CONTRACT SPECIFICATIONS
SECTION 34 11 23
SPECIAL TRACKWORK FABRICATION
PART 1 - GENERAL
1.01 SUMMARY
A. This Section includes specifications for furnishing all labor, materials, and equipment for the designing, manufacturing, testing, fabricating, packaging, shipping, and unloading of switch point rails, stock rails, movable point frogs, flange-bearing diamond crossing, restraining rail,, guard rails, guard rail plates, switch plates, frog plates, standard plates for single rail, lead rails, closure rails and bonded insulated joints. This applies to the procurement of crossover units and the required spare parts. Design all special trackwork to be compatible with special trackwork direct fixation fasteners.
1.02 REFERENCES
A. This Section incorporates by reference the latest revisions of the following documents:
1. American Railway Engineering and Maintenance-of-Way Association (AREMA)
a. AREMA Manual for Railway Engineering (AREMA Manual)
b. AREMA Portfolio of Trackwork Plans (AREMA Plans)
2. ASTM International (ASTM)
a. ASTM A325 Specification for High Strength Bolts for Structural Steel Joints
b. ASTM A490 Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength
c. ASTM B633 Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel
d. ASTM D224 Standard Test Method for Rubber Property – Durometer Hardness
e. ASTM E10 Standard Test for Brinell Hardness of Metallic Materials
3. American Welding Society (AWS)
a. AWS D1.1 Structural Welding Code - Steel
4. American Institute of Steel Construction (AISC)
a. Steel Construction Manual
5. American Society of Mechanical Engineers (ASME)
a. B18 Lock Washers Specification
1.03 SUBMITTALS
A. Procedures:
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1. Transmit: Name(s) of supplier(s) and manufacturers for the special trackwork components
2. Shop drawings and supporting drawings for the various components of special trackwork.
3. Transmit: Installation and maintenance instructions by the manufacturer for the various trackwork components.
4. Transmit: Rail inspection results in accordance with Section 34 11 13, Track Rails
5. Transmit: Tests for Frog Depth Hardening
B. MAINTENANCE/MATERIAL
1. Transmit: Provide special trackwork shop drawings for spare parts for emergency stand-by stock for turnout components as follows:
a. Right and Left Hand Turnout Switch Parts
1) One pair of turnout switch points and adjacent stock rails for No 10 RH turnout.
2) One pair of turnout switch points and adjacent stock rails for No 10 LH turnout.
b. Spare parts shall be painted “Spare Parts” and identified by stating specific shop drawing numbers.
2. Transmit: Frogs
a. One of eachEach type of frog to be provided including the moveable point frogas follows:.
1) Turnout Frog
2) Turnout Frog in Double Crossover
3) Turnout Movable Point Frog
4) Double Crossover Center or Middle Frog
a.5) Double Crossover End Frog
b. Shop drawings to show 25-inch longer toe length and 25-inch longer heel length.
3. Transmit: Specific direct fixation fasteners under each component shall be supplied as spare parts and match marked “spares for the specific components.” One set of fasteners for each type of component.
1.04 QUALITY ASSURANCE/QUALITY CONTROL
A. Develop and maintain a quality control program regulating methods, procedures, and processes to ensure compliance with standards of quality required by the Contract Documents, as specified in the Contract Documents, including inspection and testing, samples and use of certificates of compliance.
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B. In the Special Trackwork each turnout and the complete double crossover and crossing shall be shop assembled prior to shipment in accordance with Article 3.04 herein. The assembled trackwork shall meet the following tolerances at a minimum. Correct deviations from the Contract Drawings that exceed specified tolerances at no additional cost to Sound Transit.
C. Switch Point
1. Mate and rest under the undercut stock rail
2. Provide a continuous contact with stock rail the length of the machined point rail face adjacent to the stock rail.
3. Bear on slide plates as shown by grease marks and feeler gages in the thrown operating position.
4. Switch points to be in full contact with switch point stops in the closed thrown position.
D. Operation of Switch Point and Movable Point Frog:
1. The switchpoint and movable frog point throw shall be unrestricted and throw force shall be minimum to the point where points can be shifted into final position by manual operation with a throw bar.
2. The switchpoint throws and the movable frog point to final dual position shall be limited to below 1500 pound force and proven by measuring at time of shop inspection.
