicate gaps for varying lengths of rail and varying rail temperatures.

B. Procedures: Provide complete details of the end-hardening procedures,

including identification of personnel to perform the procedure, the equipment, and the test results required no less than 30 days prior to initiating any end-hardening.

C. Equipment to be used on roadbed: Submit weights and dimensions of

equipment proposed for use on roadbed prior to employing it on roadbed. D. Rail Mounted or Hi-Rail Construction Equipment: Submit a complete list

of equipment for use during trackwork construction, within 30 days after


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receipt of the Notice to Proceed. Include rail-mounted geometry inspection vehicle. 1. Equipment to be utilized shall not exceed design clearance

envelope and loading criteria for the Light Rail System. 2. Submit a complete description of all proposed modified equipment,

including calculations verifying that loading criteria for the light rail system will not be exceeded.

3. Certify that the equipment modifications will clear all structures

and other facilities at the areas where the equipment will be used. 4. Certify rail wheels are in good condition, without excessive wear.

Damage to frogs, crossing panels, etc. shall be repaired or replaced as determined by the Construction Manager.

E. Product Data: Submit Manufacturer's data for Contractor-furnished material including non-woven filter fabric and adhesive for bonding tags to concrete. Submit installation information and sufficient description to verify that materials comply with the specifications. Include specification data and Manufacturer's installation instructions for nonwoven filter fabric.

F. Samples: Submit sample for non-woven filter fabric. G. Test Reports: Submit summaries of test results within one week for field

weld tests, Brinell Hardness Tests, insulated joint continuity tests, track geometry vehicle measurements, and any other periodic testing required by Contract.

H. Rail Laying Record: Submit records in accordance with Article entitled

“Laying Continuous Welded Rail,” herein. I. Track-to-Earth Resistance and Rail Insulated Joint Testing Information

1. Resumes of the testing supervisor and field testing personnel 2. Detailed written description of the proposed testing procedures

and a sample of all test data sheets, showing the proposed format for the documentation of the test data.


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3. List of instruments to be used. The list shall include the manufacturer’s name, model number, serial number, and calibration certificate for each instrument. All test instruments shall have been calibrated within 12 months of field use.

J. Superelevation tag detailed drawing showing dimensions, material and

stamped (or embossed) information, and the method for fixing the tag to the track support structure.

1.06 QUALITY ASSURANCE

A. Comply with:

1. Codes and regulations of the jurisdictional authority. 2. AREMA Manual. 3. Contractor’s Quality Plan.

B. Employ personnel qualified by experience in conventional and Special

Trackwork installation as foremen or leaders for Trackwork installation. C. Use proper tools and equipment for track construction. D. Use a qualified land surveyor registered in the State of Texas to establish

and maintain alignment and elevation. E. Isolation of running rail from the concrete invert is essential to contain the

returning traction power current within running rails. Clean site of miscellaneous materials and contaminants such as moisture, dirt, debris and metallic wires and banding. Unkempt trackways will degrade the results of electrical testing specified elsewhere in these specifications. Where tracks will be constructed to connect to existing operating tracks and railroads, install two insulated joints at the connection point. Tracks shall remain electrically segregated until track under construction has passed the electrical isolation test or as directed by the Construction Manager.

F. Lubricate special trackwork with approved lubricants.


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1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING

Furnish materials required for track construction.

1.08 SURVEYING A. The Contractor shall set monuments at all points as shown on the contract

drawings. B. The Construction Manager will furnish the Contractor with identifications

and elevations to 1/100 of a foot for all existing baseline. C. Do not use controls for surveys other than monumentation described

above unless otherwise approved by the Construction Manager. D. Perform surveying required and assume full responsibility for all

dimensions and elevations taken and the setting of lines and grades relating thereto.

1.09 CONSTRUCTION EQUIPMENT

A. No excess load is permissible for ballast cars, tie cars, or the rail train, and all equipment loads shall conform to the loading requirements.

B. Oversize Equipment: Operate equipment only on parts of the system where clearances have been checked for the equipment, with the following restrictions:

1. Past station platforms: Stop clear of platforms, check clearances, then proceed at 10 mph or less, and be prepared to stop.

2. Under overpasses: Stop clear of structure, check clearance, then proceed at 10 mph or less, and be prepared to stop.

3. Tangents: Speed restricted to avoid excessive rocking.

4. Curves:

a. Track not at final alignment and superelevation: Proceed at speed of 10 mph or less, and be prepared to stop.

b. Track at final alignment and superelevation: Speed controlled to avoid excessive lean or rocking.

C. Equipment Condition:


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1. Operate only equipment on the roadbed which is in good state of repair and with all safety appliances and protective devices in place and functioning.

2. Brakes shall be capable of stopping and holding equipment on a 6 percent grade. The Construction Manager may require braking demonstrations at any time, in any weather condition, and with any allowable load, to verify the safe operation of the equipment.

3. Rail-mounted equipment shall be provided with brakes, including trailers and push carts. Semi-permanently coupled units may be treated as a single braking system.

4. Rail-mounted equipment shall be provided with mechanical devices to permit the equipment to be securely anchored to the rails while unattended.

5. Rail wheels with flat spots whose length exceeds 8 percent of the wheel diameter are prohibited. Equipment with a wheel having a flat spot exceeding 5 percent of the wheel diameter is restricted to a maximum speed of 10 mph on aerial structures and ballasted deck bridges. Remove equipment with a wheel which develops a flat spot whose length exceeds 8 percent of the wheel diameter.

1.10 STRUCTURAL WEIGHT LIMITS AND CLEARANCES

A. For the purposes of this Article, structure shall be understood to mean any constructed element within the completed roadbed which may interfere with or obstruct the track construction, including bridges or aerial structures, station platforms or foundations, road crossing headers, manholes, foundations, and conduit terminations (stub-ups).

B. Roadbed Structural Capacity:

1. Aerial structures, ballasted deck bridges, culverts, and other structures under the roadbed are designed to support train loads applied through the track structure only, unless otherwise shown.

2. If any construction vehicles are to be moved across bridge structures, the move shall be approved by the Construction Manager, the Contractor shall submit calculations signed and sealed by a registered Professional Engineer in the State of Texas to indicate the developed stresses do not exceed those of the equivalent train load.


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PART 2 - PRODUCTS

2.1 RAIL

A. 115 RE section either standard or premium rail as specified in Section 34 14 00 Rail.

2.2 TIES

A. All ballasted track construction on yard tracks shall use concrete crossties.

B. Concrete crossties: 8 feet 3 inches in length unless specified elsewhere, and conforming to Section 34 14 36 Concrete Crossties.

C. Concrete switch ties of varying lengths, and conforming to Section 34 14 37 Special Trackwork Ties, and the Manufacturer’s shop drawings.

D. Concrete ties for at-grade road crossings shall be 10 feet in length, and conforming to Section 34 14 37 Special Trackwork Ties, and the Manufacturer’s shop drawings.

2.3 NON-WOVEN FILTER FABRIC (GEOTEXTILE)

A. Geotextile fabric shall be non-woven polypropylene, Mirafi 1100N, or

approved equivalent, and shall have the following properties:

Property Acceptable Value, min.

Water Permeability (k) (ASTM D4491) 0.20 cm/sec

Thickness (ASTM D5199) 2.25 mm

Apparent Opening Size (U.S. Standard Sieve)

(ASTM D4751)

100-120

Grab Strength, Ultimate (ASTM D4632)* 250 lbs.

Grab Elongation, Ultimate (ASTMD 4632)* 50%

Mullen Burst Strength (ASTM D3786) 450 psi

Puncture Strength (ASTM D4833) 120 lbs.

Trapezoidal Tear Strength (ASTM D4533) 100 lbs.


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* Tests shall be run on wet samples soaked 24 hours in water at ambient

temperature.

2.4 BOLTED JOINTS

Joint bars, bolts, nuts and washers for bolted joints shall be suitable for the rail

size indicated and conform to Section 341415 Other Track Materials. Provide 6-

hole joint bars unless otherwise noted.

