part 1 - general - san franciscomission.sfgov.org/oca_bid_attachments/fa51206.pdf · a. aisc steel...

DIVISION 5: METALS 05650: BASIC TRACKWORK MATERIALS AND METHODS

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PART 1 - GENERAL 1.01 DESCRIPTION

A. Work shall include furnishing, handling, delivering trackwork and trackwork accessories.

1.02 SECTION INCLUDES

Section 05650: Special Trackwork Section 05690: Rail Welding Section 06130: Composite Ties

1.03 REFERENCES

A. AISC Steel Construction Manual

B. American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, herein referred to as the AREMA Manual.

C. AREMA Portfolio of Trackwork Plans, herein referred to as the AREMA Portfolio.

D. ASTM A 36 Standard Specification for Structural Steel.

E. ASTM A 194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service.

F. ASTM A 354 Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners.

G. ASTM A 563 Standard Specification for Carbon and

Alloy Steel Nuts.

H. ASTM A 572 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel.

I. ASTM E 18 Test Method for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials.

J. ASTM E 140 Standard Hardness Conversion Tables for Metals.


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K. ASTM F 436 Standard Specification for Hardened Steel Washers.

L. SAE J429 Steel Fasteners - Mechanical and Material Requirements for Externally Threaded Fasteners - SAE J429.

M. SSPC-SP 10 Steel Structures Painting Council, Surface Preparation Specification No. 10, "Near- White Blast Cleaning".

1.04 SUBMITTALS

A. Product data, manufacturer's instructions and samples for all materials furnished and specified in Part 2 Product of this specification.

B. Shop drawings for all materials and components not fully detailed on the Plans.

C. Test reports for all tests mentioned as being required in applicable AREMA

Manual, AREMA Portfolio and as specified in the Contract Plans and Specifications.

D. Rail end hardening procedure, and list of qualified personnel who will perform

end-hardening of the rail.

E. Two samples of end hardened rail for each rail section as specified in this Contract Specification.

F. Certified test reports of end-hardening tests specified in this Section.

1.05 QUALITY CONTROL

A. End-Hardening:

End hardening is required at bolted joints for running rails which do not have a minimum of 340 Brinell hardness. High strength tee rails certified with a minimum of 340 Brinell hardness do not require the end hardening at bolted joints.

1. Qualification Tests: Two samples each of 115#RE rail shall be end-

hardened in accordance with the submitted procedure and tested by the Supplier's independent testing laboratory. Acceptance of the end-hardening procedure and personnel will be subject to the result of specified tests and samples.


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a. End-hardened rail shall be tested for Rockwell Hardness in accordance with ASTM E 18 in 1/4 inch increments longitudinally, transversely, and vertically for a distance of 6 inches starting from the hardened end of the rail. Rail ends shall be end-hardened between 340 and 400 HB, as converted from Rockwell Hardness using ASTM E 140.

b. After the hardness test has been performed, one sample shall be

sectioned longitudinally for 1 foot along the centerline of rail, and the other sample shall be sectioned transversely ½ inch from the end of the rail. Both cross sections shall be etched to facilitate the observation of the hardness pattern.

2. Production Tests: Supplier shall have an independent testing laboratory

inspect and test rail ends end-hardened by the Supplier. a. End-hardened rail shall be tested for Rockwell Hardness in

accordance with ASTM E 18 in ¼ inch increments longitudinally, transversely, and vertically for a distance of 6 inches starting from the hardened end of the rail. Rail ends shall be end-hardened between 340 and 400 HB.

b. The hardness number and location shall be recorded.

c. Hardness pattern produced by the procedure shall exhibit a

uniform distribution.

(1) The hardness shall decrease uniformly from between 340 and 400 HB at the end of the rail to the hardness of the untreated rail in a distance of not less than 2 inches.

(2) The hardness pattern shall be uniform across the top

surface and sides of the rail head.

B. Demagnetizing Rail Components: 1. Supplier shall take measures and precautions in their work means and

methods to minimize residual magnetism in ferromagnetic materials that may affect the proper performance of track circuitry. This includes materials such as rail and other ferrous metal trackwork components.

1.06 ALIGNMENT DATA


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A. Engineering stationing along the survey line shown is used to reference all

geometric control points. Where shown, independent stationing is provided and represents the stationing along the centerline of that track.

1.07 TRACK GEOMETRY

A. Vertical alignment is based on the profile of track centerline and is the average of two rails of a track if a superelevation is designed. Vertical curves are symmetrical and parabolic, unless shown otherwise on the Plans.

B. For tangent track, horizontal alignment is centerline of track, equidistant

between the gauge sides of the running rails.

C. For curved track, horizontal alignment is centerline of track with outside rail located 2 feet 4 ¼ inches radial from the centerline measured in plane with rails.

D. Track gauge: Standard track gauge for tangent and curved tracks in the

following shall be measured at right angles between gauge lines in a plane 5/8 inch below top of rail. 1. Tangent and curve radii more than 200 feet: 4 feet 8 ½ inches.

