DIRECT FIXATION FASTENERS 05675-1
SECTION 05675
DIRECT FIXATION FASTENERS
PART 1: GENERAL
1.01 DESCRIPTION:
A. This Section includes specifications for designing, manufacturing and testing of single-rail direct fixation fasteners (DFF’s), including anchorage assemblies and rail clips, but only a limited number of anchor inserts are included in this procurement. These DFF’s are for replacement of DFF’s on Section C of the Baltimore Metro from approximately 300 feet east of Charles Center Station to the Johns Hopkins tail tracks, not including the double crossover. Each single-rail direct fixation fastener shall support and fasten one running rail only. In this Section, DFF’s are also known as “direct fixation fasteners” or “fasteners”.
1.02 ABBREVIATIONS: AC alternating current C Celsius cm centimeters DC direct current DFF Direct Fixation Fastener F Fahrenheit Hz Hertz kHz Kilohertz kV Kilovolt psi: Pounds per square inch
1.03 SUBMITTALS:
A. Prepare and transmit submittals in accordance with Section 01300, Submittals.
B. Submit the following, not later than 30 days after NTP. Do not begin production of deliverable DFF’s (except samples) until after MTA approval of these submittals.
1. Shop Drawings:
a. Full assembly of a direct fixation fastener with all parts attached, including a table listing all part numbers, names
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and quantities.
b. Fastener body, including notes clarifying material types and locations of elastomer.
c. Rail clips, including notes describing material, type and thickness of plating.
d. Anchor assembly, including anchor insert, anchor bolt, lock washer, and lateral adjustment washer. Add notes describing material types and specifications, and type and thickness of plating.
2. Samples:
a. Submit two sample direct fixation fasteners so that the Administration can confirm that they fit in existing track and existing anchor inserts. Each direct fixation fastener shall consist of one fastener base portion, two rail clips, two lateral adjustment washers (cover plates), two anchor bolts and two lock washers.
b. Submit two anchor inserts and two additional anchor bolts. Confirm that all the threads of the anchor bolts can be fully screwed into the anchor inserts with no added height adjustment shims.
3. Design Qualification Tests:
a. Submit test reports for all tests listed in Article 3.01.D, including test procedures, setups, and results.
4. Calculations: Submit calculations of the lengths of anchor bolt and their unthreaded portions, conforming to the requirements of Article 2.02.E.6.
C. Submit the following, not later than 30 days before shipping of deliverable DFF’s to the MTA.
1. Production Tests: Submit test reports for all Production Tests specified in Article 3.01.E.
2. Installation Torque or Tension: Submit manufacturer’s recommendation for torque or tension for installation of anchor bolts. Submit recommended method for achieving recommended tension such as torque and/or lubrication of nuts.
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3. Shipping and handling procedures for each unit, including methods of handling, packaging, loading, shipping and delivery.
1.04 PRODUCT DELIVERY, STORAGE, AND HANDLING:
A. Pack and ship direct fixation fastener bodies separately from anchor assemblies, rail clips and shims.
B. Direct fixation fastener bodies shall be palletized and banded. Package smaller components by component type in secure and waterproof shipping kegs or boxes and clearly identify as to content and quantity. All identification shall be waterproof.
C. Stacking of fastener bodies for shipping and handling shall be limited so that the load on any direct fixation fastener does not exceed 1,000 pounds.
D. Do not store direct fixation fasteners in a wet location or where the ambient temperature will exceed 120 degrees Fahrenheit. Package direct fixation fasteners to permit outdoor storage in a secured area, off the ground and covered by a tarpaulin secured in place.
E. All fastener materials shall be handled, shipped, and unloaded with special care to avoid damage. Damaged fastener materials noted during final inspection shall be replaced or repaired.
F. Notify the Engineer at least 30 days before scheduled day(s) for shipping of Contract materials to Baltimore, Maryland. Coordinate with the Engineer for locations of each delivery location, and conditions and timing for access to the material storage areas that the materials shall be delivered to. Deliver materials between 7 a.m. and 2 p.m., Monday through Friday, excluding holidays. Do not ship or deliver Contract materials to Baltimore without the approval of the Engineer.
1.05 QUALITY ASSURANCE:
A. Conduct design tests and control tests in accordance with Section 01450, Quality Assurance and Quality Control, and as described herein.
B. Materials and testing shall comply with the following standards and specifications. Unless otherwise specified, the current edition of each standard shall be used.
1. ASTM International (ASTM) formerly known as American Society for Testing and Materials:
A148: Standard Specification for Steel Castings, High Strength, for Structural Purposes
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A536: Standard Specification for Ductile Iron Castings
A668/A668M: Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use
B117: Standard Specification for Operating Salt Spray (Fog) Apparatus
B633: Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel
B695: Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel
B850: Standard Guide for Post-Coating Treatments of Steel for Reducing the Risk of Hydrogen Embrittlement
D395: Standard Test Methods for Rubber Property- Compression Set
D412: Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers-Tension
D429 Standard Specification for Rubber Property – Adhesion to Rigid Substrates
D471: Standard Test Method for Rubber Property- Effect of Liquids
D573: Standard Test Method for Rubber-Deterioration in an Air Oven
D1149: Standard Test Methods for Rubber Deterioration- Cracking in an Ozone Controlled Environment
D1229: Standard Test Method for Rubber Property- Compression Set at Low Temperatures
D2240: Standard Test Method for Rubber Property- Durometer Hardness
D5964: Standard Specification for Rubber IRM 901, IRM 902, and IRM 903 Replacement Oils for ASTM No. 1, ASTM No. 2, ASTM No. 3 Oils, and IRM 905 formerly ASTM No. 5 Oil
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E23 Standard Test Methods for Notched Bar Impact Testing of Metallic Materials
E162 Standard Test Method for Surface Flammability of Materials Using a Radiant Heat Energy Source
F1136/F1136M Standard Specification for Zinc/Aluminum Corrosion Protection Coatings for Fasteners
F1941 Standard Specification for Electrodeposited Coatings on Mechanical Fasteners, Inch and Metric
F2833 Standard Specification for Corrosion Protective Fastener Coatings with Zinc Rich Base Coat and Aluminum Organic/Inorganic Type
F3125/F3125M Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions
2. American Railway Engineering and Maintenance-of-Way Association Manual for Railway Engineering, AREMA Manual, Chapter 4, Part 1, Design of Rail.
PART 2: PRODUCTS
2.01 DESIGN FUNCTIONS: Direct Fixation Fasteners shall provide the following primary functions:
A. Support a single running rail and secure it to the concrete trackbed.
B. Provide vertical, lateral and longitudinal stability, and provide for lateral adjustments.
C. Provide a longitudinal restraint within a specified range.
D. Provide electrical insulation for the running rail, thus isolating it from the concrete trackbed.
E. Mitigate ground-borne vibrations and attenuate noise generated by the moving wheels of the vehicles on the running rails.
