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No. 10 Double Crossover Track for Vienna Station K08

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No. 10 Double Crossover Track for Vienna Station K08 SPECIFICATION NUMBER REVISION EFFECTIVE DATE PAGE SPN – 0024 K08 1 1/8/2013 Page 1 of 21 Washington Metropolitan Area Transit Authority 600 5th Street, NW Washington, DC 20001 RFP FQ13036/FRV Part III – Section 1 TECHNICAL SPECIFICATIONS No. 10 Double Crossover Track For Vienna Station K08 Table of Contents 1.0 SCOPE........................................................................................................................................................ 3 2.0 APPLICABLE DOCUMENTS ......................................................................................................................... 3 3.0 TECHNICAL SPECIFICATIONS ...................................................................................................................... 3 3.1 CONTRACTOR’S RESPONSIBILITY................................................................................................... 3 3.2 MATERIALS .................................................................................................................................... 4 4.0 INSPECTION AND ACCEPTANCE TESTING ................................................................................................. 15 4.1 AUTHORITY NOTIFICATION ................................................................................................................ 15 4.2 TESTING LABORATORY: ..................................................................................................................... 15 4.3 TESTING EQUIPMENT: ...................................................................................................................... 15 4.4 DOCUMENTATION: .......................................................................................................................... 16 4.5 QUALITY ASSURANCE/CONTROL: ................................................................................................ 16 4.6 QUALITY CONTROL INSPECTION: ........................................................................................................ 17 4.7 REFERENCE SPECIFICATIONS: SEE SECTION 9.1 .................................................................................... 18 4.8 SHOP DRAWINGS AND SUBMITTALS ........................................................................................... 18 4.9 PACKAGING: ................................................................................................................................ 19 5.0 SAFETY CERTIFICATION............................................................................................................................ 20 6.0 WARRANTY ............................................................................................................................................. 20 7.0 TRAINING ................................................................................................................................................ 20 8.0 DELIVERY SCHEDULE................................................................................................................................ 20 9.0 APPENDICES ............................................................................................................................................ 21 9.1 REFERENCE DOCUMENTS AND SPECIFICATIONS ..................................................................................... 21 9.2 CONTRACT DRAWINGS ...................................................................................................................... 21 SPN- 0024 K08 No. 10 K08 Turnout Yards Rev. 1 - 1/8/2013 Page 2 of 21 1.0 Scope 1.1 The Washington Metropolitan Area Transit Authority needs to purchase a No. 10 double crossover track (herein referred to as “Special Trackwork”) for the Vienna Station Interlocking. Total replacement is required in order to restore the WMATA standard layout and alignment and improve service and reliability. The existing diamond was installed in 1995 and the turnouts in 2004. These specs provide for the manufacturing, testing, shop assembly, inspecting, packaging, and shipping of Special Trackwork. 1.2 Drawings for the Special Trackwork are provided in Specifications Section 9.2 Contract Drawings (Herein referred to as the ‘Contract Drawings’.) 2.0 Applicable Documents 2.1 American Society for Testing & Materials (ASTM) A36, E329, D395, D412, F436, D471, A490, D518, A536, A563, D573, D1149, D1229, D2240; IFI-100, IFI-101, AWS D1.1., AWPA Standards C6 and M3, ISO 9001, and AAR Signal Manual. Also, the AREMA Manual of Railway Engineering and the AREMA Portfolio of Special Trackwork Plans (herein collectively referred to as AREMA or AREMA requirements). 