2.5 TRACK DRAIN AND TRACK UNDERDRAIN PIPE

A. All PVC Schedule 80 pipe shall be manufactured from a Type I, Grade 1 Polyvinyl Chloride (PVC) compound with a Cell Classification of 12454 per ASTM D1784.

E. The pipe shall be manufactured in strict compliance to ASTM D1785 for

physical dimensions and tolerances. Each production run of pipe manufactured in compliance to this standard, shall also meet or exceed the test requirements for materials, workmanship, burst pressure, flattening, and extrusion quality defined in ASTM D1785.

C. Product marking shall meet the requirements of ASTM D1785 and shall include: the manufacturer’s name (or the manufacturer’s trademark when privately labeled); the nominal pipe size; the material designation code; the pipe schedule and pressure rating in psi for water @ 73°F; the ASTM designation D1785; and the date and time of manufacture.

D. Perforations shall be 1/2 inch diameter holes at three inches on center and 60 degrees on each side of bottom centerline.

PART 3 - EXECUTION

3.01 TOOLS AND EQUIPMENT

A. Track gauge, flangeway width, curve radii, rail sections and special

trackwork components are designed for light rail vehicle operation and

are as specified herein and indicated on the plans. The width of

flangeway for all frogs and frog guard rails shall be 1-7/8 inches. The

Contractor's on-track equipment shall be modified, if required, to operate

over this track without causing damage to the track structure, passenger

station platforms, or other obstructions within the envelope of the


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Contractor’s equipment. Damages to the track structure shall be repaired

by the Contractor.

B. Contractor's equipment shall not exceed the design loads shown in

Figures 3.06-1 and 3.06-2 of this Section. Further information concerning

vehicle characteristics will be provided upon request by the Contractor.

Contractor shall verify that proposed equipment meets these

requirements.

C. Rail trains shall be worked in an up-slope direction wherever possible to

reduce the chances of runaway equipment.

D. Tools used in track construction shall conform to AREMA Specifications

and Plans for Track Tools, or approved equal. All tools shall be calibrated

as appropriate for use.


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3.02 NON-WOVEN FILTER FABRIC

A. Use non-woven material for subgrade stabilization at locations indicted on the Approved Drawings.

B. Install fabric in accordance with Manufacturer's installation instructions.

3.03 GAUGE

A. Measure the track gauge between the inside faces of running rails measured at a point 5/8 inch below the top of each running rail.


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B. Tangent and curved track above 500 foot radius shall have a gauge of 4 feet 8-1/2 inches. Curved track with less than 500 foot radius will widen incrementally from 4 feet 8-1/2 inches to 4 feet 8-3/4 inches.

C. Gauge widening shall be at a constant transition rate of 1/4 inch in a distance of 31 feet.

D. For curves without spirals, full gauge widening shall be accomplished on the tangent in approach to the point of curve and removed following the point of tangent.

E. Special trackwork track gauge: 4 feet 8-1/2 inches.

F. Allowable gauge variation is listed in Table 34 14 40-1.

3.04 ALIGNMENT

A. Alignment consists of a series of straight lengths of track referred to as tangents, connected by simple, compound or reverse curves, with or without spirals. Alignment is based upon centerline of track, and on tangent track is equidistant to the gauge sides of the running rails.

B. The track shall be constructed to the alignment and profile indicated on the plans, within the tolerances specified in Table 34 14 40-1.

C. Alignment of curved track is based on centerline of track, with the gauge line of the low rail locate 2 feet 4-1/4 inches measured horizontally from the profile grade line in the plane of the rails. Measurements to gauge are at 5/8 inch below the top of the rail head. Gauge widening is obtained be offsetting the high rail.

D. Track alignment may use station equations.

E. Profile rail – The Contractor shall designate right or left rail, while facing the direction of increasing stationing, to control the grade of all tangent tracks. The low or inner rail on all curves shall be used to control grade.

F. Line Rail – The Contractor shall designate right or left rail, while facing

the direction of increasing stationing, to control alignment of tangent tracks. On curves, the inside rail shall be designated the line rail.

3.05 SURVEYING REQUIREMENTS

A. Basic geometry data is indicated on the drawings. Verify layout information shown in relation to the existing METRO-provided


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monuments and existing structures before proceeding with layout of the actual work. As the work proceeds, check every major element of work for line. Bring discrepancies in location of structures to the attention of the Engineer before starting trackwork. Maintain an accurate surveyor's field book of such checks; make available for the Construction Manager's reference. Record any deviations which are accepted by the Construction Manager on the Record Drawings.

B. Furnish and place markers for the control points and reference points of the track centerlines, as indicated. Stake the centerlines at station platforms, grade crossings, and bridge structures for inspection by the Construction Manager.

C. Furnish the Construction Manager with a plan sheet showing the horizontal distance, azimuth, and angle from the control points indicated to the references indicated.

D. Maintain control points and reference points for the duration of the project.

3.06 CURVATURE

A. Curve information shall be as shown. Shop fabricated rail shall be marked by the Manufacturer for installation.

3.07 TRACK SURFACE

A. Track surface is the relationship of opposite rails to each other in profile and crosslevel:

1. Track profile is the running surface along the top of the grade rail.

2. The ideal surface is a uniform profile consisting of straight gradients connected by vertical curves, with zero crosslevel on tangents, and predetermined crosslevel on curves.

3. Do not raise the profile of track being surfaced above established grades.

4. When surfacing or raising track, select one rail, usually the lower rail on curves and the line rail on tangents, as the grade rail. Bring the other rail to surface by adjusting the crosslevel as needed.


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B. Rail Cant (Inclination):

1. Construct embedded mainline trackwork with 1:40 cant toward the track center and special trackwork with no rail cant.

3.08 RAIL

A. Refer to approved drawings in determining exact location and lengths of premium and standard rail, and for locations of restraining rail.

B. High strength running rail shall be installed under the following conditions:

1. On curves with a radius of 500 feet or less. High strength rail is to extend a minimum of ten feet onto the adjacent tangent.

2. Throughout the limits of special trackwork as shown on the contract drawings.

3. Make adjustments to the field welding procedure as required for the welding of high strength rail.

C. Precurved rails shall be installed in horizontal curves with radii equal to or below 300 feet, or in vertical curves of equivalent radii less than 1,500 feet. Precurved rails shall extend a minimum of ten feet beyond the limits of the curve onto tangent track. Precurved running rail shall be installed in track and joined to CWR by field welding in accordance with Section 34 14 75 Rail Welding. Make adjustments to the field welding procedure as required for the welding of high strength rail. Yard installations shall be jointed as specified herein.

3.09 CUTTING AND DRILLING RAIL

A. Use only the following tools for cutting rail:

1. Rail saw

2. Abrasive cutting wheels

B. When jointed rail is called for or required, drill holes:

1. Drill new holes; do not punch, slot, or burn with a torch.

2. Holes in the ends of the rails for joint bar and restraining rail installation shall be located as indicated on the shop drawings, and shall be of the diameter required by the shop drawings.


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3. Drill with the joint bars removed or before their application. Mark the location of the center of the hole, or drill through an approved template. Do not drill bolt holes using the joint bars as a template.

4. When bolt holes are drilled with a power track drill, maintain a uniform feeding pressure. Reduce pressure as the bit point breaks through the opposite side of the web. Do not force the drill.

5. Remove all rough edges from drilled rail holes.

6. Do not leave bolt holes in the ends of rail to be welded.

7. Reaming of under sized hole using a reamer specially made for rail and approved by the Construction Manager will be allowed. All other reaming or enlarging incorrectly drilled holes to allow joint bar bolts to be installed will not be permitted. Rejected holes shall be sawcut from the rail.

8. Torch cuts or blown holes will not be acceptable.

9. Rail strings having handling holes shall be cropped before welding to eliminate these holes.

3.10 RAIL JOINTS

Installation of rail joint and bolt assemblies shall conform to AREMA and Section 34 14 15 Other Track Materials, and shall be prepared and installed as follows:

A. Either weld or bond rail joints as indicated on the Contract Drawings.

B. Field weld rails in accordance with Section 34 14 75 Rail Welding.

C. Install insulated joints in track that is in its final horizontal and vertical alignment, with ballast tamping completed.