E. Track Tolerances: Refer to Contract Documents for the tolerance for direct fixation track.
F. Turnout Assembly Tolerances
1. Switch Point Location: Within 1/4 inch of the engineering station.
2. Movable Point Frog, Actual Point Location: Within1/4 inch of the engineering station.
3. Maximum Switch Point Stagger: 1/8 inch.
4. Lead: Within 1/4 inch.
5. Gauge Tolerance in Turnout: Within 1/16 inch.
6. Gauge Tolerance throughout turnout and double crossover components and Actual (Movable) Point Frog: Plus 1/16 inch, minus 0 inches.
1.05 DELIVERY STORAGE AND HANDLING
A. Each turnout and the entire double crossover and crossing assembly shall be match marked, banded and palletized as described in Article 3.04 herein prior to shipment. Submit the proposed method of grouping, packaging, handling, and loading for items in this Contract to the Resident Engineer for review during the submittal of Shop Drawings.
B. Carefully handle rail and special trackwork components to minimize the chance of damage. Do not drop or strike rails sharply. Handle and ship rail and special trackwork in accordance with AREMA MRE, Chapter 4 and the AREMA “Specifications for Special Trackwork”.
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C. For components pre-assembled for inspection prior to shipment, including movable point frog, and flange-bearing diamond crossing, ship in complete partial subassemblies. Contractor is responsible for shipping special trackwork subassemblies in sizes that can be delivered through the tunnels to their proposed locations.
D. Ship small loose parts in secure shipping boxes and kegs. Do not ship in cardboard boxes or pallets that are not fully banded. Loose items for shipping will not be acceptable.
E. Clearly mark or tag assembled parts, pallets, bundles, boxes, and kegs in the appropriate turnout identification color with the following: Identify items contained, Contractor's name, shipping date, number of pieces, destination, gross weight, turnout letter designation, and special trackwork unit for which parts are intended.
PART 2 - PRODUCTS
2.01 GENERAL
A. Fabricate special trackwork components out of new materials as indicated on Contract Drawings, approved Shop Drawings, and in accordance with AREMA specifications and recommended practices.
B. For special trackwork use direct fixation construction as documented on the Contract Drawings. Insulate special trackwork to restrict stray current leakage.
C. Construct special trackwork with zero cant throughout the installation.
2.02 RAIL
A. Running rail for switch, frog, stock, closure, guard and lead rails for special trackwork and precurved:
1. 115 RE Section in accordance with AREMA Manual and Section 34 11 13, Track Rails.
2. All special trackwork shall be high strength rail, as specified in AREMA Manual, Chapter 4, Part 2, Section 2.1 Specifications for Steel Rails.
3. Accompanied by manufacturer’s records of rail inspection as described in AREMA Chapter 4 Part 2 Section 2.1.14.
B. Guard Rails for Frog and Diamond Crossing
1. 115 RE Section machined and drilled to guard length indicated on Contract Drawings.
C. Stock rail: Undercut to suit the 5100 switch point design. Use stock rails of sufficient length to provide thermite welds clear of the switch area.
D. Lead rails and closure rail: Lengths and curvatures based upon the geometric data shown on the Contract Drawings.
E. Switch point rail for special trackwork: As indicated. Fit the curved switch point for lateral track movement with a manganese protective wear point.
1. Switch point rail for mainline track construction: Floating heel block design.
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2. Throw of switch (distance through which the points of switch rails move sidewise and measured along the center line of the No. 1 switch (throw) rod): 3-3/4 to 4- 3/4 inches.
3. Curving and planing of switch points and undercutting of stock rail: properly nestle the switch points into the undercut stock rail within the full length of the required side-planing length. Design switch point to allow adjustment of the “throw of switch” from 3-3/4 inches to 4-3/4 inches width and to gradually narrow the throw width at the separation of heads to a flangeway width of 1 3/4 inches (minimum) after the switch points are in either thrown positions.
2.03 SWITCH APPURTENANCES
A. Switch Points
1. 5100 (Samson) switch point design in accordance with AREMA Plan 221.