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2.02 PHYSICAL REQUIREMENTS – DIRECT FIXATION FASTENERS:
A. Furnish L. B. Foster Company Model F23R4, Progress Rail Model SW24C40T or approved equal, direct fixation fasteners with at least five years proven record of successful performance and that comply with the following requirements. Direct fixation fasteners shall be right-hand and shall provide a 1:40 rail cant as shown on Figure 2.
B. Overall characteristics:
1. The fastener shall consist of as few components as is economically and technically feasible for ease of assembly, disassembly and maintenance. The assembly, as furnished in this contract for replacement fasteners, shall include:
a. One body assembly
b. Two rail clips
c. Two anchor bolts
d. Two lock washers
e. Two lateral adjustment washers.
2. Anchor inserts for spot replacements of damaged inserts shall be furnished. For quantities, see bid form.
3. Vertical spring rate shall comply with test requirements in Article 3.04.C.1 herein.
4. Adjustment Requirements:
a. Lateral adjustment:
(1) Lateral adjustment shall be provided at the anchor bolt assemblies, not at the rail clips or rail clip shoulders.
(2) The total fastener assembly, including each anchor assembly, shall provide a minimum of 1 inch of total lateral adjustment (plus or minus ½ inch to each side of center position) in 1/8-inch increments.
(3) The base element of the fastener body shall include lateral adjustment serrations that are integrally cast or machined into it. The bottom of each vertical serration shall be raised a minimum of 1/8 inches
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above the top of the base element of the fastener body. Serrations shall be machined or cast to a minimum depth of 5/64 inch above the bottom of the serration. At each anchorage location, there shall be a minimum of three interlocking serrations engaged with the lateral adjustment washer in any position of lateral adjustment.
(4) Each anchor assembly shall include a metal lateral adjustment washer with serrations that match the serrations in the base element of the fastener body, and designed so there are a minimum of three interlocking serrations engaged in any position of lateral adjustment and a total of three inches of serrations engagement per fastener. The lateral adjustment washer shall completely cover the slotted opening of the base element of the fastener body in any position of adjustment and form a reasonable seal to prevent the intrusion of dirt, metallic particles, and other material.
5. With the full assembly installed on a concrete base slab that is formed on a horizontal plane and zero percent track grade, the rail seat shall have no slope in the longitudinal direction and 1:40 cant towards the center of track in the lateral direction.
6. The fastener design shall permit the removal and replacement of the rail after removal of the rail clips and lifting the rail vertically until it is completely free of the fastener, without disturbing the horizontal or vertical alignment of the fastener. When the fastener assembly is installed in track it shall not be necessary to raise the rail more than 1.5 inches to remove and install the fastener.
7. The fastener shall be designed to permit installation or replacement of the entire bonded assembly, or any of its non-bonded components, by one man using hand tools.
8. Neither the fastener nor the elastomer shall be bonded to the rail or supporting base.
9. Electrical isolation:
a. The fastener shall provide an electrical leakage distance of not less than 1-1/2 inches, measured from the grounded portion of the fastener to the charged portion by the most direct path that does not pass through an insulating material.
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The length of the most direct path does not include the length of recesses and other geometric configurations, which can collect and hold conductive materials.
b. Elastomer thickness between top metal element and bottom metal element at any point shall be a minimum of 1/4 inch, and designed so the complete assembly complies with the electrical resistance and impedance tests specified in Article 3.04.C.7 herein.
c. No surface cut-outs, gaps, edge voids, or edge cut-outs shall be allowed which could permit an accumulation of dirt, metallic particles, or other material which could provide electrical leakage to ground.
10. The stability of the rail fasteners in any direction shall not be dependent solely upon the strength of the bond of the elastomer to metal. In addition, failure of the elastomer bond shall not result in a complete loss of the fastener’s ability to hold rail gage and alignment.
11. All free surfaces (those which are not controlled by other requirements such as the rail seat) shall be contoured for easy cleaning and to discourage the collection of water and other materials.
C. Fastener Body:
1. The body shall include a metal base and a metal top element with elastomer bonded between them. Bonding shall occur during the vulcanization process.
2. The metal top element of the fasteners shall have raised shoulders on each side of the rail seat which position and secure a 115 RE (5½ inch base width) rail against lateral movement when the spring clips are not installed. Shoulders shall not extend more than 1.5 inches above the base of the rail. The rail shall rest directly on the top element with no pads or shims beneath the rail.
3. The fastener body shall be rectangular in shape. The fastener design shall include turned up metal plate edges designed such that loss of elastomer bond will not result in complete loss of the fastener’s ability to hold line and gage.
4. The underside of the fastener shall be a flat plane, with no projections that will extend into or below height adjustment shims or the concrete trackbed.
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5. In the molding/bonding/vulcanization process, all surfaces of the metal top and base elements (but not including the bottom of the base element, the rail seat area, and other seating areas for the rail hold-down clip and anchorage components) shall be covered with a minimum, including clearances, of 1/16 inch of elastomer. The top of the bottom plate in vicinity of the anchor bolts shall be coated with elastomer as close to the seating area of the bolts as possible. The bottom of the fastener body shall be free of elastomer except that minimal flashing will be acceptable provided that it does not interfere with the retention of proper anchor bolt tension.
6. Anchor bolts shall not pre-compress the elastomer on the fastener body in their installed position.
7. The Contractor’s name or trademark, and model number, shall be molded into a top area of the elastomer, so that is easily visible to track inspectors. Each cavity in a mold shall have a mold identification mark, which is molded into the elastomer. If more than one mold is used, then each cavity in a mold shall have a mold identification mark molded into the elastomer. Each molding cycle which produces one or less fastener from each cavity in a mold is a heat. Consecutive heats from a mold shall be numbered consecutively. The elastomer’s production batch number and the heat number shall be marked on each fastener in a permanent manner. The location and method of marking of identification data shall be shown on the shop drawings. In an orderly manner, each mold/heat/cavity permutation shall be assigned a unique sequential part number, and part numbers shall be assigned to lots. A tabulation of lot, part, batch, mold, heat, and cavity shall be developed as part of the Quality Control Program. An alternate method of marking fasteners to insure traceability will be considered by the Administration if the method is submitted in writing.
8. Except as required to meet other requirements specified herein, elastomer surfaces shall be smooth with a finish and appearance equal to or better than an F-3 designation in accordance with the Rubber Manufacturers Association Handbook.
9. Material Requirements:
a. Metal components:
(1) Metal used in casting the top and bottom elements of the fastener body components shall be made from ductile iron or forged, cast steel, and have corrosion
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resistant properties to withstand the environment described in ASTM B117 consistent with strength and hardness requirements. Metal components shall not be brittle, shall be able to withstand handling at minus 29 degrees C and shall be sufficiently ductile to withstand installation and maintenance activities.