2. Curve radii of 200 feet to more than 100 feet: 4 feet 8 5/8 inches.

3. Curve radii of 100 feet or less: 4 feet 8 ¾ inches.

E. Flangeway width for Tee-Rail: 1. Tangent and curve radii of more than 200 feet: 1 3/8 inches.

2. Curve radii of 200 feet to 100 feet: inside flangeway, 1 ½ inches, and outside flangeway, 1 5/8 inches.

3. Curve radii of 100 feet or less: inside flangeway, 1 5/8 inches, and outside flangeway, 1 7/8 inches.

1.08 ALLOWABLE VARIATIONS A. Horizontal and vertical alignment: Unit variation of 3/32 inch per 25 feet for

tangents and 3/16 inch per 25 feet for curves; total variation of 1/2 inch (plus and minus 1/4" from the design alignment).

B. Cross level: Plus or minus 3/32 inch. (Difference between the design elevation


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and the actual rail elevations of opposite rails of the same track.)

C. Tangent track gauge: Plus 1/8 inch, minus 1/8 inch.

D. Curve track gauge: Plus 1/8 inch, minus 1/8 inch.

E. Flangeway depth and width: Plus 3/32 inch, minus 0 inch. F. Guardrail height: Plus 1/8 inch, minus 0 inch.

G. Joint alignment: Horizontal and vertical: 1/32 inch.

H. Joint openings: 0 inch to 1/32 inch. Extra rail length shall be provided at joints

in order to allow cutting rail to make future field adjustments.

I. Width of head out of square at ends: 1/32 inch.

J. Vertical surface of casting end faces. Plus or minus 1/32 inch. PART 2 - PRODUCTS 2.01 GENERAL

A. All material shall conform to this Specification and applicable AREMA Manual provisions.

B. See Drawing CL-28586 for additional information. 2.02 RUNNING RAIL

A. Running rail shall be as shown on the Drawing and as specified herein.

B. Tee rail shall be 115#RE High-Strength rail with a minimum hardness of 341 HB on the sides and top of the rail head.

C. Rail shall have a maximum sulfur level of 0.020%.

D. All running rail shall be suitable for thermite welding.

E. Shop Curving of Running Rail.

1. Rail in track having a centerline radius of 300 feet or less, or vertical radius of 600 feet or less, shall be shop curved.

2. Shop curving of rail shall be performed by methods and equipment


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approved by the City.

3. The Supplier shall use full-length rails to the maximum extent possible. The minimum length of rail used shall be 15 feet unless Plans indicate otherwise.

4. Shop curved rail shall be curved to true indicated radius throughout its length and shall be identified as to radius of curvature and curve number. The Supplier shall take account both horizontal and vertical alignment.

5. Shop curved guard rail assembly shall extend a minimum of 10 feet into adjacent tangent track unless Plans indicate otherwise.

6. Rail web shall remain perpendicular to rail base after shop curving with an out-of-square not more than 1/16 inch with respect to web centerline.

2.03 GUARDRAIL, SEPARATOR BLOCKS AND END BLOCKS

A. Guardrail shall be machined from tee running rail and shall be as shown on the Plans.

B. Guardrails at each side of a guardrail joint shall not be less than 10 feet.

C. Guardrail shall be shop curved in accordance with shop curving requirements

for running rail.

D. Top of installed guardrail shall be 3/8 inch above top of running rail.

Four-inch (4”) separator blocks for the guardrail shall be between every other rail fastening assembly. Ten-inch (10”) end blocks shall be at every guardrail joint and at each end of guardrail.

1. Separator and end blocks, and shims, shall conform to ASTM A 36. 2. Separator and end blocks shall conform to the dimensions and bolt hole

locations as shown on the Plans. 3. Separator and end block shims shall be fabricated to a configuration to

match the separator and end blocks, and as shown on the Plans. Shims shall be provided to adjust flangeway width as shown on the Plans.

2.04 BOLTS, WASHERS AND NUTS


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A. Bolts, washers and nuts shall be furnished at all bolted connections, including

guardrail spacer blocks.

B. Bolts shall be minimum 1 inch diameter, hex head, and shall conform to SAE J429 Grade 8 or ASTM A 354 Grade BD. Lengths shall be as required for proper installation, with a maximum of 5/8 inch projecting beyond the nut. Provide adequate number of bolts to replace bolts loosened after future installation.

C. Hardened flat steel washers shall conform to ASTM F 436.

D. Heavy hex nuts shall be Class 12 (Grade DH) and conform to ASTM A 563 or

Grade 2H and conform to ASTM A 194. 2.05 BOLTED RAIL JOINT ASSEMBLIES

A. General: Bolted rail joint assemblies shall be provided at all compromise joints indicated on the Plans.

B. Joint bars shall be a minimum of 1 ½ inches thick, toeless type similar in profile

to the Metro “D” Bar of Allegheny Rail Products, not interfering with the use of rail clips, and fabricated and machined to have full contact with the fishing space of the rail being joined. Inside face of joint bars shall be smooth with no stamping or branding. 1. For uninsulated joints, joint bar material shall be quenched carbon steel

or microalloyed, conforming to AREMA Chapter 4 Part 2. 2. Joint bar length shall be 30 inches, except for compromise joints that

shall be 36 inches or as required in the AREMA Portfolio. 3. Joint bars shall have 6 holes with 5 inch hole spacings and 2 ½ inch hole

edge distances at ends of joint bars, except for compromise joints that shall have 6 inch hole spacings and 3 inch hole edge distances at end of bars.