2. Uniform riser design with runoff beyond the heel of switch.
3. Constructed of reinforcing bars, 1/2 and 1-1/4 inches thick, drilled and assembled to the switch points by square head bolts, hex nuts and cotter pins. Pin bolt assembly is not acceptable.
B. Switch Assembly
1. Switch rods of the insulated vertical design as indicated shown and in accordance with AREMA Plan 222
2. Equipped with vertical rod type MJS clips with bolts, security locknuts and cotter pins.
3. Adjustable switch rods
a. Throw: 3 ¾ to 4 ¾ inches.
b. Clearance between the top of switch rods and base of stock rails: 3/16 inch maximum
c. Each rod project under and beyond the stock rail base in both thrown positions.
C. Floating heel block assembly (two-bolt): design in accordance with AREMA Specifications for Special Trackwork, Article M3, Carbon Steel Castings.
D. Rail Brace Supports
1. Adjustable design, preferably with boltless connection, at locations indicated.
2. Type A as shown on AREMA Plan No. 224 or an approved equal.
3. Modified as required to permit the installation of switch point heaters under the head of the stock rail.
E. Ensure Switch Point Stops
1. Are of sufficient height to bear against the supporting stock rails when points are in the thrown operational positions.
2. Are in accordance with AREMA Plan 221.
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F. Joint Bars: Section 34 11 19, Track Rail Joints.
G. Track Bolts, Hex Head Bolts, Square Head Bolts, Security Locknuts, and Washers:
1. Are in accordance with AREMA Specifications.
2. Hex Or Square Head Bolts For Use In Bonded Joints: ASTM A325.
H. Metal Components
1. Corrosion-resistant and consistent with strength and hardness requirements
2. Not brittle, and able to withstand handling at minus 29 degrees C.
3. Sufficiently ductile to withstand installation and maintenance activities. For iron castings use ductile iron.
I. Elastic spring clips: right hand mounted, and considered part of the insulated switch plate or direct fixation fasteners.
J. Direct Fixation Special Trackwork Switch Fasteners
1. In accordance with Section 34 11 36.13, Direct Fixation Fasteners.
2. Attached with special trackwork direct fixation fasteners as provided by L.B Foster Company, Atlanta, GA, or other accepted design. Alternative design proposals shall have a proven 3-year successful service history.
a. Ensure direct fixation fasteners for single rail fasteners have two anchor bolts in the first and third quadrants as shown on the Contract Drawings.
3. Direct Fixation Special Trackwork Anchor Bolts and Other Threaded Elements:
a. Threaded elements: High strength steel conforming to ASTM A325, compatible with anchor inserts. Thread length may vary from that specified for structural bolts. Anchor bolts shall be fully threaded into inserts with minimum interference.
b. Anchor Bolts: 7/8-inch diameter, 9 UNC, Class 2A thread and capable of providing a minimum of 1-1/2 inch of insert thread engagement with 1/2 inch of vertical shims under the rail fastener.
c. Threaded elements in the fastener: Include a positive means of preventing the loosening of the element due to in-service vibrations.
d. Furnish threaded element installation data for the use by others. Include, at the least, data on the bolt torque range in foot-pounds. For the torque range provide the minimum tension as specified by the AISC - Steel Construction Manual.
e. Bolts: Coated with a water-resistant coating as thread protection against rusting prior to shipment.
f. Washers: 7/8-inch diameter, zinc-plated in accordance with ASTM B633, Type III, SC2.
1) Lock: ASME B18.21.1, Type 302, extra duty.
2) Circular: ASME B18.22.1, Type B, regular.
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4. Direct Fixation Special Trackwork Anchor Inserts
a. Female threaded anchor inserts with 7/8-inch anchor bolts: Used to secure the rail fastener to the concrete trackbed.
b. High strength steel C-1045 compatible to ASTM A325, with a 7/8-inch diameter, 9 UNC, Class 2B thread fit.
c. Furnished With an Installed Threaded Plug:
1) Metal or plastic material
2) Precludes the entrapment of moisture, concrete, or other foreign materials during transport, handling, and installing.
3) Able to be easily removed by using a socket or other common device.