(2) Ductile iron shall be ASTM A536 Grade 65-45-12 or equal.
(3) Cast steel shall be ASTM A148 Grade 80-40 or equal.
(4) Forged steel shall be ASTM A668/A668M Class C or equal.
b. Elastomer:
(1) The elastomer shall be composed of natural rubber, or a blend of natural rubber and neoprene with 51 percent minimum natural rubber content.
(2) The elastomer shall pass all material tests specified in Article 3.02 herein.
D. Rail clips:
1. The rail shall be held to the top element of the fastener body with two resilient and detachable one-piece threadless spring clips, and with one clip on each side of the rail base.
2. Rail clips shall be Pandrol Model e-2055, Progress Rail Part No. U4700 or approved equal.
3. Rail clip design characteristics:
a. Clips shall be “right-handed”, one piece, threadless and detachable.
b. Clips shall be forged from alloy steel bars and heat treated to achieve the minimum spring action holding power as specified below.
c. Holding force shall be generated by spring action, with nominal vertical hold down force (toe load) per clip of 2,750 pounds and a maximum allowable range of between 2,400 and 3,100 pounds.
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d. Clip shall be a proven design and produced by an ISO 9000 certified manufacturer with a minimum of ten years documented installations in track in the United States.
e. Longitudinal rail restraint with both clips installed shall be identical in both longitudinal directions, and in accordance with testing requirements specified in Article 3.04.C.5.
f. Clips shall be capable of being removed without disturbing anchor bolts, and without damaging the top element of the fastener body, and without damaging the elastomer by abrasion, scratching or other means.
4. The rail clips shall be held to the fastener body with clip shoulders that are integrally cast with the top metal element of the fastener body.
5. Rail clips shall be zinc-coated in accordance with one of the following:
a. ASTM F1136/F1136M Zinc/Aluminum Corrosion Protection Coatings for Fasteners, Grade 3.
b. ASTM F2833 Corrosion Protective Fastener Coatings with Zinc Rich Base Coat and Aluminum Organic/Inorganic Type, Grade 1.
c. ASTM B695 Coatings of Zinc Mechanically Deposited on Iron and Steel, Thickness Class 55 or thicker.
E. Anchor assemblies:
1. Each anchor assembly shall include an anchor bolt, a female-type anchor insert for embedment in the concrete track bed, a lock washer, and a serrated lateral adjustment washer (cover plate). However, the Contractor shall only furnish the limited number of anchor inserts listed on the bid form, which the Administration will use to replace existing damaged anchor inserts in track.
2. With each fastener assembly, furnish two anchor assemblies, not including anchor inserts. The Administration will use anchor assemblies to secure the fasteners to existing anchor inserts in a concrete track bed.
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3. The anchor assembly shall provide lateral adjustment design features specified in Article 2.02.B.4 herein.
4. Anchor bolt locations:
a. As shown on Figure 2
b. Anchor bolts shall be located 5 1/4 inches to each side of the centerline of the rail when measured perpendicular to the rail (10 1/2 inch spacing) and 1 3/4 inches from the centerline of the fastener when measured in line with the rail (3 1/2 inch spacing).
5. The anchor insert shall have a maximum allowable length of 5 inches and a minimum allowable length of 3 ½ inch. Length and configuration shall also conformance to the torque and pullout test requirements specified in Article 3.05 herein.
6. Lengths of Anchor Bolt and its Unthreaded Portion:
a. Length of Anchor Bolt Measured from Bearing Surface under the Bolt Head:
(1) With 1/2 inch total thickness of shims under the base of the DFF, the minimum length of the anchor bolt shall provide a minimum of 7/8 inch thread engagement with the threads in the anchor insert.
(2) With no shims under the base of the DFF and the lock washer fully compressed, the maximum length of the anchor bolt shall not extend down to the bottom of the threads in the anchor insert, assuming 2 inches of thread length in both new and existing anchor inserts.
b. Length of Unthreaded Portion of Anchor Bolt Measured from Bearing Surface under the Bolt Head:
(1) With no shims under the base of the DFF and the lock washer fully compressed, the maximum length of the unthreaded portion of anchor bolt shall not extend down to the top of the anchor insert.
(2) The minimum length of the unthreaded portion of anchor bolt shall be 3/8 inch less than the maximum length of the unthreaded portion of anchor bolt, as computed above.
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7. Material Requirements:
a. Anchor Bolts:
(1) Furnish 7/8 inch diameter, hex head structural bolts manufactured from high strength steel conforming to the chemical and mechanical requirements of ASTM F3125/F3125M, “High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions, Grade A325”, and having Class 2A and 2B thread fit. Thread length may vary from that specified for structural bolts.
(2) Anchor bolts shall be zinc-coated in accordance with one of the following:
(a) ASTM F1136/F1136M Zinc/Aluminum Corrosion Protection Coatings for Fasteners, Grade 3.
(b) ASTM F2833 Corrosion Protective Fastener Coatings with Zinc Rich Base Coat and Aluminum Organic/Inorganic Type, Grade 1.
(c) ASTM B695 Coatings of Zinc Mechanically Deposited on Iron and Steel, Class 55.
(d) ASTM B633 Electrodeposited Coatings of Zinc on Iron and Steel, Service Condition 2 or 3. Post heat-treat per ASTM B850, Table 1.
(e) ASTM F1941 Electrodeposited Coatings on Mechanical Fasteners, Inch and Metric, Coating Designation Fe/Zn, Coating Type Zinc, Thickness Designation 5. Post heat- treat per ASTM B850, Table 1.
b. Anchor Inserts:
(1) Anchor inserts shall be ductile iron castings conforming to ASTM A536, Grade 65-45-12 and have a 7/8 inch diameter, 9 UNC Class 2B thread fit.
(2) Include a feature to prevent rotation of the insert
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after the concrete has reached its design strength.
(3) In the installed position, the top of the anchor insert shall provide a flat surface parallel to the rail base with a minimum of 1/8 inch bearing area surrounding the anchor bolt hole.
(4) The anchor insert shall have a minimum engaging threaded length of 2 inches.
(5) Furnish inserts with an installed plug of metal or plastic material to preclude the entrapment of any moisture, concrete, or other foreign materials during transport, handling, and installation. Removal of the plug shall be simple by using a socket or other common device.
(6) Coat inserts with an epoxy resin insulating coating.
(a) Coating material shall be a 100 percent dry powder epoxy resin such as Scotch Kote Fusion Bonded Epoxy Coating No. 203, manufactured by the Minnesota Mining and Manufacturing Company; Corvel Epoxy ECB-1363A, manufactured by the Polymer Corporation; or approved equal.