4. Joint bar holes shall be 1/16 inch larger than the bolt. 5. Steel joint bars for track with a radius of less than 300 feet shall be shop

curved to conform to the radius of the track to which it will be installed. 2.06 NOT USED


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2.07 RAIL FASTENING FOR TIE AND BALLAST SYSTEM

A. Tie Pads: Shall be 1/4 inch thick, uncoated, unpunched, masticated rubber pads, cut to the same plan dimensions as the tie plate and as manufactured by International Track System, Inc., or by Alert Manufacturing, or by American Track System, Inc. Provide tie pads for each tie plate.

B. Tie Plates:

1. Tie plates shall be provided at every location where the trackwork crosses a tie.

2. Tie plates for tangent track tee rail shall be Pandrol tie plates, which accommodate rail clips, unless otherwise shown on the drawings.

3. Tie plates for curved and tangent track double tee rails shall be twin tie plates with Pandrol fastening as shown on the Drawings, and shall be 3/4 inch thick unless otherwise noted.

C. Shim and Gauge Plates: Shim and gauge plates for tie plates shall conform to ASTM A 572, with minimum yield strength of 50 ksi.

D. Cut Spikes: Shall be high carbon steel track spikes, 5/8 inch by 6 inch.

E. Screw Spikes: Shall be 15/16 inch diameter by 6 inch long screw spike as manufactured by Pandrol, unless otherwise indicated.

F. Rail Clips and Shoulders: Rail clips shall be Pandrol Right Hand "e" 2000 series clips. The Pandrol modified "e" clip shall be used at rail joints if the joint bar interferes with the standard rail clip. Clip Shoulders shall be Pandrol self-aligning shoulders for tee rail as indicated in the Drawings.

2.08 NOT USED 2.09 NOT USED

PART 3 - EXECUTION 3.01 RAIL CUTTING, DRILLING AND BEVELING

A. Rails shall be cut for traffic routing requirements and other requirements. Cuts or holes shall not be permitted except as indicated on the Plans or specified herein.

1. Rails shall be cut square and clean by means of either rail saws or


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abrasive cutting discs. Torch cutting is prohibited.

2. Holes in rail shall be accurately spaced and drilled with a rail drill. a. Holes of AREMA specified diameter for the size bolt required shall

be drilled through and shall be perpendicular to the web of the rail.

b. A template shall be used as a drilling guide. In no case shall a joint bar, separator block or end block be used as a drilling guide.

c. Peen and/or grind to remove all sharp edges.

B. Rail ends of existing and new running rail shall be beveled per AREMA Portfolio Plan No. 1005.

C. Rail branding and stamping within 2 inches of bolted joints shall be ground smooth.

3.02 RAIL JOINTS

A. Running rail shall be joined by welding as specified in Section 05690, except: Connections to compromise joints, which shall be bolted joints as shown in the Plans.

B. Bolted Joints:

1. Bolted joints shall be installed at the locations indicated in the Contract

Documents. 2. Bolted joints in opposite rails of the same track shall be staggered a

minimum of 4 feet. 3. Rail ends of existing and new running rail shall be beveled per AREMA

Portfolio Plan No. 1005 and end-hardened to between 340 and 400 HB. Joint bars shall be removed from rail ends during the end-hardening process.

4. Branding and stamping within 2 inches of a joint shall be ground

smooth.

5. Peen and grind to remove sharp edges.

6. Joint bars and surfaces to be covered by joint bars shall be cleaned by sandblasting to the equivalent of SSPC-SP 10.


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3.03 GUARDRAIL

A. Guardrail as indicated on Plans and shop drawings.

B. 4 inch separator blocks and shims for the guardrail shall be between every other rail fastening assembly. 10 inch end blocks and shims shall be at every guardrail joint and at each end of any guardrail. The shims shall be used to adjust the width of the flangeway as indicated on the Contract Documents.

3.04 NOT USED

END OF SECTION 05650

DIVISION 5: METALS 05660: SPECIAL TRACKWORK

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A. This work shall include designing, furnishing, fabricating, loading, delivery and unloading of special trackwork materials.

As applicable to complete the special trackwork, the above also includes the following:

1. Complete turnouts.

2. 115 RE running rail.

3. 115 RE closure rail and guard rail, including bolts, end blocks,

separator blocks and shims.

4. Bolted rail joints, including compromised joints.

5. Rail plates, rail clips, shim pads, threaded inserts, anchor bolts, and lock washers for complete fastening system.

6. Switch holding devices for non-electric switches

1.02 RELATED WORK Section 05650: Basic Trackwork Materials and Methods 1.03 REFERENCES A. American Railway Engineering and Maintenance-of-Way Association

Manual for Railway Engineering herein referred to as the AREMA Manual. B. AREMA Portfolio of Trackwork Plans, herein referred to as the AREMA

Portfolio.

C. ASTM E 10 Standard Test Method for Brinell Hardness of Metallic Materials.

D. ASTM E 18 Test Method for Rockwell Hardness and Rockwell

Superficial Hardness of Metallic Materials. 1.04 SUBMITTALS

A. Quality Control Plan: provide within four (4) weeks after Notice to Proceed.


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B. Detailed description of the rail and manganese steel casting manufacturing,

methods of fabrication, shipping and stacking of special trackwork within four (4) weeks after the Notice to Proceed.

C. Design calculations for special trackwork switches and frogs, to derive

proper wheel tread width, flangeway width and depth, and track gauge and transitions within four (4) weeks after Notice to Proceed.