D. The fishing area shall be cleaned of all mill scale, rust, and dirt by wire

brushing, compressed air, solvents, or a combination of these or other

methods.

E. After cleaning, as a protection against rust, all joint bars and the parts of rail covered by joint bars shall be painted with a metal preservative, NO- OX-ID “A-Special”, or approved equal.

F. Bolt Assembly Installation and Tightening:


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1. Holes drilled for bolted joints shall conform to the AREMA Manual, Section 4.1.3 Rail Drillings, Bar Punchings, and Bolts. They shall be cylindrical, free from burrs, and with sharp edges removed. Templates that meet the hole tolerances specified shall be used for hole drilling.

2. Joint bars shall be installed with their full number of bolt assemblies unless otherwise noted.

3. Bars shall be properly seated on the rail and the bolts tightened beginning at the center of the joint and working toward the ends of the bars, alternating between rails.

4. Bolts used shall be of the proper diameter and length for the rail

and joint bars at the joint. The use of extra washers to shim out track bolt nuts is prohibited.

5. The nut is sufficiently tight when the spring washer is fully

compressed and closed flat against the joint bar.

G. Metal rail expansion shims shall be used when laying running rail. Shim

design shall be subject to the approval of the Construction Manager.

Wooden sticks shall not be acceptable. The Contractor shall have a large

enough supply of each shim available to permit rail laying to progress

without delay.

3.11 LAYING CONTINUOUS WELDED RAIL

A. Unload and lay CWR in a place and in a manner that prevents damage to the ties, rails, and structures.

B. Lay opposite CWR strings in a manner which results in a 10 foot minimum stagger of welds unless approved by the Construction Manager.

C. Make every effort to minimize or eliminate field cuts and field welds in CWR. Designate location in finished track by route name, stations of ends of rail string, and right or left rail as determined by facing in the direction of increasing stationing. Place all rail numbers on the same side of the CWR string.


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D. Record the following information at the time of laying the rails on the crossties or DF plinth and again at the time of anchoring CWR. Furnish copies of this documentation to the Contracting Officer.

1. Location by station, track designation, and rail.

2. Date and time.

3. Rail weight and section, mill brand, year rolled, and the heat number of the end rails in each CWR string.

4. Length of CWR string in feet.

5. The following temperatures, at the beginning of the activity and again at the end of the activity:

a) Ambient temperature.

b) Rail temperature.

6. Approximate weather conditions.

7. Adjustment applied (type and rail end movement).

E. Between the time of laying the rail (placement on the ties) and anchoring the rail, the Contractor shall monitor rail temperatures and adjust each Dutchman as required to avoid rail buckling or rail end batter

3.12 RAIL TEMPERATURE

A. Determine rail temperature by means of an AREMA standard rail thermometer as specified in the AREMA Manual.

1. Place rail thermometers on the shaded side of the rail base next to the web and leave in place until no change in its reading is detected, but not less than five minutes.

2. Take rail temperature at the time of adjusting the gap between rail ends.

3.13 RAIL GAP

A. During rail laying below the indicated zero thermal stress temperature, determine the required gap between CWR strings and between CWR and bolted rail by using the equation:

G = (t - T) L K + Q


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Where:

G = Required rail gap (inches).

t = Specified anchoring temperature in °F for type of track construction.

T = Actual rail temperature at time of laying in °F.

L = Length of rail in feet (one-half of the sum of lengths of the CWR string being laid and the preceding CWR string).

K = Coefficient of thermal expansion for rail steel (0.000078 inch per foot per °F).

Q = Rail gap as required by Manufacturers of field weld kit in inches. For bolted standard joints, Q equals 0.125 inch, and for bonded insulated joints, Q equals the end post thickness.

3.14 DUTCHMAN

A. Insert a Dutchman after the rail has been laid, equal in length to G minus 1/2 inch where G is determined by the formula above, to prevent damage to the rail ends during rail laying, ballasting, and other operations requiring passage of on-track equipment over the rail joints.

B. Do not insert a Dutchman if the calculated rail gap G is less than 1-1/2 inches.

C. Remove the Dutchman prior to anchoring or when an increase of temperature results in a calculated closure of the rail gap.

D. Rail end batter in excess of 1/16 inch shall be removed by cutting out at least 15 feet of rail at the joint, replacing the joint with a plug rail, and field welding both ends. End batter repair by welding is not acceptable.

3.15 TEMPORARY FASTENING

A. Temporarily fasten track for use of on-track equipment.

B. Prior to equipment being placed on newly laid rail, secure the rail in a manner that will prevent damage to the CWR, rail fasteners, and other track materials.

C. Move equipment over newly laid rail in such a manner as to prevent damage to trackwork materials.

D. Temporarily fasten newly laid rail on ballasted track at not less than:


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1. Every third tie on tangents and on curves having a radius greater than 1,900 feet.

2. Every other tie on curves having a radius of 1,900 feet or less.

E. Do not field weld or bond between contiguous CWR strings, if the combined string length will exceed 1600 feet, and between CWR strings and special trackwork units before the rail has been brought to final vertical and horizontal alignment, before the rail has been adjusted to the indicated zero thermal stress range, and before the rail has been fully fastened.

3.16 PERMANENT RAIL FASTENING

A. Adjust the CWR string lengths for the specified zero thermal stress temperature:

1. When closing on a fully anchored string, remove 300 feet of existing rail clips, readjust the existing string for temperature and refasten before executing the field weld.

2. Fasten the CWR strings in a manner which ensures that there is no unfastened portion of rail greater than 100 feet in length between fastened portions of the same string.

3. When joining newly constructed track to existing track in operation, adjust the adjacent 300 track feet of the existing track for zero thermal stress temperature in conjunction with the de-stressing of the new track.

4. Obtain approval of the METRO's light rail operating department through the Construction Manager prior to de-stressing existing track in operation. De-stressing work of operating track shall not be scheduled during light rail transit (LRT) operating hours.

B. Vibrate the rail to relieve internal rail stresses and fully fasten the string. Record movement at quarter points and submit to the Construction Manager daily.

1. Use vibrators, approved by the Construction Manager, to relieve internal rail stresses.

2. Do not strike CWR with objects which might damage the rail surface.


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3. Use approved rail heaters as required.

C. Temperature of a rail, when being fastened opposite a previously fastened rail, shall be within 5°F of the previously fastened rail's temperature at the time of its fastening.

D. Once the rail has been adjusted to achieve zero thermal stress at the specified temperature, maintain the correct rail gap until the rail is fully fastened.

3.17 ZERO THERMAL STRESS TEMPERATURE

A. Zero thermal stress temperature for ballasted track shall be 100°F plus 10°F and minus 5°F.

B. The temperature of opposite rails to be within 5°F. of each other.

3.18 ZERO THERMAL STRESS

A. Zero thermal stress at the specified temperature in CWR may be achieved by heating, cooling, or pulling the rails, or a combination thereof. When zero thermal stress at the specified temperature is obtained, begin fastening immediately.

B. Maintain the stress within the rail to achieve the specified zero thermal stress range during installation of joints.

C. When zero thermal stress is obtained, begin fastening immediately.

D. The method and equipment proposed for achieving zero thermal stress

must be submitted to the Construction Manager for approval.

3.19 FIELD WELDING

A. Perform field welds in accordance with the requirements of Section 341475 Rail Welding.

B. Join CWR strings in the field by the field welding process unless otherwise indicated to be joined in the field by bonded standard joints. The location of bonded standard joints is shown on the Approved Drawings.

C. Do not locate a field weld within the following locations:

1. Within 10 feet of any weld in the opposite rail, except at special trackwork and ends of pre-curved rail.


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2. Within 15 feet of a field weld in the same rail.