4) Capable of reinsertion, and if reinserted, still preclude concrete and other materials from entry.
d. Coated With Epoxy Resin Insulating Coating or Approved Equivalent
1) 100 percent dry powder epoxy resin such as:
a) Scotch Kote Fusion Bonded Epoxy No. 323, manufactured by the Minnesota Mining and Manufacturing Company, (3M).
b) Corvel Epoxy ECB-1363A, manufactured by the Polymer Corporation, or approved equivalent.
2) Applied in accordance with the manufacturer's recommendations and the following requirements:
a) No thinner than 10 mils or thicker than 20 mils when tested by a magnetic mil gauge at not less than two areas of the insert. Epoxy coating having runs, sags, or chips will not be accepted.
b) Hardness: No less than 85 nor more than 90 Shore D, in accordance with ASTM D2240.
3) Tested by the epoxy coating applicator to ensure the absence of pinholes and breaks
a) Place Insert in a weak electrolytic solution.
b) Apply a 100 Vdc electrical current between the electrolyte and the insert;
c) Acceptance: No circuit closes when the insert is immersed in the electrolytic solution.
d) Determine the frequency of testing in accordance with a sequential statistical quality control plan developed by the epoxy coating applicator.
e) Verify the average defective rate does not exceed 2 percent and the maximum defective rate not exceed 5
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percent. Demonstrate these defective rates at a 90 percent degree of confidence.
e. Equipped with a feature to prevent rotation of the insert after the concrete has reached its design strength.
f. Length: 4-1/2 inches to 5-1/2 inches.
g. Installed position: top of the anchor insert flat and parallel to the direct fixation fastener base with a minimum of 1/8-inch bearing area surrounding the anchor bolt hole.
h. Engaging Threaded Length: 2 inches, minimum.
i. Anchor Insert Testing: Comply with Section 34 11 36.13, Article 2.02E.
2.04 FROGS
A. Five different types of No 10 Turnout and Crossing (Diamond) Frogs will be required as follows:
1. Turnout Frog – Solid manganese boltless frog, 115 RE contoured head with welded rail steel toe and heel frog arms; flange bearing design as shown on the Contract Drawings.
2. Turnout Frog in Double Crossover – Solid manganese boltless frog, 115 RE contoured head with welded rail steel toe and heel frog arms; flange bearing design with extended guard rail arm in the double crossover diamond area as shown on the Contract Drawings.
3. Turnout Movable Point Frog – manganese movable point frog, 115 RE contoured head point with welded 115 RE wing rails for frog toe and heel arms as shown on the Contract Drawings.
a. Movable point frogs shall conform to the applicable requirements of both the AREMA Portfolio and Specifications for Special Trackwork and the AREMA C&S Manual.
4. Double Crossover Center or Middle Frog - Solid manganese boltless frog, 115 RE contoured head with welded rail steel toe and frog arms; flange bearing design and fully guarded with bolted adjacent rails as shown on the Contract Drawings.
5. Double Crossover End Frog - Solid manganese boltless frog, 115 RE contoured head with welded rail steel toe and frog arms; flange bearing design and fully guarded with bolted adjacent rails as shown on the Contract Drawings.
B. Frogs shall be designed as shown on the Contract Drawings and in accordance with AREMA standards for solid manganese castings for frogs with the exception frogs shall be flange bearing and internal support ribs for flangeway floor shall be provided.
C. Castings
1. Castings shall be depth hardened by explosive 3 shot impacts to a Brinell Hardness range of 365BHN.
2. Castings shall have the special stainless steel interface welding to add the extended rail steel toe and heel arms.
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3. Castings at wheel running surfaces shall be contoured to match the 115RE rail head crown radii.
4. Casting material shall be manganese steel in accordance with AREMA standards.
5. The overall stated length of movable point frog, the toe and heel lengths shown on the Contract Drawings are subject to change to suit the supplier’s specific design for movable point frog.
D. Welded Installation – all special trackwork rail connections, with the exception of insulated joints, shall be Thermite welded in accordance with the Contract Documents.
E. Special Trackwork Direct Fixation Fasteners
1. Special trackwork direct fixation fasteners shall be per supplier’s standards compatible for direct fixation installation for all turnout and crossing diamond components, except the movable point frog.