D. Shop fabrication drawings showing dimensions and details of each special

trackwork component, and drawings showing the layout of all special trackwork within four (4) weeks after the Notice to Proceed.

E. Not used.

F. Detailed description of the methods of shipping and stacking of special

trackwork four (4) weeks prior to delivery.

G. Not used.

H. Mill certificates and certified test results for all tests prior to shipment of special trackwork from the plant.

I. Certificates of Compliance with hardness requirements and other

documentation: Provide notarized certificates prior to the Notice for Final Inspection.

J. In-plant QA/QC inspection report ten (10) working days prior to notice for

Final Inspection.

K. Notice for Final Inspection. 1.05 TRACK GAUGE AND FLANGEWAY A. Track gauge and flangeway width shall conform to Section 05650 and as

specified herein. B. A 1/8 inch minimum clearance shall be provided between the wheel flange

and points and intersections of flangeway walls. C. Supplier shall perform calculations for special trackwork, switches and

frogs, to derive proper wheel tread width, flangeway width and depth, and track gauge and transition based upon the vehicle characteristics and gauge defined herein.

1.06 ALLOWABLE VARIATIONS

A. Allowable variations except as defined herein, shall be as specified in Section 05650.


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B. Vertical surface of casting end faces: Plus or minus 1/16 inch.

1.07 VEHICLE CHARACTERISTICS A. Wheel contour is shown on Figure I (attached).

B. Wheel gauge: 4 feet 8 ¼ inch, plus or minus 1/16 inch. C. Wheel diameter: 26 inches, plus or minus 2 inches. D. Truck wheel base: 6 feet 3 inches. E. Nothing shall interfere with use of the vehicle’s electromagnetic track

brakes. 1.08 QUALITY CONTROL

The Supplier shall take all steps necessary to check and insure that materials to be provided comply with Specifications, are within allowable variations and tolerances, and will properly fit together in the field without modification.

A. The Supplier shall engage at his/her expense a qualified independent testing

laboratory to inspect and test rail and special trackwork materials furnished under the Contract. Special trackwork inspection and testing shall include fabrication and finishing defects, depth and end-hardening, horizontal and vertical alignment and geometrical layout.

B. All items shall be visually inspected for external defects. Rail shall be

ultrasonically tested for internal defects in accordance with the AREMA Manual. Twenty-five percent (25%) of all castings shall be radiographically tested. The area of each manganese steel casting within 2 feet on each side of the points shall be radiographically tested for internal defects. Radiographic testing shall be in conformance with the AREMA Portfolio Specification for Special Trackwork.

C. The Supplier shall inspect special work at plant and verify required testing

has been completed prior to shipment. D. All special work shall be laid out and pre-assembled prior to delivery. 1. Such layout shall be of sufficient size, with adequate overlapping of

sections to insure proper off-site assembly and final fit up in the field.

1.09 SCHEDULE


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A. The schedule shall include milestone dates for each shipment including:

1. Casting 2. Fabrication

3. Finishing 4. Testing

5. Inspection

6. Shipping 7. Delivery PART 2 - PRODUCTS 2.01 GENERAL A. All special trackwork material and assemblies shall conform to the

applicable requirements of the AREMA Manual and AREMA Portfolio, modified by the instructions herein.

B. Special trackwork based on AREMA designs shall have rail ends profiled to

match running rail and modified for use with the vehicle characteristics and requirements herein, and to allow installation within the tolerances of Section 05650.

C. Manganese steel casting shall be "high integrity". Foundry practices and

risering techniques shall ensure that "high integrity" manganese steel castings comply with the radiographic internal soundness levels specified in the AREMA Portfolio Plan Nos. 1012 through 1017. Internal soundness levels for manganese steel castings shall be similar to the AREMA Portfolio Plans.

D. Forged and machined areas shall be inductively normalized to relieve any

stresses.

E. Contact Areas: Tread, gauge corners, gauge and guard faces, points and flangeways less than 1 ¼ inch deep of castings shall be depth hardened to 352 HB. Other surfaces within one inch of contact areas and gauge and guard lines shall be depth hardened to a minimum of 321 HB. Hardness testing shall be in accordance with ASTM E 10 or E 18.

F. Unless otherwise noted, flangeway depth shall be 3/4 inch at intersections

of frogs. This depth shall be carried to where width of wheel tread contact


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surface is 1/2 inch or to the actual points of frogs and then transition smoothly at no greater than 1 to 48 slope to 1 ½ inch or to match the connecting rail. Transitions in guard faces shall be smooth. Points of frogs shall be depressed similar to AREMA Portfolio Plan No. 600B.

G. Ends of castings and running rail to be bolted shall be beveled as shown in

AREMA Portfolio Plan No. 1005 and end-hardened as specified in Section 05650. End faces of castings and running rail shall be vertical and flat.

H. Casting arms shall be extended and the arm ends shall be fabricated and

profiled to match and bolt to the connecting rail sections indicated on the Plans, including guardrail. The casting arms and connecting rail sections shall be connected with joint bars and end blocks. The length of arms shall be sufficient to give at least 6 ¼ inches clearance between vertical webs at ends of joint bars. The length of frog arms shall be a minimum of 3 feet. Joint bar contact surfaces of castings shall be machined to provide full contact with joint bars.