3.0 Technical Specifications 3.1 CONTRACTOR’S RESPONSIBILITY 3.1.1 All materials and equipment required for this procurement shall be the responsibility of the Contractor. 3.1.2 The work specified in this Section consists of manufacturing, testing, shop assembly, inspecting, packaging, and shipping of Special Trackwork turnout/crossover materials. 3.1.3 Furnish Ballasted and Direct Fixation track turnouts and crossovers as shown in the the Contract Drawings. SPN- 0024 K08 No. 10 K08 Turnout Yards Rev. 1 - 1/8/2013 Page 3 of 21 3.1.4 The fastening system to be used for fixing rails to plates shall be the Pandrol system utilizing the left hand Pandrol “e” 2056 clip or APPROVED equal. 3.2 MATERIALS 3.2.1 Special Trackwork materials, including oval-neck track bolts of one-inch nominal diameter, nuts and spring washers, and Special Trackwork assemblies: Provide in accordance with AREMA as modified and as shown in the Contract Drawings. 3.2.2 Rail, switches, frogs and other track material: Provide in accordance with AREMA dimensional requirements for 115 RE rail section or as shown in the Contract Drawings. 3.2.3 Heel ends of switch rails, and ends of stock, closure and connecting rails beveled in accordance with AREMA requirements. 3.2.4 Cut at rail ends in accordance with AREMA requirements except that tolerance to be taken up in the rail base. 3.2.5 Drill rail ends to receive 36-inch, six-hole joint bars in accordance with AREMA and as shown in the Contract Drawings. Standard joints shall be drilled to allow butting of rail ends. Insulated joints shall be drilled to allow for a 1/4 - inch end post. Drill holes in accordance with joint manufacturer’s instructions, plus or minus 1/32-inch. 3.2.6 All rail shall be in accordance with AREMA and as shown in the Contract Drawings. 3.2.7 Guard rails: 132 RE section. 3.2.7.1 Drill and ream holes with edges beveled. 3.2.7.2 All joints required for installation shall be new material. 3.2.8 Supply all ties in accordance with Section 3.2.25, Timber Ties 3.2.9 STOCK RAILS, CLOSURE RAILS AND CONNECTING RAILS 3.2.9.1 Length: As shown in Contract Drawings plus or minus 1/8 inch. 3.2.9.2 All rail ends drilled as shown in Contract Drawings except ends to be connected to CWR. 3.2.9.3 Connecting rail drilled to match frog guard rail drilling. SPN- 0024 K08 No. 10 K08 Turnout Yards Rev. 1 - 1/8/2013 Page 4 of 21 3.2.10 Standard Rail 3.2.10.1 Rail Section and Weight shall be new 115 RE rail section, and shall be in conformance with AREMA Recommended Rail Sections, 115 RE Rail Section and Specifications for Steel Rails, 1994 except as otherwise specified. 3.2.10.2 Rail shall be suitable for joining into continuous welded strings using both electric flashbutt and exothermic welding methods. 3.2.10.3 Length as shown in the Contract Drawings. 3.2.10.4 The standard lengths of new rails used for fabrication are either 39, 78 or 80 feet. 3.2.11 High Strength (Head Hardened) Rail. 3.2.11.1 High strength rail shall meet all of the requirements of Standard Rail. 3.2.11.2 High strength rail shall be head hardened. 3.2.11.3 High strength rail shall conform to all requirements for high strength rail specified in AREMA. 3.2.11.4 Rails shall have a Brinell Hardness in the range of 341 to 388. A maximum hardness of 388 BHN may be exceeded provided a fully fine pearlitic structure is maintained. 3.2.11.5 Minimum tensile strength: 140,000 psi. 3.2.11.6 Minimum yield strength: 95,000 psi 3.2.12 FROGS 3.2.12.1 Railbound manganese steel construction as shown in the Contract Drawings. 3.2.12.2 Frog casting 3.2.12.2.1 Depress heel of manganese frog casting in accordance with AREMA and as indicated in the Contract Drawings. SPN- 0024 K08 No. 10 K08 Turnout Yards Rev. 1 - 1/8/2013 Page 5 of 21 3.2.12.2.2 Depth-harden impact areas of manganese frog castings. 3.2.12.3 Frog inserts 3.2.12.3.1 Cast inserts of carbon steel in accordance with AREMA Specification M3. 3.2.12.3.2 Provide inserts of one-piece construction. 3.2.12.3.3 Provide inserts having full-face contact conforming to configuration of 115 RE rail. 3.2.12.3.4 Provide available bonding area per inch of length equivalent to that available for bonded standard joints where applicable. Adjust dimensions of bonded inserts to allow for glue and fabric. 3.2.12.4 Ensure the inserts are smooth and straight and do not exceed the following permissible variations as shown in the Contract Drawings: 3.2.12.4.1 Width between rail webs: Plus or minus 1/32-inch. 3.2.12.4.2 Depth of flangeway groove: Plus or minus 1/16-inch. 3.2.12.4.3 Length of insert: Plus or minus 1/8-inch. 3.2.12.4.4 Straightness of all portions of inserts adjacent to rail using 36-inch straightedge: Plus or minus 1/32-inch. 3.2.12.4.5 Finishing height variance of inserts from that required for bonding area: Plus or minus 1/64-inch. 3.2.12.5 Assembly: Prior to delivery, assemble frogs as shown in the Contract Drawings. 3.2.12.5.1 Bonding
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