2. Special trackwork fasteners at the movable point frogs may be impacted by the design of base plates required in the main design of the frog component.
a. The movable point frog by design has three separate rails with the middle rail to function as a movable point. In such a design, integral base plates are included for completion of the frog assembly.
b. These integral base plates may now act as substitute fasteners to the normal direct fixation fastener and as such the Contractor shall detail custom a rail fastening system that fully anchors the frog to the concrete plinths while providing the resilient stiffness, electrical isolation and acoustical isolation similar to the special trackwork fasteners.
c. Or the frog integral base plates may be attached or seated to the normal direct fixation fastener simplifying the fastener requirements, but impacting the plinth height standard requirements due to a thicker combined two fastener base heights. The plinth heights under the frog fastener plate arrangement would have to be reduced and a special plinth sized to accommodate and outline this movable point frog fastener requirement.
2.05 FROG GUARD RAILS
A. Manufactured in accordance with the Contract Drawings.
B. 115 RE Section, machined and drilled to guard rail lengths as shown on the Contract Drawings.
C. Furnished with the accessories as indicated on the Contract Drawings.
1. Separator Blocks: malleable or ductile iron.
D. Flangeway
1. 1-3/4 inches, fully adjustable to increments of 1/8 inch shims.
2. Width: 1-3/8 inches to 1-3/4 inches, when used with unworn rails.
3. End block and separator blocks: Allow adjustment of the flangeway width.
E. Frog Guard Rail Bolt
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1. High strength, conforming to the requirements of ASTM A325, ASTM A490 or Grade 8, and class 2A and 2B thread fit.
2. Thread length may vary as required for the specified structural bolts.
3. Use a steel spring washer or equivalent spring device as positive means of preventing the loosening of the element due to in-service vibrations.
F. Fasteners: Designed as indicated in the Contract Drawings.
2.06 RAIL FASTENER ASSEMBLIES
A. Rail Clips
1. Boltless, threadless, elastic design,
2. Permit removal of the rail, switch or frog without the removal of plate’s anchor bolt assembly.
3. Elastic Clips: Section 34 11 36.13, Direct Fixation Fasteners.
2.07 TRACK JOINTS
A. Thermite welded and bonded insulated as indicated on the Contract Drawings.
B. Bond insulated joints in accordance with Section 34 11 19, Track Rail Joints.
2.08 SPECIAL TRACKWORK TURNOUTS
A. As indicated on the Contract Drawings including materials necessary to provide a complete installation and the required turnout spare as specified herein.
B. Furnish at least the following materials in accordance with the bill of materials on the `drawings for turnouts and crossovers:
1. Switch Lubricant
a. Dry graphite, insulating film-type such as Dixon 500, Whitmore Easy Switch, Superior Graphite Co., or an approved equal.
PART 3 - EXECUTION
3.01 RAIL PRECURVING
A. Perform precurving of rail to conventional railroad industry frog and switch shop procedures in accordance with the track centerline radii shown on the Contract Drawings and approved Shop Drawings. Precurve rail such that after curving the base of rail lies level or flat when positioned on the switch or tie plate. Do not use the fastening to draw the rail base down.
3.02 RAIL CUTTING, DRILLING, AND BEVELING
A. Cut rails square and clean by means of rail saws or abrasive cutting wheels in accordance with AREMA Manual Chapter 4, Part 2 Specifications.
B. Where required, drill rail ends for 36-inch, 6-hole insulated joint bars as shown on approved Shop Drawings and in accordance with the AREMA Manual chapter 4, Part 1. Grind drilled bolt holes to remove sharp edges.
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3.03 FROG DEPTH HARDENING
A. Explosive depth hardened or otherwise treated castings accordance with the AREMA Specifications, Article M2.7, except attain a minimum Brinell hardness of 370. After the castings are hardened, employ an approved testing agency to inspect each casting as follows:
1. Visually inspect or penetration test for cracks, flaws, or porosity.
2. Test hardness in accordance with ASTM E10.
B. On Shop Drawings specify the general procedures to be used in the depth hardening process, the portions of each frog that are to be depth hardened, and the Brinell hardness pattern that the Contractor normally achieves with such procedures.
C. Submit reports of the tests and inspections to the Resident Engineer for review including repaired defective casting damage found in this inspection as specified in Article 3.04, herein. Reharden castings rejected for lack of hardness at no additional cost. Defects detected in the immediate wheel running surfaces of the castings will be rejected and not be repaired. Replace non-repairable castings at no additional cost.