I. See Drawing CL-28586 for additional information. 2.02 TRACK SWITCHES AT SHOOFLY TURNOUTS

A. Split Switches for shoofly track turnouts that are identified as SP #9 and SP #10 shall generally conform to the AREMA Portfolio, Plan No. 112 with stock rail, Samson type points and switch-point guard rail. Running rails and stock rails shall be welded by installation Supplier unless otherwise shown on the drawings.

B. The switch points and housing shall be designed to permit the switch being

“run through” in the trailing direction without damage to any component.

C. For electrified switches within tunnel and Eureka Station, the switch points and their housings shall be designed to be thrown by Alstrom GM4000A switch machines suitable for split switches. The Supplier shall coordinate the design of switches and switch machine assemblies to insure functionality for operation and maintenance of the system.

2.03 FROGS

A. Turnout frogs for the shoofly track turnouts shall be self-guarded solid

manganese steel frog and shall generally conform to AREMA Portfolio Plan No. 641, except as modified herein and as described in these Specifications and Section 05650.

B. Frogs shall have guard rails tapered to meet connecting rails at ends.


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2.04 CLOSURE AND CONNECTING RAILS

A. Closures and connection rails shall be fabricated of girder rail, tee rail, guardrail, separator and end blocks, as specified in Section 05650 and as shown in the Plans.

2.05 BOLTED RAIL JOINT ASSEMBLIES

A. Bolted rail joint assemblies shall be as specified in Section 05650. They shall be provided at all connections to manganese steel castings and insulated joints, and bolted compromise joints indicated in the Plans.

2.06 BOLTS, WASHERS AND NUTS

A. Bolts, washers and nuts shall be as specified in Section 05650, except as modified:

All bolted connections shall be designed to be bolted with minimum 1 inch diameter bolts. Larger diameter bolts shall be used when indicated in the AREMA Portfolio.

2.07 RAIL FASTENINGS

A. Rail fastenings shall be as specified in Section 05650 of these Specifications and Contract Drawings. Rail shim pads, plates, clips and shim plates supporting special trackwork components, closure rails and connecting rails and applicable track foundation components layouts shall be dimensioned and manufactured to suit accordingly.

1. Rail fastening system shall be provided at each side of casting,

closure rail and connecting rail.

2. Plate spacing shall be as indicated in AREMA Portfolio, except maximum spacing shall be 2 feet on center, and 1 foot 4 inches at the switch throwing device.

PART 3 - EXECUTION 3.01 RAIL CUTTING, DRILLING AND BEVELING

A. Rail cutting, drilling and beveling shall be as specified in Section 05650. 3.02 SHOP CURVING

A. Shop Curving shall be as specified in Section 05650. 3.03 MARKINGS


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A. Stencil Painted Markings: 1. Stencil painted markings identifying the installation location of each

component of special trackwork shall be painted before shipment. Such markings shall be placed on the side of and near the end of the piece. Markings shall not be in any area which will be covered by joint bars or other components. Markings shall be stencil painted with white paint on a permanent black steel paint background with letters and numerals not less than 1 inch high.

2. Frogs shall be stencil marked with the angle and radii. 3. Each shop curved rail shall be stencil marked with the curve

identification number and the curve radius. Markings shall be on the outside web, 3 feet from one end and at each point of change in curvature.

B. Cast Markings: 1. Switch housings shall be cast with markings to indicate “curved”

with radius and manufacturer. 2. Frogs shall be cast with markings to indicate radius, angle and

manufacturer. 3. Cast markings shall be located where they will be visible after track

is embedded, shall not be in the wheel tread area and not be subject to wear from rail vehicles, and not be recessed more than 1/4 inch below top of casting.

3.04 OFF-SITE ASSEMBLY A. All special trackwork shall be assembled, inspected and approved by the

Supplier’s independent inspector and the City Inspectors at the Supplier’s plant prior to shipment. The Supplier shall submit QA/QC reports, indicating the special trackwork components, alignment and geometry comply with the Contract Specifications, ten (10) working days prior to the scheduled plant inspection of the special trackwork by the Supplier’s independent inspector and City inspectors designated by the City.

B. The control points of each layout, such as points of intersection, curvature

and vertical alignment shall be laid out by survey techniques, and the special work layout shall be built according to the survey and the working drawings.


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C. If assembly to the vertical alignment is not practical, the Supplier shall ensure proper field fit by lengthening closure rails and make adjustments where required.

D. No bracing will be permitted to hold components to proper gauge and

alignment.

3.05 PACKAGING, HANDLING, SHIPPING, UNLOADING AND STACKING A. Packaging 1. Components shall be packaged to permit outdoor storage in an

unsecured area. 2. Small loose parts shall be shipped in secure weatherproof shipping

boxes and kegs. Such containers shall be palletized for fork lift handling.

3. Kegs, bundles and packing boxes shall be clearly marked with the

following: purchase order number, supplier name, shipping date, number of pieces, gross weight and detailed description of items contained and bid item to which they refer.

4. An identification scheme in which markings are applied on

components, in accordance with subsection 3.03, shall be developed so as to facilitate the assembly of the special trackwork components. Six copies of a one-sheet drawing shall be provided to show the component layout along with their markings for each special trackwork item.

B. Handling, shipping, unloading and stacking 1. All materials shall be handled carefully to avoid damage. 2. All materials shall be delivered to and unloaded and stacked at a

delivery site within the San Francisco City limits as directed by the City. Arrangements for delivery of materials shall be made at least three (3) working days in advance of the Supplier’s intention to deliver the material. The Supplier shall furnish all equipment, labor, rigging, dunnage, and other materials necessary to perform this work.