(b) The coating application shall be in accordance with the coating manufacturer’s recommendations and the following general requirements.
(c) The epoxy coating shall not be thinner than 10 mils nor thicker than 20 mils when tested by a magnetic mil gage at not less than two areas of the insert; epoxy coating having runs, sags, or chips will not be accepted.
(d) When tested in accordance with ASTM D2440, epoxy coatings shall have a hardness of not less than 85 nor more than 90 Shore D. Test the coated insert for pin holes and breaks in a weak electrolytic solution. Apply a 100 volt DC electrical current between the electrolyte and the insert; the coating will be acceptable if the circuit is not closed when
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the insert is immersed in the electrolytic solution. The above tests shall be performed by the epoxy coating applicator at a frequency specified in the sequential statistical quality control plan developed by the epoxy coating applicator and approved by the Engineer. The plan shall ensure that the average defective rate shall not exceed two percent and that the maximum defective rate shall not exceed five percent. These defective rates shall be demonstrated at a 90 percent degree of confidence.
c. Lock Washers:
(1) 7/8 diameter helical spring lock washers shall conform to ANSI/ASME B18.21.1 and shall be heavy helical spring lock washers or extra duty helical spring lock washers.
(2) Galvanize washers using one of the methods specified below. Use a method that will not embrittle steel.
(a) Mechanically deposit a zinc coating in accordance with ASTM B695, Class 40, Class 50, or Class 55. Washers shall be given a stress relief heat treatment prior to cleaning and metal deposition. The temperature and time at temperature shall be 190 +/- 15 degrees Celsius for a minimum of 3 hours, as specified in ASTM B695, Article 6.2.1.
(b) ASTM F1136/F1136M, Zinc/Aluminum Corrosion Protective Coatings for Fasteners
(c) ASTM F2833, Corrosion Protective Fastener Coatings with Zinc Rich Base Coat and Aluminum Organic/Inorganic Type.
d. Serrated Lateral Adjustment Washer (Cover Plate):
(1) Material shall conform to Article 2.02.C.9.a herein.
(2) Galvanize the adjustment washers after fabrication in accordance with ASTM B695, Class 110 or thicker,
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and with a minimum coating thickness of 107 micrometers.
F. (Not Used)
G. Dimensional Requirements:
1. The assembled fasteners shall comply with the dimensional requirements shown on Figure 2 and specified herein.
a. Height of Assembly:
(1) The total thickness of the fastener assembly at the centerline of rail shall be 1 7/8 inches, not including height adjustment shims.
(2) No part of the complete fastener assembly shall project more than 2 ¾ inches above the rail base when the installed in track with no superelevation.
2. Tolerances:
a. Length and width: Plus or minus 1/16 inch
b. Thickness: Plus or minus 0.03 inch
c. Squareness: Plus or minus one degree (in a 360 degree circle)
d. Anchor slots in base element of fastener body:
(1) Spacing of anchor slots: Plus or minus 1/32 inch, in both lateral and longitudinal spacing directions.
(2) Length of anchor slots in base element of fastener body: Plus or minus 1/16 inch.
(3) The width of anchor slots shall not be less than 0.020 inch nor more than 1/16 inch greater than the nominal diameter of the 7/8-inch anchor bolt, with a tolerance of (+/-) 1/32 inch.
e. Diameter of hole in adjustment washer for anchor bolt: Plus zero inches or minus 1/16 inch.
f. Rail seat in top element of fastener body:
(1) Variation of width: Plus or minus 1/16 inch.
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(2) Variation of width between rail shoulders: Plus 1/16 inch, minus zero inch
(3) Variation of height of rail shoulders: Plus or minus 1/32 inch.
(4) Slope tolerance: plus or minus 0.37 percent
(5) Flatness: maximum allowable convexity and concavity of 0.001 inch per inch when measured with a straight edge.
PART 3: EXECUTION
3.01 QUALIFICATION AND PRODUCTION QUALITY TESTING:
A. Perform both qualification and production testing for direct fixation fastener materials and assembly as specified herein. The figures referenced in the test descriptions of this Section are the figures included in this Section.
B. Qualification and production testing shall be performed by an independent testing facility approved by the Administration that is a member of the American Council of Independent Laboratories, or a preapproved equal.
C. Some or all of the qualification and production testing may also be performed at a manufacturer’s testing facility, provided that the facility satisfies the requirements of the American Council of Independent Laboratories “Manual of Practice, Quality Control System – “Requirements for Testing and inspection Laboratory,” and the Administration has approved a submittal from the manufacturer that includes a full description of the testing facility, a record of past testing of the same type run there for previous contracts, a description of testing equipment at the facility and records of their calibration, and qualifications and experience of testing personnel.
D. Qualification Tests:
1. The Administration will accept test results of previously accepted qualification tests instead of performing the qualification tests specified herein, subject to conditions of Section 01450, Article 1.10, and the submittal and approval of a test report including all relevant test methods and results. The previous tests shall have been performed on direct fixation fasteners of the same design as those to be supplied under this Contract, using the same test method, test loadings and in compliance with the acceptance
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criteria.
2. Perform all specified qualification tests, with the approval of the Administration, before production begins.
3. Perform the following tests:
a. Elastomer tests, in accordance with Article 3.02.
b. Fastener body metal components tests, in accordance with Article 3.03.
c. Fastener assembly tests, in accordance with Article 3.04.
d. Anchor assembly tests, in accordance with Article 3.05.
E. Production Tests:
1. Production tests must be performed and submitted to the Administration for approval.
2. Perform production quality control testing in accordance with Section 01450, Article 1.11, as modified herein.
3. All qualification test results of elastomer, anchorage assemblies, and assembled fasteners shall be approved by the Administration before production of fasteners and fastener components.
4. Perform the fastener assembly production tests specified in Article 3.06.
3.02 ELASTOMER TESTS:
A. Each test listed below shall be performed on two specimens. The specimens used for the test shall be certified by the Contractor to have been taken from the batch used for making the fastener and to have been cured in a manner equivalent to the cure used for the fastener. Prior to the testing, all elastomer specimens shall be conditioned for not less than two days at 23 degrees C, plus or minus 2 degrees C, and 50 percent plus or minus 5 percent relative humidity.
B. Hardness Test: The Durometer hardness shall be between 40 and 70 as measured in accordance with ASTM D2240.
C. Tensile Strength and Ultimate Elongation Test: When tested in accordance with ASTM D412, the tensile strength shall be 1,500 psi or greater and the ultimate elongation shall be 350 percent or greater.
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D. Compression Set at High Temperature Test: The elastomer shall be tested for 22 hours at 70 degrees C in accordance with ASTM D395, Method B. The Compression Set shall not exceed 25 percent.