3. Within 15 feet from the center of a bonded standard joint.

4. Within 5 feet of a shop weld in the same rail.

5. Within 6 inches of a tie.

6. Within 8 feet of each end of a road crossing unless approved by the Construction Manager.

D. Weld Gap:

1. At the time of field welding, providing the proper rail temperature as indicated is present, establish the rail gap recommended by the Manufacturer of the weld kit.

2. Should the rail gap on fastened CWR be larger than the weld manufacturer's recommended gap after the CWR strings have been readjusted for zero thermal stress, saw a length of rail from one end of one of the fastened CWR strings and insert a rail not less than 15 feet long to provide the recommended gaps for field welding.

3. At a location where the rail gap is smaller than the Manufacturer's recommended gap, obtain the recommended gap by sawing a piece from one rail.

E. Repair of field welds will not be permitted. Excessive grinding, dipped or peaked welds, and shear tears shall be cut out and replaced with a plug rail not less than 15 feet long. The replacement of the rail and the two additional field welds shall be at no expense.

3.20 RAIL END-HARDENING

A. End-harden standard rail ends in the field at all bonded joints. Remove joint bars from rail ends during the end-hardening process.

3.21 END-HARDENING TESTS

A. Personnel to perform end-hardening shall prepare one sample rail in accordance with the AREMA Manual.

1. Test the one sample through an independent laboratory approved by the Construction Manager and submit the test results to the Construction Manager.


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2. Acceptance of the end-hardening procedure and personnel will depend on the sample passing the tests specified below.

B. The sample of end-hardened rail shall be tested for Brinell hardness in accordance with ASTM E10 in a grid pattern of 1/4-inch increments for a distance of 6 inches from the end of the rail.

C. Record the Brinell hardness numbers and locations.

D. A Brinell hardness number not less than 341 nor more than 401 shall be attained when measured at a point on the centerline of rail 1/2 inch from the rail end. The decrease in hardness shall occur uniformly over a distance not less than two inches. The hardness pattern shall be uniform across the top surface of the rail head. End hardening shall be performed only by personnel qualified as specified above, and with procedures which produce sample specimens that have passed the above mentioned tests.

3.22 RAIL BEVEL

A. Bevel rail ends at bonded joints in accordance with AREMA Standard Plan Basic Number 1005.

3.23 RAIL GRINDING

A. Upon completion of the track to the specified tolerances, but prior to the

final acceptance, the running rail of all mainline track shall be ground

with a high speed fully equipped, self-propelled, rail-mounted grinder.

B. The grinder shall make two separate passes over mainline track. The

grinding machine shall remove metal from the surface of the rail in a

constant, uniform and consistent manner. The grinding machine must be

capable of metal removal of 0.005 inch per pass across the center two

inches of the top surface of the rail head. The equipment must be capable

of grinding at angles of 45 on the gauge side to 15 on the field side of the

rail regardless of the flangeway or field side obstructions.

C. The grinding machine must be capable of grinding to a specified rail

surface radius and gauge corner relief without leaving ridges between

facets.

D. The grinding machine must have a positive control system for corrugation

removal to ensure that only the peaks of the rail corrugations and other


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track deformities are removed. No grinding should be done in the

corrugation valleys or low spots of the other track deformities.

E. The grinding machine shall be capable of holding grinding patterns

centered over the correct location on the rail regardless of curve elevation

or changes in rail gauge.

F. The rail grinder must be capable of operation on curves of 175 foot radius,

superelevation of up to six inches, grades of up to 7%, and must be of such

size and weight that it can safely pass over structures designed for light

rail vehicle loadings. LRV design loadings are shown on Figures 3.06-1

and 3.06-2.

G. The grinding machine used must be capable of:

1. Grinding through sections of concrete embedded track, concrete

road crossings, and timber grade crossings without damaging the

track system.

2. Grinding on one rail or both rails simultaneously.

3. Travel speeds between 10 and 15 miles per hour.

H. The grinding equipment must be supplied with adequate lighting to allow

for safe and efficient grinding at night.

I. The grinding machine must have adequate shrouding and protection to

retain grinding sparks, slag dropping and broken stones within the

confines of the track structure. The shrouding and protection must be in

good repair and well maintained.

J. The grinding machine used must be capable of collecting the grinding

dust and debris resulting from the grinding operation without spreading

the material into the surrounding air.

K. The trackway shall be cleaned of any rail grinding material after the rail

has been ground. At insulated joints, filings due to grinding shall be

removed throughout an area five feet each side of the centerline of the

joint measured along the rail, to prevent electrical bridging of the

insulation.


34 14 40 - 27

1/23/2014

L. The grinding contractor shall arrange for the off-loading and reloading of

the grinding machine onto the transport vehicle. The contractor must be

aware of the 750 volt DC OCS line which runs above each track. The

minimum allowable clearance of the OCS line at street intersections is 18

feet.

M. The type of equipment and method of operation shall be submitted to the

Construction Manager and accepted by the Construction Manager prior to

initiation of rail grinding.

3.24 FINAL ALIGNMENT AND TRACK INSPECTION

A. Survey the track to determine if the horizontal and vertical alignment, gauge, crosslevel, and superelevation are within the tolerances specified.

B. Correct track deviations which exceed tolerances.

C. Track Geometry Measured Results.

1. All measurements shall be displayed in a format to be approved by the Construction Manager.

3.25 TRACK-TO-EARTH RESISTANCE TESTING

A. Track-to-earth resistance testing shall be conducted in accordance with ASTM G165 and Contractor’s Quality Plan.

1. Testing shall be conducted as track construction progresses to ensure proper rail isolation is being achieved during construction. Test sections shall not exceed 4,000 track feet in length.

2. The Contractor shall notify the Construction Manager when corrosion testing can be conducted in order to avoid construction conflicts. A minimum of three days notice is required.

3. All track shall be retested for final acceptance after all signaling and traction power components and wiring have been installed.

B. The Contractor shall undertake corrective measures at all locations that do not meet the track-to-earth electrical resistance requirements as specified. All repaired locations shall be re-tested until the track-to-earth resistance characteristics meet the required acceptance criteria. All corrective measures and re-testing shall be completed at the expense of the Contractor.


34 14 40 - 28

1/23/2014

C. Acceptance criteria: Track-to-earth resistance shall not be less than:

1. Ballasted track: 625 ohms/1000 track feet (two rails).

3.26 RAIL INSULATED JOINT TESTING

All rail insulated joints shall be tested for electrical insulating characteristics in

accordance with AREMA C&S Manual, Part 8.6.35, Recommended Instructions

for Insulated Rail Joints and Other Track Insulations.

3.27 TRACK CONSTRUCTION TOLERANCES

TABLE 34 14 40-1

Type of Track Gauge

Variation

Cross Level and

Superelevation Variation

Vertical Track Alignment

Horizontal Track Alignment

Total Deviation

Middle Ordinate

In 62' Chord

Total Deviation

Middle Ordinate

In 62' Chord

Yard Ballasted Track

+1/8” - 1/8"

+ 3/16" + 1/2" + 1/4" + 1/2" + 1/4"

Notes:

(1) Total deviation is measured between the theoretical and actual alignment centerline at any point in the track.

(2) Total horizontal and vertical deviation in road crossings + 1/4 inch.


Section 34 14 50 – Grade Crossings

34 14 50 - 1 01/23/2014

SECTION 34 14 50

GRADE CROSSINGS PART 1 - GENERAL 1.01 DESCRIPTION

The Section specifies the grading and preparing of the crossing support surface and furnishing and installing the concrete grade crossings and drain pipe as shown on the Contract Drawings.

1.02 DEFINITIONS

A. The term “Construction Manager” as used in this Section shall mean the Houston Rail Transit (HRT) Project Joint Venture.


of grade crossings as specified in this Section. C. The term “Manufacturer” shall mean the entity that fabricates the grade

crossings.