3. Materials shall be bundled, fully identified, shipped, unloaded and

stacked together for each entire material item, special trackwork unit and curve.


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DIVISION 5: METALS 05690: RAIL WELDING

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A. The work shall consist of welding of rails, which includes guardrails, to form continuously welded rail (CWR). Rails shall be welded using an approved welding process. All welds shall be tested by an independent testing laboratory as specified below.

1.02 SECTION INCLUDES

Section 05650: Basic Trackwork Materials and Methods 1.03 REFERENCES

A. ANSI/AWS D1.1 Structural Welding Code - Steel.

B. AREMA Manual for Railway Engineering, herein referred to as the AREMA Manual, Vol. I, Chapter 4, Part 2 - Specification for Fabrication of Continuous Welded Rail.

C. ASNT-SNT-TC-1A Recommended Practice for Qualification and Certification of Non-Destructive Testing Personnel.

D. ASTM E 10 Standard Test Method for Brinell Hardness of Metallic Materials.

E. ASTM E 18 Test Method for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials.

F. ASTM E 142 Standard Method for Controlling Quality of Radiographic Testing.

G. ASTM E 709 Standard Guide for Magnetic Particle Examination. 1.04 SUBMITTALS

A. Description of equipment, method and procedure for welding rail.

1. Thermite Welds: The method and procedure employed shall comply with the directions of the weld kit manufacturer and include details of the following operations.

a. Preparation of rail for welding.

b. Rail end spacing, tolerances, and procedures to maintain rail gap during the welding operation.


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c. Rail alignment.

d. Placing and bolting of prepared molds.

e. Preheating of rail, including method, temperature, and time.

f. Crucible tapping and procedures including duration of weld, control on cooling and cooling time.

g. Method to be used for removing gates and risers.

h. Method of weld finishing.

2. Electric Flash Butt Welding Process: The method and procedure

employed shall comply with the directions of the weld equipment manufacturer. Provide complete details of equipment, special fittings and accessories, rail preparation and handling procedures, and weld finishing procedures.

B. Inspection and testing program, including:

1. Testing agency, including personnel identification and qualifications

records.

2. Testing procedure and equipment for visual, magnetic particle, ultrasonic, radiographic and hardness testing.

C. Certified written test report of demonstration and production welds, including:

1. Record in accordance with Table 1 of this section showing all

applicable data.

2. Film of radiographic examination.

3. Section through demonstration welds, longitudinal to rail.

4. Assemble records with test reports starting with demonstration welds, followed by production welds in station order, by track and location of weld, and bind in a loose leaf binder. Submit records.

Certified test results of all tests and all film of all radiographic tests shall be submitted within five (5) working days of the test. Copies shall also be delivered to Rail Welder.

D. Procedures for straightening rails.


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E. Procedures to maintain hardness of rail during welding.

1.05 QUALITY CONTROL

A. Rail Straightness:

Rails shall be checked for end straightness by the Rail Welder immediately before welding. Rails which are at or exceed the tolerances shown in AREMA Chapter 4, Part 2, shall be inspected and rail ends that cannot be straightened shall be cut back a sufficient distance to meet the specified rail end straightness criteria. Rail ends shall be straightened as incidental work.

B. Demonstration Welds:

The Rail Welder shall demonstrate qualifications of welding process, equipment, material and welders by producing demonstration weld samples at his/her expense. Samples of welds for each weld process used by Rail Welder and each rail section and metallurgy to be welded, shall conform to the following requirements: 1. Training: The supervisor of each welding crew shall be trained and

certified to perform rail welding by the manufacturer supplying the weld material and equipment.

2. Samples: Samples shall be prepared by the Rail Welder’s welding crews in accordance with the method and procedure for welding.

3. Performance: Each welding crew shall perform at least 2 sample welds for each rail section and metallurgy.

4. Approvals and Qualifications: Approval of the weld procedures, equipment and materials, and qualification of welding crews will depend on weld samples satisfying the specified requirements. Weld samples shall be approved and each welding crew shall be qualified prior to performing production welds for the work.

5. Demonstration weld samples shall be tested for defects by visual

(including longitudinal sectioning), magnetic particle, ultrasonic, radiographic and hardness testing.

C. Testing of Welds:

The Rail Welder shall arrange and provide at the Rail Welder’s expense a qualified independent inspection agency to provide all testing. Testing shall be as follows:


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1. Personnel Qualifications: Personnel performing nondestructive testing

shall be qualified in accordance with ASNT-SNT-TC-1A. Only personnel qualified for NDT Level II may perform testing.

2. Visual Inspection: Examine for alignment, finishing and other defects.

3. Magnetic Particle: Testing shall be by the coil method (longitudinal

magnetization) using the dry powder method in accordance with ASTM E 709.

4. Ultrasonic: Ultrasonic testing shall be performed in accordance with

ANSI/AWS D1.1, Section 6, Part C, "Ultrasonic Testing of Groove Welds." At a minimum, the weld shall be scanned from the top surfaces of rail, rail web, and rail base flanges, using 0 degree, 45 degree, and 70 degree search units as appropriate for the rail being tested. The weld shall be scanned from both sides of the weld axis on the same face for longitudinal and transverse discontinuities using the applicable scanning pattern or patterns shown in Figure 6.12 of the above mentioned Code. The inspection agency’s ultrasonic testing procedure shall detect incompletely fused welds.

a. Weld Hardness: Testing shall be in accordance with ASTM E 10

or E 18. Test the head 0.4 inch from gauge side of the rail in the center of the weld, immediately each side of the weld in the center of the heat affected zones, and 3 foot each side of the center of the weld.

b. The center of the heat affected zone shall be determined by

etching the demonstration weld longitudinal rail section.

