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
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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.
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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.
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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 adhesive: As manufactured for bonded joint bars by Allegheny Drop Forge Company, Portec, Inc. or APPROVED equal, applied as directed by the manufacturer to all contact surfaces between inserts and rail.
3.2.12.5.2 Secure frog, except for insert, with 1-3/8 inch diameter high -strength bolts in accordance with AREMA
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requirements.
3.2.12.5.3 Assemble inserts with 1-1/8-inch diameter high-strength bolts, ASTM A490, and lock nuts. Position bolt holes in accordance with AREMA Plans 621-89 and 1010-89 and as shown in the Contract Drawings. Bolt holes are 1-3/8 inches in diameter plus or minus 1/32- inch.
3.2.12.5.4 Flat washers: ASTM F436.
3.2.12.5.5 Equip bolts as shown in the Contract Drawings with one beveled or flat headlock washer and one flat or beveled washer to provide square bearing and to permit tightening of nuts by wrench.
3.2.12.5.6 Lock nuts: IFI-100 and IFI-101, ASTM A563, Grade C.
3.2.12.5.7 Tension bolts to between 75 percent and 85 percent of proof load. Ascertain bolt tension by means of torque wrench. Determine desired torque by test similar to that described in IFI-101.
3.2.12.6 FROG GUARD RAILS
3.2.12.6.1 Length: 12'-6"
3.2.12.6.2 Complete with blocks and bolts as shown in the Contract Drawings.
3.2.13 SWITCHES
3.2.13.1 Minimum steel yield strength: 95,000 psi.
3.2.13.2 Switch rails and stock rails: As specified and shown in the Contract Drawings and AREMA Plan 221-62, Detail 5100.
3.2.13.2.1 Switch rails may be thick web or constructed with reinforcing bars.
3.2.13.2.2 Switch rail lengths: as shown in the Contract Drawings or as required for switch panel.
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3.2.13.2.3 Bolts, rivets, fittings and spring washers in accordance with Appendix A of AREMA Portfolio of Special Trackwork Plans.
3.2.13.2.4 Fabricate five bolt heel joint assembly in accordance with AREMA Plan 221-62 and AREMA Specifications for Special Trackwork.
3.2.13.2.5 Fabricate forged steel rail stops in accordance with AREMA requirements.
3.2.13.2.6 Switch inserts with bolts: As specified in AREMA for frog inserts.
3.2.13.2.7 Drill stock rails for ballasted Special Trackwork as shown in the Contract Drawings. Switch heaters will be furnished and installed by others.
3.2.13.2.8 Floating heel blocks for No.10 switch as shown in the Contract Drawings.
3.2.14 SWITCH RODS
3.2.14.1 Switch rods and clips of vertical design, Type MJS, modified as shown in the Contract Drawings.
3.2.14.1.1 Insulated construction.
3.2.14.1.2 Assembled.
3.2.14.2 Test in accordance with the AAR Signal Manual requirements.
3.2.14.3 Length: As shown in the Contract Drawings.
3.2.14.4 Switch rods must be capable of at least one (1) inch plus/minus adjustment after the initial specified throw has been set.
3.2.14.5 Contractor’s Shop Drawings (See Specifications Section 4.8) shall provide the required spread measurement for each switch rod needed to support the specified throw.
3.2.15 RAIL BRACES
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3.2.15.1 Boltless adjustable brace equal to those formerly manufactured by Bethlehem Steel, and as shown in the Contract Drawings, modified to permit installation of one inch diameter electric switch heaters on rail web of turnouts.
3.2.15.2 Shop weld rail brace backing blocks to switch plates.
3.2.15.2.1 Rail brace backing blocks to permit mounting on 3/4-inch thick flat plates. Allow for modification to fit 1/4-inch recessed gauge plates. Ensure that distance from rail base to horizontal bearing surface of backing block is the same in each case to permit use of standardized wedge.
3.2.15.2.2 Clearance between backing block and rail base: Determined by design of selected brace.
3.2.15.2.3 Brace shall use left-hand Pandrol “e”2056 rail clip or APPROVED equal.
3.2.16 PLATES
3.2.16.1 Furnish Special Trackwork units with special plates as shown in the Contract Drawings, fabricated of 3/4-inch thick steel, ASTM A36, in accordance with AREMA requirements.