E. Compression Set at Low Temperature Test: The elastomer shall be tested at minus 10 degrees C for 70 hours in accordance with ASTM D1229, the compression set at 30 minutes after release shall not exceed 65 percent.
F. Accelerated Aging Test: The elastomer shall be aged for 70 hours at 70 degrees C, in accordance with ASTM D573. Measure and record the change in hardness and the percentage change of properties from the original tensile strength and ultimate elongation. The percentage of decrease of tensile strength shall not exceed 25 percent; the percentage of decrease of ultimate elongation shall not exceed 25 percent; and the change in hardness, measured on the Durometer A Scale, shall not exceed 10 points.
G. Resistance to Ozone Cracking Test: Test specimens shall be tested in accordance with ASTM D1149 at a temperature of 40 degrees C and at an ozone partial pressure of 0.05 Pascals. The elastomer shall not exhibit any cracking when examined in accordance with ASTM D1149 at the end of a 100-hour exposure.
H. Oil Absorption Test:
1. One test shall be conducted with ASTM No. 3 oil or IRM 903 oil at 23 degrees C for 70 hours, and another test using a different sample shall be conducted with ASTM No. 1 oil or IRM 901 oil at 23 degrees C for 70 hours in accordance with ASTM D471. The volume change for the ASTM No. 1 oil or IRM 901 oil shall not exceed 20 percent; and for the ASTM No. 3 oil or IRM 903 oil, the volume change shall not exceed 100 percent.
2. IRM 901 oil and IRM 903 oil shall conform to ASTM D5964.
I. Adhesion to Metal Test: When tested in accordance with ASTM D429, Method B, the failure must be entirely Type R, (i.e., elastomer tears before bond fails). The metal substrate, preparation, adhesive and bonding process shall be the same as that used for the manufacture of the direct fixation fastener.
J. Flame Spread and Smoke Generation Test: The elastomer shall be tested in accordance with ASTM E162 to determine the Radiant Panel Index. The elastomer shall be tested in accordance with NFPA No. 258, Smoke Generated by Solid Materials Test, in both the flaming and nonflaming modes to determine the Smoke Generation Specific Optical Index, Ds. The
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elastomer shall not exhibit any flaming drippings when tested. No acceptance criteria are specified for the Radiant Panel Index, and the Smoke Generation Specific Optical Index, Ds. These indices shall be reported for information only.
3.03 FASTENER BODY METAL COMPONENTS TESTING:
A. Test in accordance with ASTM E23 at a temperature of 21 degrees C. The fracture energy shall be greater than nine foot-pounds for irons and greater than 15 foot-pounds for steels. The test report shall include all information in Paragraph 12 of ASTM E23. In the event the stated fracture energy requirement cannot be met, the Engineer will review the data and may grant a waiver, depending upon test results.
B. Three specimens shall be tested.
3.04 TESTING OF DIRECT FIXATION RAIL FASTENER ASSEMBLIES:
A. General: Before commencing any tests, the rail fasteners shall be stabilized at a temperature of 23 degrees C, plus or minus 2 degrees C and 50 percent relative humidity for a period of at least four hours or as specified herein. All testing shall be performed when the ambient temperature is 23 degrees C, plus or minus 2C degrees, unless specified otherwise. Preloading of the fastener assembly before running the actual tests is required to stabilize fastener components.
1. Rail Fastener Selection: From an initial lot of sixteen, select eight rail fasteners complete with sixteen rail clip and anchorage assemblies for testing. The other eight rail fasteners, complete with sixteen rail clip and anchorage assemblies, shall be delivered to the Authority and retained if additional follow-up testing is required.
2. Visual Inspection of Rail Fastener Assembly: Examine and measure each rail fastener, rail clip assembly anchor assembly, and test block selected for testing for compliance with these specifications and Contractor’s shop drawings.
3. Test rail fastener identification: Four pairs of rail fasteners selected for testing shall be indelibly marked A through D.
4. Test Assemblies:
a. Except as otherwise specified herein, each test shall be performed on a pair of single rail fasteners assembled with a section of 115-pound RE rail not shorter than one-foot mounted thereon. Before assembly, the metal parts and elastomer shall be wiped clean and dry, and assembled as
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shown on the shop drawings and installation description. Anchor bolts shall be tensioned as specified by the Manufacturer of the rail fastener.
b. Rail fasteners, complete with rail clip assemblies, rail, and anchorage assemblies shall be mounted on a concrete test block.
c. For a two-fastener rail assembly, center and mount a section of rail not shorter than 40 inches on rail fasteners spaced on 30-inch centers; apply the test load at a point midway between centerline of rail fasteners for lateral loading and midway between centerline of rail fasteners and rail for vertical loading.
d. For single fastener rail assembly, center and mount a section of rail not shorter than 12 inches on assembly; apply test loads at points at centerline of rail fastener for lateral and vertical loadings.
B. Performance of Testing. Eight rail fasteners selected in Paragraph 3.04.A.1 shall be subject to the following sequence of tests and as indicated in Figure 1.
1. Rail Fasteners A, B, C, and D: Subject rail fastener pairs A, B, C and D to the Static Tests as specified in Paragraphs 3.04.C.1 through 3.04.C.7.
2. Rail Fastener A: After completion of the static tests, subject rail fastener A to the Vertical and Lateral Repeated Load Test and the Vertical and Lateral Repeated Load Test with One Anchor Bolt Loosened; and then retest rail Fastener A through each of the Static Tests without replacing any components. Upon completion of the Vertical and Lateral Repeated Load Test with One Anchor Bolt Loosened Test, neither disassemble fasteners from rail nor reposition or reinstall or retorque rail clip assemblies before running the Static Tests.
3. Rail Fastener B: After completion of the static tests, subject Rail Fastener B to the Dynamic to Static Stiffness Ratio Test; then the Heat Aging Process; then each of the Static Tests without replacing any component; and then repeat the Dynamic to Static Stiffness Ratio Test.
4. Rail Fastener C: After completion of the static tests, subject Rail Fastener C to Heat Aging Process; then the Uplift Repeated Load
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Test; and then repeat each of the Static Tests without replacing any component.
5. Rail Fastener D: After completion of the static tests, subject rail fastener D to the Push-Pull Test; then repeat each of the Static Tests without replacing any component.