D. Defective Welds: Shall be determined as follows:

1. Welds that fail to meet rail straightness and deviates rail alignments more than those permitted in AREMA Manual, Chapter 4, Part 2.

2. Unsatisfactory finishing. Finishing that is not within tolerances.

3. Welds showing a response at any level that is identifying a crack or lack

of fusion.

4. Any defect area exceeding 3/32 inch diameter in the head and 1/16 inch diameter elsewhere in the rail.

5. Any defect exceeding 3/16 inch in length in any direction.


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6. Hardness of weld or immediately adjacent rail in the heat affected

zones:

a. Varying more than 15 HB from the average hardness of the two rails joined, 3 foot away from the weld.

b. Less than 270 HB.

c. More than 400 HB.

PART 2 - PRODUCTS 2.01 WELD MATERIALS

A. Welded materials shall be described in the approved submittal of welding procedures.

PART 3 - EXECUTION 3.01 GENERAL

A. Join all rail section by welding unless otherwise indicated or specified herein. Welding shall be in accordance with accepted welding procedures.

B. Welds shall not be located:

1. Within 15 feet of a joint in the same rail.

2. Within 4 feet of a joint in the opposite rail of the same track.

3. Within 6 inches of a rail fastener or restraining rail separator block.

C. Preparation of Rail Ends:

1. Cut rail ends with a saw or use an abrasive wheel at right angles to the

rail to provide a smooth and clean surface.

2. Clean rail surfaces for a length of 6 inches from the ends of rails to remove grease, dirt, loose oxide, oxidized metal, scale, moisture and other impurities.

3. Remove burrs, lipped metal, mill brands and other irregularities which

would interfere with the fit of the mold.


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D. Weld Gap:

1. Provide rail gap as required by accepted welding procedure and align rail to produce a weld conforming with the alignment requirements herein.

2. Where the rail gap is larger than manufacturer's recommended gap,

remove sufficient length of rail 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 production welding.

E. Weld Finish: Trim and grind weld to achieve the following tolerances:

1. The top and gauge side of the weld at rail head shall be finished to

within plus 0.005 inch or minus 0.00 inch of the parent section.

2. The remainder of the rail weld shall be finished to within plus 0.125 inch or minus 0.00 inch of the parent section.

a. Eliminate notches created by offset conditions by grinding to blend variations.

b. Remove protrusions and gouges in the welded area, and blend welded area into the rail contour by grinding in a manner that will eliminate fatigue crack origins.

c. Remove defects visible to the unaided eye by grinding, except that if removal by grinding cannot be accomplished within the finishing requirements, the weld shall be replaced at no cost to the City.

3. Do not overheat the rail surface by application of grinding pressure.

4. Complete heavy grinding of the weld or rail shearing while the rail is

still hot from welding.

F. Rail Wastage: Shortage of rail due to Rail Welder’s waste, rejected welds or rail damaged by the Rail Welder shall be replaced by the Rail Welder at no additional cost to the City.

3.02 REPAIR OF DEFECTIVE WELDS

A. Welds rejected during inspection or testing shall be cut out and rewelded if possible, or replaced with at least one 15 foot rail welded in its place by two welds.


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B. The Rail Welder may replace the defective weld with a special wide thermite weld. Prior to use in track fabrication, sample welds of this special weld shall be tested and accepted as specified for demonstration welds.

C. All welds repaired shall be tested as follows after repairs have been completed:

visual inspection, magnetic particles, ultrasonic and hardness. 3.03 QUALITY CONTROL

A. Rail shall be cleaned of anything which may interfere with testing.

B. Welds shall be tested for defects as specified in 1.05 C and 1.05 D, with the exception of radiographic testing (demonstration welds only) and as specified hereinafter.

1. All welds shall be visually inspected.

2. Welds selected for ultrasonic and magnetic-particle testing shall be well

representative of the rail welds that are to be installed in each 1,000 feet of trackwork fabrication. At least one-third (rounded up to the next highest whole number, but not less than two welds) of each group of welds as defined above shall be selected for testing. Prior to the testing, the Rail Welder shall submit a copy of sketch that identifies the selected welds with track and rail stations. Should one ultrasonic or magnetic particle defect be detected, the rest of the welds in the same group shall be ultrasonically and magnetic particle tested. Any defective welds shall be recorded and repaired.

3. Not used

C. Certified Test Reports: Form shall include record number, location of weld in

rail, results and date of visual inspection, results and date of ultrasonic inspection, results and date of hardness testing, including recommendation for correction of defects found, name of inspector, and other information as needed.

D. Weld Records: A complete and current record of all welds and their locations

shall be maintained by the Rail Welder and provided to the City. The record shall show all information indicated in Table 1 herein.