1.03 REFERENCES

A. American Railway Engineering and Maintenance-Of-Way Association (AREMA)

1. Manual for Railway Engineering (Manual)

B. ASTM International (formerly American Society for Testing and

Materials) (ASTM)

D257 Standard Test Methods for DC Resistance or Conductance of Insulating Materials

D412 Standard Test Methods for Vulcanized Rubber and

Thermoplastic Elastomers—Tension D2240 Standard Test Method for Rubber Property – Durometer

Hardness


34 14 50 - 2 01/23/2014

1.04 RELATED WORK


B. Section 34 14 10 Ballast

C. Section 34 14 15 Other Track Material

D. Section 34 14 37 Special Trackwork Ties

E. Section 34 14 40 General Track Construction

F. Section 34 14 20 Ballasted Track Construction

1.05 SUBMITTALS

The following shall be submitted to the Construction Manager for review and approval in accordance with the Supplier’s Quality Plan. A. Manufacturer's description for Geotextile Filter Fabric material.

B. Manufacturer's description for PVC drain pipe, both solid and perforated.

C. Traffic Control Plan.

D. Manufacturer’s description and installation procedures for Concrete Grade Crossing, including Abrasion Pads and Flangeway Fillers.

PART 2 - PRODUCTS 2.01 CONCRETE GRADE CROSSINGS

A. New concrete grade crossing panels, assemblies, flangeway filler, and end deflectors shall be supplied. Grade crossings may be manufactured by one of the following suppliers: 1. Concrete Grade Crossing Panel, by Omega Industries, Inc. 2. Startrack Railroad Crossings, by Oldcastle Precast 3. Premier Modular Railroad Crossing, by Hanson Crossings supplied by other Manufacturers may also be approved. See Plans for locations of particular types of grade crossings.


34 14 50 - 3 01/23/2014

B. Dimensions of the crossing materials shall be appropriate for 115 RE rail. The crossings shall be designed to provide a flangeway along each rail with a minimum width of 2-1/4 inches on tangent track, and have a minimum depth of two inches. Crossings for curved track shall accommodate a gauge of 4 feet 8-3/4 inches, as well as a restraining rail with a flangeway of 2 inches.

C. Crossing panels shall have no rail-to-ground connections that would

cause grounding of the rail or shunting of the track signal circuit. The crossing system shall not create any electromagnetic interference with either vehicle systems or the wayside equipment. Crossing module shall be designed to retard stray current.

2.02 ABRASION PADS

Pads shall be 1/4 inch in thickness, made from commercial grade neoprene. The pad material shall meet the following requirements:

A. Material shall be capable of withstanding temperatures of –20°F to +160°F

and dynamic forces generated by trains without a detrimental effect on their performance.

B. Hardness, measured in accordance with ASTM D2240: Between 50 and 80

durometer value, Shore A. C. Tensile Strength, measured by ASTM D412: 1,500 psi, minimum. D. Volume Resistivity, measured in accordance with ASTM D257 shall be a

minimum of 1 x 1012 ohm-cm. E. Material shall be resistant to ozone.

2.03 RUBBER FLANGEWAY FILLER

The rubber flangeway panels, if applicable, shall be installed to fit snugly to the web and head of the rail. Any damage to the flangeway panels resulting from handling and installation by the Contractor shall be repaired, or the materials replaced.

2.04 OTHER TRACK MATERIAL (OTM)

Except where otherwise specified by the grade crossing Manufacturer, OTM used in connection with installation of grade crossings shall be as specified in Section 34 14 15 Other Track Material.


34 14 50 - 4 01/23/2014

PART 3 - EXECUTION 3.01 SEQUENCE OF WORK PLAN

The approved Sequence of Work Plan submitted under Section 34 14 20 Ballasted Track Construction, shall be fully implemented prior to beginning any Work on the grade crossing.

3.02 LAYOUT OF THE CROSSINGS

The Contractor is responsible to provide all survey and measurements required to layout the grade crossing and associated Work in accordance with these Specifications and the crossing Manufacturer’s requirements.

3.03 TRACKBED PREPARATION

A. The trackbed shall be constructed as shown on the Contract Drawings. B. Surface ditches and other drainage facilities shall be installed as indicated

on the Contract Drawings to provide positive drainage away from the grade crossing. All existing drainage ditches and channels adjacent to the grade crossing shall be cleaned and sloped to provide drainage away from the grade crossing.

C. Installation of the Grade Crossing

1. The Contractor shall be familiar with the type of installation to be performed and shall follow the Manufacturer’s recommended installation procedures.

2. No bolted rail joints shall be permitted within the limits of the

crossing. Any welded rail joints located within the limits of the crossing shall be ground smooth to parent rail section to eliminate interference with the rubber flangeway panels.


Section 34 14 75 – Rail Welding

34 14 75 - 1 01/23/2014

SECTION 34 14 75

RAIL WELDING PART 1 - DESCRIPTION 1.01 INTRODUCTION

A. The Work covered in this Section includes the welding of rails into continuous welded rail (CWR) strings, joining of CWR strings, testing, inspection, transportation of rail and CWR, and qualification of welding and welders.

Rail welds shall be of two types:

1. Pressure Welds: Rail for track outside the limits of special

trackwork shall be welded into continuous welded rail (CWR) strings using the electric flash-butt pressure welding process.

2. Thermite Welds: Thermite welding process shall be used for

joining continuous welded rail (CWR) strings together and to Special Trackwork. Shop precurved rail shall be welded in place in the track by thermite welding process. With the Construction Manager’s approval thermite welds may be used to join individual pieces of rail into strings.

B. Pressure welding may be performed using either a fixed or a mobile

electric flash-butt welding plant. C. Electric flash-butt welding may be substituted for thermite welding,

where practical. D. The Contractor shall make its own assessment as to the number of rails to

be welded, and the number of welds that can be made by each welding process, based on the information contained in this specification and the Contract Drawings. Every effort should be made to maximize the length of CWR strings.

E. Welded rail joints shall not be within five feet of the opposite rail joint in

track unless approved by the Construction Manager.


34 14 75 - 2 01/23/2014

1.02 DEFINITIONS A. The term “Contractor” and “Construction Manager” as used in this

Section shall mean the Houston Rapid Transit (HRT) Project Joint Venture.

B. The term “Manufacturer” shall mean the supplier of the welding machine for pressure welding and/or welding kits for thermite welding.

1.03 RELATED WORK


B. Section 34 14 20 Ballasted Track Construction 1.04 QUALITY CONTROL

A. Comply with the Contractor’s Quality Plan. B. Rail Straightness: The Contractor shall check rail for end straightness

before welding. Examine both ends and tops of all rails using a three foot metal straightedge. Deviations from end straightness shall be measured with a metal taper gauge. Rails which exceed the tolerances specified in the Section 34 14 00 Rail, shall not be welded.

C. Plant Rail Welding Procedure Qualification - Prior to beginning of

production welding, two test welds will be made with each welding machine, using the same welding procedure that will be used in production welding. 1. Magnetic Particle Testing: Each weld will be magnetic particle

tested by the coil method (longitudinal magnetization) using the dry powder method in accordance with ASTM E 709.

2. Ultrasonic Weld Testing: Each weld will be ultrasonic tested in

accordance with the requirements contained in Article 1.04.F. 3. Acceptance will be based on the weld quality requirements as

described in Article 1.04.F.3. 4. Retesting: If any of the test welds from a single machine are

unacceptable, necessary alterations to the procedure must be made by Contractor, and two additional test welds produced and tested.


34 14 75 - 3 01/23/2014

5. Production welding may not begin on a machine until two consecutive acceptable test welds have been produced. Two consecutive acceptable test welds will also be required each time a welding machine is restored after a period of malfunctioning, after a welding crew is replaced in total, or the welding crew supervisor is replaced. Acceptance must be in accordance with Article 1.04.F.3.

D. Laboratory Testing of Qualification Sample Welds - The sample welds

shall be tested as follows:

1. Ultrasonic Test and Magnetic Particle Test: The test samples for pressure and thermite welds shall undergo ultrasonic and magnetic particle testings. Certified test reports shall be submitted to the Construction Manager for review and approval. Acceptance shall be per Article 1.04.F.3 and 1.04.F.2, respectively.