C. Qualification Tests
1. Vertical Load Test (test a two-fastener rail assembly):
a. Test Procedure: A vertical load increasing in increments of 2,000 pounds to a maximum load of 28,000 pounds at a rate not less than 1,000 pounds per minute and not more than 4,000 pounds per minute, shall be applied downward at the center of the rail head at the centerline of the test assembly normal to the rail. Preload the test assembly by vertically loading from 0 to 28,000 pounds 6 times prior to measuring deflections at a rate of 14,000 pounds per minute. For each increment of load, measure the vertical deflection of the rail head at the centerline of each fastener body to the nearest 0.001 inch. Remove the load and measure and record the final position of the rail head. Plot the recorded values for the vertical load versus defection.
b. Test Acceptance Criteria:
(1) The load per fastener versus average deflection curve shall be plotted for loads in the range of 4,000 pounds per fastener to 10,000 pounds per fastener. The average spring rate of the fastener (slope of the load-deflection curve) shall be 135,000 pounds per inch +/- 20% for loads between 4,000 and 10,000 pounds per fastener determined by linear regression. After removal of the maximum load, the fastener shall return to within 0.005 inch of its original position within one minute.
(2) At no time during the test shall any fastener component exhibit any sign of failure by slippage, yielding or fracture. Slippage is defined herein to mean any movement of the fastener components relative to their initial position not attributed to deflection or yielding. The deflection measured at 12,000 pounds per fastener divided by the design thickness of the elastomer component shall be used
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to establish the fastener's compliance with the requirement for a maximum vertical deflection not to exceed 25 percent of the elastomer thickness. The values obtained when this test is repeated on any fastener shall be within 20 percent of the initial test values on that fastener.
2. Vertical Uplift Test
a. Test Loads: Continually apply 2,000 pounds alternated in an upward and downward direction normal to rail head.
b. Point of Test Load Application: Center of rail head along centerline of rail fastener.
c. Rate Load Applied: Constant, between two and four minutes per cycle.
d. Test Procedure
(1) Pre-condition fastener by cycling from zero load to maximum compression, to maximum tension, and back to zero load not fewer than six times.
(2) Run test without pause, after pre-conditioning cycles, for not fewer than 10 complete.
(3) Continually measure and immediately record loads and corresponding deflections to the nearest 0.001- inch on a load-versus-time graph and a deflection- versus-time graph, respectively. Recordings shall be accurate to within two percent of full-scale readings.
(4) Test reports shall include load-deflection, loading time, deflection-time, and calibration recordings.
e. Test Acceptance Criteria:
(1) Ratio of the deflection for the total uplift test to the deflection for the total vertical downward test load: Shall be between plus 105 percent and plus 205 percent of the deflection for a 2,000-pound Downward Vertical Load as determined from the Vertical Load Test.
(2) Stability: No indication of backlash and free play when the vertical load is continuously varied from
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vertical upward to vertical downward. No visual slippage, yields, fractures, or bond failures during testing.
(3) Recovery of fastener to original rail head position: Within 0.005 inch of its pretest position within one minute after application of the 2,000-pound Upward Test Load and again after application of the 2,000- pound Downward Test Load.
3. Lateral Load Test (test a two-fastener rail assembly)
a. Test Load: Apply a 26,000-pound vertical load downward to the rail head. Maintain vertical load, and apply horizontal loads increasing in increments of 2,000 pounds per minute until 16,000 pounds is applied concurrently with 26,000 pounds vertical load.
b. Point of Test Load Applications:
(1) Vertical Load: As shown in Figure 3, vertical, and midway between centerlines of rail fasteners.
(2) Horizontal Load: As shown in Figure 3, horizontal, and midway between centerlines of rail fasteners.
c. Test Procedure
(1) Measure lateral deflections of the rail head at a point 0.625 inch below the top of rail and at the centerline of each rail fastener, to the nearest 0.001 inch, and record average values for lateral loads versus deflection on a graph.
(2) Remove lateral and vertical loads, and measure and record final horizontal position of rail head.
d. Test Acceptance Criteria
(1) Average lateral deflection of rail head while 8,000- pound test load is applied: Not more than 0.15 inch.
(2) Average lateral deflection of rail head while 15,000- pound test load is applied: Not more than 0.37 inch.
(3) Difference between original and final horizontal positions of rail head after test: Not more than
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0.062 inch.
(4) Stability: No visual slippages, yields, fractures, or bond failures during testing.
4. Lateral Restraint Test (test a two-fastener rail assembly)
a. Set Load: Lateral load increasing in increments of 1,000 pounds, from zero to 10,000.
b. Test Load: Lateral load increased in increments of 1,000 pounds from zero to 10,000. Maintain maximum loading for one minute.
c. Point of Load Application: Normal to and at base of rail, midway between centerlines of rail fasteners.
d. Test Procedure: Apply and release set load, set deflection indicators to zero, apply test loads, measure and record, after each increment of loading, deflections at intersection of each rail fastener centerline and rail gauge line to nearest 0.001 inch.
e. Test Acceptance Criteria
(1) Average lateral deflection of rail when fully loaded: Not more than 0.125 inch.
(2) Difference between the original and final positions of gauge line: Not more than 0.062 inch.
(3) Stability: No visual signs of slippage, yields, or fractures during testing.
5. Longitudinal Restraint Test (test a two-fastener assembly)
a. Rail Support: Roller or other low-function support properly elevated to prevent binding the rail to the fasteners.
b. Test Load: Increments of 500 pounds increased to 8,000 pounds (for two fasteners) or until rail deflects 0.6 inch from its original position, whichever occurs first. The rate at which load is applied shall be between 500 and 1,000 pounds per minute.
c. Point of Test Load Application: Longitudinally at centroid of rail at base of rail.
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d. Duration per Increment of Test Load: Until longitudinal deflection of rail ceases.
e. Test Procedure:
(1) Mark rail and rail clip at point common to both.
(2) Measure and record the longitudinal movement of rail for each load to the nearest 0.001 inch.
(3) Remove the longitudinal load at slippage of rail, and measure and record the final position of rail.
(4) Plot the recorded values for longitudinal load per fastener-versus-movement of rail as shown on Figure 4.
f. Test Acceptance Criteria:
(1) The longitudinal load versus deflection curve, when plotted on Figure 4, shall lie entirely within the hatched area defined by Limit A and Limit B.
(2) Difference between initial and final rail position: Not more than 0.125 inch plus slippage between rail clip and rail.
(3) Stability: No visual yields fractures, bond failures, and slippages during and after test, except slippage that may occur between rail clip and rail.
6. High Voltage Withstand Test
a. Effect of High Voltage on Quality of Elastomer
(1) Test Procedure: Place ground plate between rail fastener and test block. Apply a DC potential of a minimum of 10 kV between rail head and ground plate for one minute.
(2) Test Acceptance Criteria: Neither cracks, pinholes, electric flash-over or arcing nor fracture occur.