E. Not used.


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Table 1 Welding Record No. Retest: (yes) (no) If yes, original welding record no. DATE: TIME: TRACK DESIGNATION: STA. RAIL, LT, RT (CIRCLE) RAIL SECTION: MILL BRAND YEAR ROLLED: (AHEAD) (BACK) RAIL IDENTITY: (AHEAD) (BACK) TYPE OF RAIL: PREMIUM STANDARD (CIRCLE) RAIL CUT REQUIRED: (YES) (NO) DEFECTIVE WELD OTHER MANUFACTURER OF WELD MATERIAL: AIR TEMPERATURE: PREHEAT TIME: COOLING TIME: RAIL TEMPERATURE: RAIL GAP (NEAREST 1.6 MILLIMETER [1/16 INCH]): WEATHER CONDITIONS: TRACK ALIGNMENT AND CONSTRUCTION: (Curve, Tangent, Grade, Etc.) NAME OF CITY REPRESENTATIVE PRESENT: NAME OF RAIL WELDER'S FOREMAN PRESENT: NAME OF MANUFACTURER'S REPRESENTATIVE PRESENT: (Initialed by those present) RECORDER: DATE: TIME: VISUAL INSPECTION: PASS FAIL (CIRCLE) MAGNETIC PARTICLE: PASS FAIL NOT APPLICABLE (CIRCLE) ULTRASONIC TEST: PASS FAIL NOT APPLICABLE (CIRCLE) RADIOGRAPHIC TEST: PASS FAIL NOT APPLICABLE (CIRCLE) HARDNESS: WELD AHEAD BACK NA NAME OF WELD TEST FIRM/AGENCY: NAME OF WELDING INSPECTOR PRESENT: ATTACH TEST LOGS AND OTHER DOCUMENTATION.



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DIVISION 6: WOOD AND PLASTIC 06130: COMPOSITE TIES

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A. The work shall consist of furnishing 7” x 9” x 8’-6” (102”) minimum engineered polymer composite (EPC) ties for trackwork.

1.02 RELATED WORK

Section 05650: Basic Trackwork Materials and Methods 1.03 DEFINITIONS OF TERMS

A. "Tie," or "Ties" shall mean cross ties and switch ties. 1.04 REFERENCES

A. AREMA Manual for Railway Engineering; hereinafter referred to as the AREMA Manual, Chapter 30.

1.05 SUBMITTAL

A. The Supplier shall obtain and provide for each shipment or batch of ties:

1. Certificate of compliance with these Specifications from supplier. 1.06 QUALITY CONTROL

A. Tie quality control shall be in accordance with AREMA Manual, Chapter 30, Part 5. Product shipments shall be traceable to the year, day, production line, and operating shift that produced the ties.

B. Prior to shipment to the job site, the Supplier shall inspect ties and determine that they comply with the Specifications.

C. Ties used in this Contract shall be from one manufacturer and one product.

1.07 HANDLING AND STORAGE

A. Except as modified herein, all ties shall be handled, shipped and stored in accordance with the AREMA Manual, Chapter 30, Part 3. To minimize damage to ties, they shall not be handled unnecessarily. Only those lifting devices that will not damage the tie shall be used.


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B. Ties stored on dunnage should sit on at least 3 points of contact, both ends and center.

C. Ties should be allowed to acclimate to the intended installation environment for a minimum of 48 hours.

D. Pre-plating should be performed indoors or under a canopy to avoid direct

sunlight during the pre-plating process. PART 2 - PRODUCTS 2.01 GENERAL

A. Ties shall conform to AREMA Manual, Chapter 30, Part 5, for engineered polymer composite (EPC) materials, and as modified by the requirements herein.

B. Ties shall be certified by the manufacturer that they are suitable for inside tunnel applications, and do not conflict with any AREMA requirements for such an application.

C. Ties shall conform to the following requirements:

1. Straight and square at the ends, with the top and bottom of each tie

parallel, and the sides parallel, and in accordance with the AREMA Manual, Chapter 30, Part 5, Section 5.3.2.

2. 3 sides of the tie shall be stamped or surface-textured or surface

patterned to increase the mechanical interlock between the tie and the ballast, and increase tie resistance to longitudinal loads, and to meet AREMA “Single Tie Lateral Push” property.

3. Ties shall meet the requirements of UL 94, HB Standard for Safety

of Flammability of Plastic Materials for Parts in Devices and Appliances.

4. Ties shall be stamped in accordance with the AREMA Manual,

Chapter 30, Part 5, Section 5.5.1. Each tie shall be permanently identified by the manufacturer’s name and year and month of production.

D. Dimensions:

1. Cross ties: 7 inch x 9 inch and length shall be 8 feet 6 inch (102


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inch) minimum, or as shown in the Drawings.

2. Switch Ties: 7 inch x 9 inch and length shall not be less than 8 feet 6 inch (102 inch) minimum, or as shown in the Drawings.

E. Properties:

Modulus of Elasticity – MOE; 220,000 psi min. Modulus of Rupture – MOR; 2,500 psi min. Rail Seat Compression; 1,200 psi min. Single Tie Lateral Push; 2,750 lbf min. Spike Pullout; 2,500 lbf min. Screw Pullout; 5,000 lbf min. Coefficient of Thermal Expansion (CTE); 4.1 x 10-5 in/in/°F (Average) Electrical Impedance; 20,000 ohms min. Surface Hardness; 5300 lbs/.25”ind min. Density; 70 lbs/ft3 max.

F. Manufacturer:

1. Acceptable manufacturer is Axion International. PART 3 - EXECUTION NOT USED



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