2. Visually examine all the test welds for cracks. Welds with surface

cracks shall be rejected.

3. Hardness Test for Sample Rail Welds: One of each type sample weld, which has passed the ultrasonic test, shall be longitudinally cross-sectioned for a distance of six inches each side of the weld, macro-etcher, and Rockwell-hardness tested with a 150 kgf diamond sphero-conical penetrator. The sample rail weld shall be tested for hardness vertically and horizontally on the longitudinal section in 1/2 inch increments for three inches each side of the centerline of the weld.

Acceptance shall be the decrease in hardness to be uniform and coincide with parent rail within a maximum of two inches from center of weld. The finished weld throughout shall have Rockwell hardness numbers between 24C and 39.5C.

4. Should any sample rail welds fail to satisfy the specified requirements, either the welding process or the welding crew, or both, will not be permitted to perform the welding. Should any supervisor of the welding crew be replaced during the work, the welding crew shall be re-qualified under the new supervisor.

E. Qualification of Testing Technician:

1. Testing shall be performed by a technician certified to have met

ASNT procedure SNT-TC-1A, Level II or III qualifications.


34 14 75 - 4 01/23/2014

Ultrasonic inspection of welds shall be performed in accordance

with ASTM E164. Prior to testing of welds, the technician certified in accordance with ASNT procedure SNT-TC-1A, Level II or III shall be tested to ensure the technician’s ability to detect defects in rail. The test shall be conducted with the calibration rail as specified below serving as the test specimen. The technician shall locate all the holes in the calibration rail by ultrasonic testing. This test will be observed by the Construction Manager or an assignee, certified in accordance with ASNT procedure SNT-TC-1A, Level II or III and experienced in ultrasonic examination of rail welds. Failure to pass this test will result in the disqualification of the technician.

F. Field Testing of Production Welds: All production pressure and/or

thermite welds shall be visually, magnetic particle and ultrasonically tested in the field for defects as follows:

1. Visual testing will be in accordance with AREMA standards. Any

rail weld showing surface cracks shall be rejected. 2. Magnetic Particle Testing shall be performed in accordance with

ASTM E709. Testing shall be conducted with the rail temperature below 800°F. Acceptance Criteria: Particles shall form a regular longitudinal pattern indicating homogeneity of the weld and freedom and defects, surface irregularities and internal discontinuities

3. Ultrasonic Testing shall be performed in accordance with ASTM

E164 and the specified procedure and equipment in Articles 1.04.G and 1.04.H respectively.

Acceptable Criteria: All welds shall be free from defect or flaw

giving a reflected display of greater than 20 percent of distance-amplitude correction curve at calibration level, or will be as listed in Table 1.


34 14 75 - 5 01/23/2014

TABLE 1

MINIMUM ACCEPTANCE LEVELS (DECIBELS)

WELD THICKNESS (in.) AND TRANSDUCER ANGLE

REFLECTOR SEVERITY

5/16 – ¾ ¾ - 1-1/2 1-1/2 to 2-1/2 2-1/2 to 4 4 to 6

70 70 70 45 70 45 70 45

Large Reflectors +8 +3 -1 +4 -4 +1 -7 -2

Small Reflectors +9 +4 +1 +6 -2 +3 -5 0

Minor Reflectors +10 +5 +3 +8 0 +5 -3 +2

G. Incorporate the following in the test procedure:

1. Scanning level shall be +20 db minimum. 2. Scan the rail in a zig-zag pattern twisting probe, on one side of the

weld only at a rate not exceeding six inches per second, so that the full weld is scanned. Each pass will overlap a minimum ten percent and the scanning is carried out longitudinally to the rail.

3. Calibrate the equipment at the start and end of each day's work,

and at least every four hours during examination, and hourly checks with DSC blocks. If any point on the distance-amplitude curve has been changed by more than 20 percent, all results since last calibration check shall be void and all welds re-examined. If the curve has moved on the sweep line by more than five percent, all non-complying welds since last calibration check shall be re-examined.

4. When a reflection of greater amplitude than the acceptance criteria

is found, scan around the full perimeter of the weld from both sides, to ensure full weld coverage and determination of size, type, and location of discontinuity.

5. Make permanent trace recording of discontinuity indications. 6. Paint the rail web at non-conforming welds on both sides across the

weld.

H. The following equipment and test report form shall be used for ultrasonic testing:

1. Ultrasonic, pulsed echo, instrument normally used for inspection of

rails with calibrated decibel gain control of minimum 2db


34 14 75 - 6 01/23/2014

increments, operating in the range 1-5 MHz, with CRT screen and scale. Equipment shall be capable of detecting a 3/64 inch discontinuity 6-1/2 inches below top of rail.

2. Calibrated paper tape recording attachments to record accurately

the CRT screen indications when a non-complying weld is located. 3. 2.25 MHz angle beam transducers 1/2 inch x 1 inch at 70 degrees

and 45 degrees. 4. Suitable high viscosity couplets of good wetting characteristics. 5. Standard IIW calibration blocks of rail steel for primary reference

response and to construct distance-amplitude correction curve, and DSC Blocks of rail steel for calibration checks.

6. A "calibration rail", a piece of 115RE running rail, 18 inches long

with a 3/64 inch diameter round bottom hole 6-1/2 inches below top of rail and in which other 1/8 inch diameter flat bottom hole patterns have been drilled as shown in Figure 34 14 75 - 1.

7. Use an ultrasonic test report form that records 20 inspected welds

per sheet. The form shall include the location of the weld in track, the results of the ultrasonic inspection including size of defects found in the head, web or base of rail, shape identity and location of all reflections, trace record, the results of the visual inspection, name of inspector, and other information as needed. Welds found defective by ultrasonic, magnetic particle, or visual inspection shall be replaced.


A. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition in effect on the bid due date shall apply to the work included in this Section.

B. Rail welding shall be in accordance with the AREMA Manual for Railway

Engineering, Vol. I Track, Chapter 4 Rail, Part 2 Specifications except as modified herein: 1. Section 2.2 Specifications for Fabrication of Continuous Welded

Rail


34 14 75 - 7 01/23/2014

2. Section 2.3 Specifications for the Quality Assurance of Electric Flash Butt Welding of Rail

3. Section 2.5 Specifications for the Quality Assurance of Thermite

Welding of Rail.

C. ASTM International (formerly known as American Society for Testing and Materials) (ASTM)

1. E 164 Standard Practice for Contact Ultrasonic Testing of

Weldments.

2. E 709 Standard Guide for Magnetic Particle Testing.

D. American Welding Society

D1.1 Structural Welding Code E. American Society of Non-Destructive Testing

SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in Non-Destructive Testing.

1.06 SUBMITTALS

A. Submittals shall be made in accordance with the Construction Quality Management Plan.

B. Submit to the Construction Manager, for review and approval, at least 30

days prior to start of Work. C General:

1. Rail handling methods and procedures including equipment to be

used in handling rail, with data on equipment performance characteristics.

2. Name and qualification of testing laboratory and procedure to be

utilized in testing. 3. Testing Laboratory: Employ an independent testing laboratory,

which shall perform all indicated weld testing. 4. Certification of ultrasonic and magnetic particle testing personnel.


34 14 75 - 8 01/23/2014

5. Ultrasonic inspection procedure, equipment description and

calibration methods. 6. Procedure for dry powder magnetic particle inspection. 7. Magnetic particle and ultrasonic inspection records for each weld. 8. Inspection records of each weld for straightness as per AREMA

requirements. 9. Daily calibration of ultrasonic inspection equipment. 10. Quality Control procedures to be followed. 11. The contractual agreements with any subcontractor employed by

the Contractor in doing the Work.

D. Pressure (Electric Flash-Butt) Welds:

1. A written description of the welding procedure, including facilities, personnel and list of similar completed projects.

2. A list of all equipment and calibration methods, method of rail end

alignment, method of rail straightening, and a schedule of lengths of rail strings to be fabricated.