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7. Electrical Resistance and Impedance Test
a. Test Setup
(1) Each fastener shall be installed separately on a test block, with a 0.25 inch thick steel ground plate dimensioned large enough and situated to extend a minimum of 0.25 inch beyond the periphery of the fastener and located between the fastener and the test block. Both anchor bolts of the fastener shall be grounded to the ground plate.
b. Dry Resistance
(1) Remove moisture, if any, from rail fastener assembly and with one lead of high potential tester connected to rail head and ground lead connected to ground plate, apply 100 volts DC for a minimum of one minute. Use the current value obtained to calculate resistance.
c. Wet Resistance
(1) Perform this test on the same fastener that passed the Dry Resistance Test. Place the fastener in a nonmetallic trough or container that is sized to provide a minimum of two inches of clearance between the sides and bottom of the fastener/ground plate assembly and the sides and bottom of the container.
(2) Prepare test water for placement in the container. Starting with distilled water, add sodium chloride to bring the water resistivity to between 1,000 and 1,500 ohm-cm.
(3) Before pouring water into the container, the temperature of fastener surfaces, test water, and air to between 60 and 80 degrees Fahrenheit. The relative humidity shall be 50 to 70 percent.
(4) Pour test water into the container to a level midway up to the rail web and covering all surfaces of the fastener. Maintain this level of immersion for 10 minutes and then allow water to drain.
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d. Test Acceptance Criteria:
(1) Dry Resistance: Minimum resistance of 10 megohms.
(2) Wet Resistance:
(a) Minimum resistance of 1.0 megohm shall be achieved prior to or at two hours after wetting.
e. Wet Impedance
(1) With rail fastener assembly still wet and with no portion of assembly cooler than 35 degrees C, apply a potential of 50 volts AC peak to peak between rail head and ground plate until reading has stabilized for 30 seconds of measurement for frequencies 1,000, 2,000, 4,000, 6,000, 8,000, and 10,000 hertz.
(2) After reading has stabilized for 30 seconds, measure impedance of each frequency within an accuracy of plus or minus two percent, and record for each frequency.
(3) Impedance for frequencies between 1,000 hertz and 10 kHz shall be not less than 10,000 ohms.
8. Vertical and Lateral Repeated Load Test (test a two-fastener rail assembly with one vertical ram and at least one horizontal ram)
a. Test Procedure
(1) Apply 7,800 pounds laterally and normal to gauge side of rail head 0.625 inch below top of rail, and concurrently apply 24,000 pounds vertically and downward to rail head, both midway between centerlines of rail fasteners; release loads. Apply 5,400 pounds laterally and normal to field side of rail head 0.625 inch below top of a rail, and concurrently apply 16,500 pounds vertically and downward to rail head, both midway between rail fasteners; release loads.
(2) Alternate lateral loads and combine with alternated application and release of vertical load for a total of three million complete cycles. (One cycle consists of
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one applied each of lateral field side load and of gauge side load, and two applications of vertical load).
(3) Regulate frequency in a manner, which will prevent temperature of rail fastener from becoming warmer than 70 degrees C.
(4) Do not retorque threaded elements after completion of 500,000 loading cycles without written consent to do so from the Administration.
b. Test Acceptance Criteria
(1) After Vertical and Lateral Repeated Load Test has been completed, reassemble rail fasteners assembly using only original components subjected to testing.
(2) Allowable visual failure of rail fastener assembly and concrete test block by slippage, yields, or fractures at any time during test: None.
9. Vertical and Lateral Repeated Load Test with One Anchor Bolt Loosened (Test a Two-fastener Rail Assembly)
a. Test Procedure
(1) After Vertical and Lateral Repeated Load Test has been completed, reassemble each rail fastener assembly using only original components subjected to testing.
(2) Apply Vertical and Lateral Repeated Load Test with gauge side anchor bolts for each fastener loosened to a minimum gap of ¼ inch, for 15,000 cycles.
b. Test Acceptance Criteria
(1) Cycles of test load with no visual evidence of failure: not less than 15,000.
(2) Allowable visual failure of rail fastener assembly and concrete test block by slippage, yields, or fractures at any time during test: None.
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10. Dynamic-to-Static Stiffness Ratio Test:
a. Test Procedure: Apply a dynamic vertical (compression) load to the rail head over the centerline of the fully assembled fastener. The load shall be of sinusoidal waveform over a range from 3,000 pounds to 7,000 pounds and shall be applied at a rate of 10 to 20 cycles per second. After a minimum of 1,000 cycles, measure and record the dynamic deflection of the fastener at 3,000 pounds and 7,000 pounds. Immediately after completing the dynamic deflection measurements, but only after the fastener deflection has stabilized, measure the static deflection at compression loads from 3,000 pounds to 7,000 pounds, in 1,000 pound increments and at a rate not exceeding 1,000 pounds per minute. Measure the deflections within an accuracy of 0.001 inch.
b. Calculate the dynamic stiffness by dividing the difference between the recorded maximum and minimum load values (the dynamic load) by the difference between the recorded maximum and minimum deflection (the dynamic deflection). The static stiffness shall be calculated by applying the least- squares linear regression method to the recorded data to obtain a straight line and determining the slope of the static load-deflection curve. The ratio shall not exceed 1.5.
11. Uplift Repeated Load Test (based on testing a two-fastener rail assembly)
a. Test Loads
(1) Apply loads to the rail head so as to produce a vertical downward load of 18,000 pounds and a vertical upward load of 2,000 pounds at a point midway between centerlines of rail fasteners and in a direction normal to the rail.
(2) Longitudinal Load: Starting at 100 pounds static load and increasing increments of 100 pounds up to a maximum load of 600 pounds at interval of not less than one increment per 100 cycles of vertical loading.
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b. Test Procedure
(1) Alternate the upward and downward loads for 1.5 million cycles.
(2) Regulate the frequency to prevent the temperature of components of the test specimen from reaching 70 degrees C.
(3) Do not retorque threaded elements subsequent to 500,000 loading cycles without written approval of the Administration.
(4) During the final 500,000 loading cycles of vertical loading, apply the longitudinal static load at centroid of rail as specified above, maintain maximum load for 30 seconds, and apply the vertical load for 30 seconds, and apply the vertical load at a rate of not less than 25 cycles per minute.
(5) For each load increment, measure the longitudinal deflection of the rail to the nearest 0.001-inch and record.
(6) Remove the longitudinal load and measure and record the final position of the rail. Plot the recorded values for the longitudinal load versus deflections on a graph similar to Figure 4.
c. Test Acceptance Criteria
(1) The rail fastener shall withstand 1.5 million cycles of load application with no evidence of failure.
(2) Upon visual inspection, no component of the rail fastener shall exhibit any evidence of failure by yields, abrasion, or fractures.
(3) The rail shall exhibit no visual evidence of wear or grooving that would contribute to a failure of the rail.
(4) The plot of the loads versus deflections for the longitudinal load portion of the test shall show that movement of the rail was due to the elastic deformation and not slippage of the rail through the rail fastener.