D. Repair defects in the castings in accordance with the AREMA Specifications Article M2.6, as modified herein. Repair defects only by shielding manual arc welding or semi- automatic arc welding, in accordance with AWS D1.1. Use only manganese filler to repair defective areas.
E. After weld repairs, employ an independent testing agency procured by the Contractor to re-inspect the repaired areas of the castings in accordance with ASTM E94 and determine the acceptance of the castings.
F. The tolerance for Brinell hardness is minus 10 Brinell points. The maximum hardness is unlimited, but subject to metallurgical steel structure detriment to the product.
3.04 SHOP ASSEMBLY AND INSPECTION
A. For special trackwork component inspection notify the Resident Engineer a minimum of four calendar weeks in advance of the proposed scheduled shop inspection dates of the completed, assembled with match marked identification of the special trackwork component.
B. Confirm the inspection date one week in advance informing that each assembly has been checked and confirmed complete for inspection by the fabricator’s Quality Control personnel and submit a documented Check List informing on the acceptable checks and the corrective actions undertaken on items found requiring corrections.
C. Shop Assembly
1. Completely assemble each turnout and the complete double crossover diamond crossing arrangement with special trackwork fasteners fully secured in place.
2. Mount each special trackwork component (separate turnouts and the complete double crossover) on a uniform plane throughout the length to allow inspection measurements.
3. Place special trackwork fasteners at the positions shown on the approved Shop Drawings developed from the Contract Drawings. Paint match marks on the rail base to indicate design location of the fasteners for easy installation duplication in the field.
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4. Undertake complete installation of bonded (glued) insulated joints within the closure rails as designated on the approved Shop Drawings and in accordance with supplier of insulated joint instructions.
D. Inspection
1. With a complete assembly undertake painting of match markings of the components parts and the joint numbering system. Identification markings for each different assembly shall be in a different color. Part identification markings shall be on the web of the rail at both ends of the part. Joint identification numbers shall be on the head of each rail at each joint. The only remaining numbering shall be assembly identification numbers, no temporary in-shop fabrication identification shall be left on any of the components.
2. During the inspection include in the shop assembly manual switch stand, to duplicate the action of the switch machine to be used in final installation, for testing of the switch point throws and the movable frog point throw.
3. The switch machine action shall confirm the switch throw distance at the first switch rod; the ease of undertaking the throw action and if difficult a measurement of force to undertake the throw; the nestling of the switch points in each throw direction to be tucked under the undercut stock rail with 75 percent contact and maximum point rail to stock rail gaps of 1/16 inch wide for gap distances under 2 feet long; the stops shall bear against the stock rails in both fully thrown positions and a final check shall be at the separation of heads with a proper flange width of 1-3/4 inches minimum.
4. The switch stand action shall confirm the point of movable frog throw distance as shown on the Shop Drawings; the ease of undertaking the throw action and if difficult a measurement of force to undertake the throw; the nestling of the movable point frog in each throw direction to be tucked under the undercut wing rail with full contact and the allowance of a 1/32-inch wide gap; if stops are provided, the stops shall bear against the wing rails in both fully thrown positions and a final check shall provide a proper flangeway width of 1-3/4 inches minimum.
E. To facilitate inspection provide the Resident Engineer with inspection equipment as straight edges; flangeway templates; track gauge measurement instrument; chalk line; and calipers with steel rule and a surveyors 100 foot steel measuring tape.
F. Resident Engineer to note approved variations from the Shop Drawing dimensions on a set of “Marked Shop Drawings” to be used as installation drawings during construction.
G. After inspection and testing is completed and approved by the Resident Engineer, disassemble the components to the degree that satisfactory loading, transport, and unloading may take place with no subsequent damage. Palletize the fasteners per special trackwork component and match mark with the identical component paint color. Package loose components as clips and bolts and match mark with the identical component paint color in long lasting weatherproof containers.
H. Spare part components shall be inspected at the same time as the main component. Position spare part components adjacent to the main component for inspection comparison. Spare parts shall be labeled as “Spare Parts” in the identical paint marking color identifying the turnout identification; component and stating the Contract No; at each end of the component.
END OF SECTION
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