3. Welding Machines Performance: Submit pressure welding

machine performance standards as provided by the manufacturer. During welding production, a recorder shall be attached to each welding machine to record platen movement and current impulses on the form "Record of Field Welds", a copy of which is attached to the end of this Specification. A record of machine performance for each weld shall be submitted to the Construction Manager, for review and approval. If the record indicates performance, which is not in conformance with the approved standards, the weld will be considered defective and shall be rejected.

4. Working Drawings: Submit Working Drawings for the pressure

welding machine and Working Drawings of the proposed method and equipment for handling and laying CWR. This submittal shall include reference data relating to where the proposed equipment and laying method were previously successfully used.


34 14 75 - 9 01/23/2014

5. Details of the equipment and procedure proposed for straightening welds if required. The submittal shall include reference data relating to where the proposed straightening equipment and method were previously successfully used.

6. The Manufacturer’s recommended procedure for welding high

strength rail if different from requirements for standard rail. 7. Pressure Weld Samples: Prior to beginning of production welding,

six test welds shall be made using the welding machine and the procedures proposed in the Manufacturer's instructions. Two of the welds shall be standard rail to standard rail; two welds shall be high strength rail to high strength rail; two welds shall be standard rail to high strength rail. The welds shall be tested by the testing service. Certified test reports shall be submitted to the Construction Manager, for review and approval.

8. Proposed location for electric flash-butt welding plant including

methods of transporting materials and equipment to the site, types and locations of environmental controls and duration of welding operations.

E. Thermite Welds:

Prior to thermite welding, submit a detailed specification of the proposed method and procedure to the Construction Manager, for review and approval. The method and procedure specified shall comply with recommendation of the weld kit Manufacturer and shall include the name of the weld kit Manufacturer.

PART 2 - PRODUCTS 2.01 MATERIAL

A. 115 RE Rail: Comply with Section 34 14 00 Rail

B. Thermite Welding: Thermite type rail welds shall be formed utilizing one of the following brands of rail welding kits, or an approved equal.

1. Railwel – a subsidiary of Railtech International

C. The rail welding kits used when welding head hardened rail shall

conform to the Manufacturer's recommended standard for such work.


34 14 75 - 1001/23/2014

PART 3 - EXECUTION 3.01 PREPARATORY WORK FOR ALL WELDS

A. Rail which must be cut for any reasons shall be cut square and clean by means of rail saws or abrasive cutting wheels in accordance with AREMA "Specifications for Steel Rails". Torch cutting of rails is prohibited. Rail ends not within 1/32 inch of square shall be cut square.

B. Rails shall conform to the AREMA "Specifications for Steel Rails", for straightness. Rail ends shall show no steel defects, dents or porosity before welding.

C. Rails shall be straightened cold in a hydraulic press or roller machine to

remove twists, waves, and kinks until they meet the surface and line requirements specified herein before. The method of permanent straightening shall be submitted to the Construction Manager for review and approval.

D. Rail that cannot be straightened permanently shall be cut back a sufficient

distance to achieve the required alignment. Burrs shall be removed. The method of end finishing rails shall be such that the rail end shall not have metallurgical or mechanical damage.

3.02 FABRICATION OF CONTINUOUS WELDED RAIL (CWR) STRINGS

A. Welded rail strings shall be of the longest lengths practical to fabricate, handle and store. String length shall be as required by the track alignment, bonded insulated joint locations, and worksite access consistent with the Contractor’s work plan.

B. A schedule of the placement of all rails by its location in track shall be developed. This rail schedule shall consist of a schedule of lengths and designations of welded rail strings to be fabricated and their proposed location in track.

C. The schedule shall indicate which strings or which portions of strings will

be high strength rail.

D. The schedule shall indicate the locations of the proposed field cuts, if any. The rail schedule shall minimize thermite welds between standard rails and high strength rails.


34 14 75 - 1101/23/2014

E. Designation of the location of rail strings:

1. Shall clearly identify location in track by line, survey stationing, track, and rail.

2. Shall be marked on the web of both end rails of each string with

paint suitable for application to steel in exterior service. 3. The marking shall provide a unique identification for each rail

string coordinated with the welding schedule indicating the location of each rail string by rail and track.

3.03 PRESSURE WELDING

A. Pressure welding shall be in accordance with the AREMA “Specification for Fabrication of Continuous Welded Rail" except as modified herein.

B. Mismatched or jagged rail ends shall be either sawed or cut with an

abrasive rail cutter. Mating rail ends by flashing shall not be accepted. C. Rails shall have the scale removed down to bright metal in areas where

the welding current-carrying electrodes contact the rail. Grind down raised rail brands in electrode areas. The weld and adjacent rail for a distance clearing the electrodes shall be rejected if in the areas of electrode contact there is not more than 95 percent of the mill scale removed. Electrode contact areas shall be examined for evidence of electrode burn. Where metal is displaced or where the oxidized areas exhibit checks or small cracks the weld shall be rejected and the rail cut back clear of the electrode burn.

D. Welds shall be forged to a point of refusal to further plastic deformation

and shall have a minimum upset of 1/2 inch, with 5/8 inch as standard. E. If flashing on electric pressure (flash butt) welds is interrupted, because of

malfunction or external reason, with less than 1/2 inch of flashing distance remaining before upsetting, rails shall be re-clamped in the machine and flashing initiated again.

F. Whenever possible, grinding shall be accomplished immediately

following welding at an elevated temperature. When grinding must be done at ambient temperature, care shall be taken to avoid grinding burns and metallurgical damage.

G. Alignment of rail in the welding machine shall be at the head of the rail.


34 14 75 - 1201/23/2014

1. Vertical alignment shall provide for a flat running surface. Any

difference of height of the rail shall be in the base. 2. Horizontal alignment shall be accomplished in such a manner that

any difference in the width of heads of rails shall be divided equally on both sides of the head. Where the difference, when divided, exceeds 0.040 inches, 0.020 inches of the difference shall be placed on the gauge side and the remaining differences in the width of heads shall be on the field side.

3. In any case horizontal offsets shall not exceed 0.040 inch at the head

and /or 0.125 inch at the base.

H. Surface and Gauge Misalignment Tolerances: Shall meet the alignment tolerances given in the AREMA Manual, Chapter 4, Part 2, "Tolerances for Inspection of Welded Rail New and Mainline Relay Rail".

I. If, at any time, seven or more of a series of 12 consecutive welds made on

one machine exceed 75 percent of the stated surface misalignment tolerances that machine shall be shut down and adjusted before work continues.

J. Re-welds shall be cut out beyond the heat affected zone of the previous

weld. K. Weld Finishing:

1. A finishing deviation of the parent section of the rail head surface

shall not exceed plus 0.010 inch of the lowest rail. 2. The sides of the rail head weld shall be finished to plus 0.010 inch

or minus 0.000 inch of the parent section. The top and bottom of the rail base shall be finished to within 0.010 inch of the lowest rail.

3. The web zone including the underside of the head, the web, and

both fillets on each side, shall be finished to within plus 0.090 inch to plus 0.010 inch of the parent section. Finishing grinding shall eliminate all cracks. Undercutting the parent section shall be cause for rejection of the weld.

4. Notches created by minor offset conditions, twisted or misshaped

rails shall be eliminated by minimum grinding to blend the variations.


34 14 75 - 1301/23/2014

5. Fins on the weld due to grinding or shear drag shall be removed

prior to final inspection.

L. One handling hole may be made in each end of a CWR string. Rail ends containing such holes shall be cut off by sawing during track construction as indicated, prior to thermite welding.

3.04 PRODUCTION, INSPECTION, AND TESTING OF PRESSURE WELDS

A. A chart recorder shall be used to monitor all significant welding parameters. The recorder shall identify each weld in each string. In addition, the rail schedule designation for each string shall be included on the recording with a notation to indicate the beginning and ending of each CWR string. Each recorder employed shall be calibrated daily. Recordings shall become the property of Houston Metro at the time the welded rail is released for installation, and shall be submitted to the Construction Manager.