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12. Push-Pull Test
a. Rail Support: Roller or other low-friction support properly elevated to prevent the longitudinal load from binding the rail to fastener.
b. Test Load: Apply a cycling longitudinally applied load to move rail plus or minus 1/8 inch about a fixed point on the testing machine, at a rate not to exceed four hertz.
c. Point of Application: Centroid of the rail.
d. Test Procedure
(1) Push and pull with the test load for 25,000 complete cycles.
(2) Repositioning or retorquing of the rail clip assembly will not be allowed.
e. Test Acceptance Criteria: The rail fastener shall withstand the 25,000 cycles of loading with no evidence of failure. Upon visual examination, no component of the rail fastener shall exhibit any evidence of failure by yielding, abrasion, slippage that may occur between rail clips and rail but not between rail clip and fastener body. The rail shall exhibit no evidence of wear or grooving that would contribute to a failure of the rail.
13. Heat Aging Process:
a. This is a conditioning process for the fasteners that shall be included in the qualification testing sequence, as shown on Figure 1.
b. Setup: Rail Fastener without rail, test block, rail clip assembly, and anchorage assembly.
c. Procedure: Age test fastener in an air oven for 336 hours at 70 degrees C, in accordance with ASTM D573.
3.05 ANCHOR ASSEMBLY TESTS:
A. Qualification Testing: The following tests shall be performed on six production examples of anchor inserts, complete with anchor bolts and washers. Anchor inserts shall be embedded in concrete test blocks measuring at least one foot square by eight inches thick and having
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compressive strength of 4,000 psi. Set insert with its axis at right angles to plan and flush with surface of concrete test block.
1. Torque Test: a. Application: Torque test load of 500 foot-pounds on installed anchor insert.
b. Test Procedure: Screw anchor bolt into female insert tight against lock nut set two inches from end of bolt. Apply torque test load to anchor bolt head.
c. Test Acceptance Criteria: Test shall show no evidence of circular movement by the female insert.
2. Pull-Out Tests:
a. Application: Upward test load of 40,000 pounds on installed anchor insert.
b. Reaction Plate: 8 inches square by ½ inch thick steel with a 3.50 inch diameter hole drilled in the center.
c. Restrained Test:
(1) Place the reaction plate over the anchor bolt installation to be tested.
(2) Set-up the accepted loading system and connect it to the bolt engaged in the anchor insert.
(3) Apply initial up-lift load of 1,000 pounds against the reaction plate. Then, increase load at rate of 1,000 pounds per second until load reaches 40,000 pounds.
d. Unrestrained Test: Remove the reaction plate and apply load of 10,000 pounds uplift load to anchor insert against reaction surface outside of six-inch radius area in which the anchor insert is centered.
e. Test Acceptance Criteria: Tests shall show no evidence of upward movement by the insert.
3.06 PRODUCTION TESTS – FASTENERS:
A. Two fasteners shall be selected from the initial production lot of 50 fasteners. From the balance of fasteners procured under this Contract,
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select another two fasteners from each lot of 2,000 or less fasteners. All of the selected fasteners shall be subjected to the Static Vertical Load Test, the Lateral Restraint Test, the Lateral Load Test, and to 500,000 cycles of the Vertical and Lateral Repeated Load Test. All of the selected fasteners shall then be subjected to the three previous static tests and then in addition subjected to the High Voltage Withstand Test.
B. Configuration or Testing and Acceptance Criteria shall be as specified above, and the value obtained for the slope of the load-deflection curve in the Vertical Load Test shall be within 20 percent of that obtained in the original compliance testing and shall have met the test requirements.
C. Should any fastener fail to meet the test requirements, two additional fasteners from the same production lot shall be tested. In the event either of the two additional fasteners fails, 100 percent of the lot shall be rejected or tested and only those successfully passing all tests shall be incorporated in the finished work. The cost of all such additional testing of any component that does not comply with these specifications shall be at the Contractor’s expense. Contractor shall certify that all direct fixation rail fasteners produced were manufactured in the same manner as the fasteners subjected to the Qualification Testing.
PART 4: MEASUREMENT AND PAYMENT
4.01 DIRECT FIXATION FASTENER:
A. Direct Fixation Fastener will be measured by the unit each. Each unit shall include one fastener body, two rail clips, two lateral adjustment washers (cover plates), two anchor bolts and two lock washers.
B. Direct Fixation Fastener will be paid for at the Contract unit price in the Unit Price Schedule. Payment will include all required design, testing, manufacturing, shipping and delivery at the approved material storage site in Baltimore.
4.02 ANCHOR INSERT:
A. Anchor Insert will be measured by the unit each. Each unit shall include one anchor insert.
B. Anchor Insert will be paid for at the Contract unit price in the Unit Price Schedule. Payment will include all required design, testing, manufacturing, shipping and delivery at the approved material storage site in Baltimore.
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FURNISHED BY CONTRACTOR 16 FASTENERS
FORWARD FOR RETAINED BY ADMINISTRATION TESTING 8 FASTENERS 8 FASTENERS
FASTENERS “A”, “B”, “C”, & “D” (CONDUCT STATIC TESTS 1-7 ON ALL FOUR SETS OF FASTENERS) 1. VERTICAL LOAD TEST 5. LONGITUDINAL RESTRAINT TEST 2. VERTICAL UPLIFT TEST 6. HIGH VOLTAGE WITHSTAND TEST 3. LATERAL LOAD TEST 7 ELECTRICAL RESISTANCE & IMPEDANCE TEST 4. LATERAL RESTRAINT TEST
FASTENER “A” FASTENER “B” FASTENER “C” FASTENER “D”
VERTICAL & DYNAMIC TO LATERAL STATIC HEAT AGING PUSH-PULL TEST REPEATED LOAD STIFFNESS RATIO PROCESS TEST TEST
VERTICAL & LATERIAL REPEATED LOAD HEAT AGING UPLIFT REPEATED REPEAT STATIC TEST WITH ONE PROCESS LOAD TEST TESTS 1-7 ANCHOR BOLT LOOSENED
REPEAT STATIC REPEAT STATIC REPEAT STATIC TESTS 1-7 TESTS 1-7 TESTS 1-7
DYNAMIC TO STATIC STIFFNESS RATIO TEST
FIGURE 1 QUALIFICATION TESTING SEQUENCE FOR DIRECT FIXATION FASTENERS
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FIGURE 2 DIRECT FIXATION FASTENER
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FIGURE 3 LATERAL LOAD TEST ARRANGEMENT
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FIGURE 4 LONGITUDINAL RESTRAINT TEST ACCEPTANCE CRITERIA ENVELOPE
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FIGURE 5 RESTRICTED AREA DURING INSTALLATION AND MAINTENANCE
END OF SECTION
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