B. Inspect all pressure welds by the dry powder magnetic particle method in

accordance with ASTM E 709. Subsequently, inspect all pressure welds ultrasonically in accordance with Article 1.04.F of this section.

C. Inspect all pressure welds in accordance with the AREMA Specifications.

D. Defective pressure welds shall be repaired or replaced immediately during production. Other defective weld findings shall be repaired or replaced as specified in Article 3.07, Repair of Defective Welds.

E. Hardness - The hardness of the weld measured on the head of the rail in the center of the weld shall be equal to the Brinell hardness of the parent metal with a tolerance of plus or minus 20 Brinell hardness numbers. One weld out of each ten will be selected at random by the Construction Manager for Brinell Hardness testing by the welding Manufacturer’s approved Testing Technician.

F. Weld testing shall be carried out by an independent testing laboratory at the expense of the welding manufacturer. The testing service and their testing program and procedures are subject to approval as specified in Article 1.04 of this Section.

G. The testing service shall certify whether or not each weld meets the quality acceptance criteria detailed and the welding manufacturer shall submit reports directly to the Construction Manager, for review and


34 14 75 - 1401/23/2014

approval. At the time of testing the testing service shall mark their findings as to acceptability or rejection on the weld itself.

H. Identifying Pressure Welds and Rail Strings: At the completion of

welding each string of CWR, a record shall be submitted to the Construction Manager, for review and approval, documenting production of the string. Included shall be the heat numbers of the first and last pieces of rail in the string, the number of welds in the string, the heat numbers of rail on each side of welds which have been cut out and re-welded, a record of machine performance for each weld, and reports for all magnaflux and ultrasonic testing. Reports shall be bound in pad or notebook form for ease of handling and retention as permanent record.

3.05 THERMITE WELDING

A. CWR rail sections in track shall be joined in the field by thermite welding. Electric flash butt welds may be substituted for thermite welds, when practical

B. Thermite welds shall not be located within the following location: 1. Within 15 feet of a field weld in the same rail. 2. Within 15 feet from the center of any bolted joint unless approved

by the Construction Manager. 3. Within eight feet from the center of any bonded (glued) joint unless

approved by the Construction Manager. 4. Within five feet of an electric flash-butt weld.

C. Bolt holes and handling holes shall not be permitted to remain in the rail

to be welded. Rail sections containing such holes shall be sawn off and the ends joined by thermite welding during track construction.

D. Preparation of Rail Ends: Rail ends shall be either saw-cut or ground at right angles to the rail to provide a smooth and clean surface. The surface of the rails for a length of approximately six inches from the end of the rails shall be cleaned by grinding to remove all grease, dirt, loose oxide, oxidized metal, scale, and moisture. All burrs and lipped metal, which would interfere with the fit of the mold, shall be removed.

E. Weld Gap: At the time of thermite welding, the rails shall have the rail gap recommended by the manufacturer of the weld kit and shall be


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aligned to produce a weld which, with respect to alignment, shall comply with the AREMA Specifications. Would the rail gap be larger than the manufacturer's recommended gap after the rails have been adjusted for zero thermal stress, then sufficient rail shall be removed from one or both rails to permit insertion of a rail not less than 15 feet long which shall provide the recommended gaps at each end for field welding. At a location where the rail gap is smaller than the Manufacturer's recommended gap, the recommended gap shall be obtained by sawing a piece from one rail.

F. Thermite Weld Preheating - The rail ends shall be pre-heated prior to

welding to a sufficient temperature and for sufficient time as indicated in the approved welding procedure to ensure full fusion of the weld metal to the rail ends without cracking of the rail or weld.

G. Thermite Weld Postheating - The molds shall be left in place after tapping for sufficient time to permit complete solidification of the molten metal and proper cooling to prevent cracking and provide a complete weld with proper hardness and ductility.

H. Weld Finish: Rail shears shall be used to trim upset weld metal from the rail after removal from the mold. Trimming and grinding of the weld shall result in the weld being within the following tolerances:

1. The top, field and gauge side of the rail head shall be finished to

within plus 0.010 inch and minus 0.000 inch of the parent section. The top and bottom of the rail base shall be finished to within plus 0.010 inch and minus 0.000 inch of the lowest rail.

2. The remainder of the rail weld shall be finished to within plus 0.090

inch to plus 0.20 inch of the parent section. Finishing shall eliminate cracks visible to the unaided eye.

3. Notches created by offset conditions shall be eliminated by

grinding to blend variations. Protrusions and gouges in the welded area shall be removed, and the weld area shall be blended into the rail contour by grinding in a manner, which will eliminate fatigue crack origins. Defects visible to the unaided eye shall be removed by grinding, except that if removal by grinding cannot be accomplished without damaging the rail, the weld shall be removed. Grinding pressure, which would overheat the rail surface, shall not be permitted.


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4. Heavy grinding of the weld shall be completed while the weld is still hot from welding.

I. Inspect all thermite welds ultrasonically in accordance with Article

1.04.F.3.

J. Defective thermite welds, as specified in Article 3.06, Defective Thermite Welds, shall be repaired as specified in Article 3.07, Repair of Defective Welds.

3.06 DEFECTIVE THERMITE WELDS

A. Defective thermite welds shall be determined as follows: 1. Weld quality, finishing alignment not in accordance with the above

mentioned standards. 2. Welds showing a response at any level that is identified as a crack

or lack of fusion shall not be acceptable. 3. Welds showing a response that is less than 50 percent of the

primary reference level shall be acceptable. 4. Welds showing a response greater than 50 percent but that do not

exceed the primary reference level are acceptable, provided that all of the following apply: a.) The defects are evaluated as slag or porosity. b.) The largest defect does not exceed 0.180 inch in its largest

dimension. c.) The total area of the defects does not exceed 0.009 square

inch. d.) The sum of the greatest dimension of defects in a line does

not exceed 3/8 inch.

5. Welds showing a response that exceeds the primary reference level shall not be acceptable.


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3.07 REPAIR OF DEFECTIVE WELDS

A. Pressure welds in rail rejected at any time through final track inspection or testing by Rail Defect Car shall be sawn and re-welded if possible, or replaced with at least a 15 foot rail welded in its place by two thermite welds in accordance with this specification.

B. Thermite welds in rail rejected during inspection or testing shall be sawn and rewelded if possible, or replaced with at least a 15 foot rail welded in place by two thermite welds in accordance with this specification.

C. Special Thermite Welds

Should a defective thermite weld replacement using an inserted piece of rail and two welds not be practical because of limitations due to precurved rails or adjacent special trackwork parts, the Contractor shall saw the defective weld and replace it with a special wide thermite weld in accordance with the Manufacturer’s recommendation. Prior to use in track, this special weld shall be tested and accepted as in Article 1.04 above.



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RECORD OF FIELD WELDS DATE: TIME: TRACK DESIGNATION: (Length of rail anchored on both sides of weld when part of the thermal distressing procedure.) LOCATION: STA. TO STA. (LT.RT) RAIL SECTION: 115RE OTHER: MILL BRAND: YEAR ROLLED: (AHEAD) (BACK) HEAT NUMBER: (AHEAD) (BACK) TYPE OF RAIL:HEAT-TREATED CONTROL-COOLED (CIRCLE) RAIL CUT REQUIRED: (YES) (NO) MANUFACTURER OF FIELD WELD KIT: AIR TEMPERATURE: RAIL TEMPERATURE: WEATHER CONDITION: RAIL GAP (NEAREST 1/16 INCH): TRACK ALIGNMENT AND CONSTRUCTION:

(Curve, Tangent, Grade, Etc.) NAME OF ENGINEER OR REPRESENTATIVE PRESENT: NAME OF CONTRACTOR'S FOREMAN PRESENT: NAME OF MANUFACTURER'S REPRESENTATIVE PRESENT:

(Initialed by those present)


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FIGURE 34 14 75 - 1 CALIBRATION RAIL NOTE: Rail section shown is for illustration purposes only. Contractor shall use the rail section specified.

metropolitan transit authority of harris county, texas · hrt or metro, provide the construction...

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