3.2.16.2 Plates complete with specified rail base backing blocks, riser plates, rail stops and rail clamp blocks welded thereon.
3.2.16.3 Riser plates and rail stops fabricated of ASTM A36 steel as shown in the Contract Drawings and as specified in AREMA requirements.
3.2.16.4 Punch holes in each plate perpendicular to face. Cut clean without torn or ragged edges.
3.2.16.5 Straighten plates cold in press or roller until surface and line requirements are met. The following tolerances are not cumulative.
3.2.16.5.1 Plate thickness: Plus or minus 1/32-inch.
3.2.16.5.2 Middle ordinate: Place plate on horizontal support. Place straightedge or wire string from one end of plate to the other on the concave side. Measure distance between
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plate surface and straightedge or string line. Distance not to exceed 0.001 inch per inch of length with surface upsweep or downsweep uniform.
3.2.16.5.3 Plate thickness of dual rail stops, single rail stops and riser plates: Plus or minus 1/32-inch.
3.2.16.5.4 Straightness of edge of dual rail stops, single rail stops and riser plates parallel and adjacent to base of running rail: Plus or minus 1/32-inch.
3.2.16.5.5 Transverse dimension of dual rail stops: Plus or minus 1/32-inch.
3.2.16.5.6 Tolerances other than those specified: Plus or minus 1/8- inch.
3.2.16.5.7 Spike hole locations for ballasted Special Trackwork: Plus or minus 1/8-inch.
3.2.16.6 Identification of plates:
3.2.16.6.1 Stamp with suitably sized characters not less than 1/2-inch in height, located on top surface and plainly visible when assembled.
3.2.16.6.2 Include Contract Number and identification designation as shown in the Contract Drawings.
3.2.16.7 Fillet weld rail braces, rail stops, riser plates and rail clamps to their respective plates as shown in the Contract Drawings and in accordance with AWS D1.1.
3.2.17 GAUGE PLATES
3.2.17.1 Switch gauge plates as shown in the Contract Drawings and as specified in AREMA requirements for plates.
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3.2.17.2 Insulation shall be a four hole 7-1/2" x 8" x 3/4" epoxy fiberglass splice block fastened to the plate with Huck type compression fasteners. The insulating material shall have a tensile strength of 70 ksi, compressive strength of 100 ksi and a tensile modulus of 3.4 x 106.
3.2.18 NOT USED
3.2.19 RAIL JOINTS
3.2.19.1 Furnish all standard and insulated joints within the turnout as shown in the Contract Drawings.
3.2.19.2 End post will be reinforced epoxy fiberglass or approved equal.
3.2.20 NOT USED GUARD RAIL STOP:
3.2.21 NOT USED MANGANESE HOUSING ASSEMBLY:
3.2.22 NOT USED SEPARATOR BLOCKS:
3.2.23 NOT USED GUARD RAIL JOINTS:
3.2.24 NOT USED ELASTOMER PADS
3.2.25 TIMBER TIES:
3.2.25.1 General Requirements:
3.2.25.1.1 All ties and timbers shall be new.
3.2.25.1.2 Physical requirements in accordance with AREMA, as modified herein.
3.2.25.1.3 Lengths of ties and timbers shall be as shown on the Contract Drawings. Ties and Timbers shall measure 7 inches deep by 9 inches wide in cross section.
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3.2.25.1.4 All ties shall be Oak wood species.
3.2.25.1.5 Sawed top, bottom and sides.
3.2.25.1.6 Free of checks over two inches deep or extending more than eight inches from end of tie.
3.2.25.2 Anti-splitting devices shall be nail plates in accordance with AREMA, as modified herein.
3.2.25.2.1 Nail plates shall be installed by a method or machine that presses them into the end of the tie. Hammer installation of nail plates is not allowed and will be a cause for the rejection of the ties.
3.2.25.2.2 Incise all sides prior to treatment to a depth of 3/4 inch. Thickness of incisor teeth shall not exceed 7/32 inch.
3.2.25.2.3 Free of knots greater than 1/2 inch diameter for areas indicated in AREMA.
3.2.25.3 Individual Requirements:
3.2.25.3.1 Cross ties:
3.2.25.3.1.1.1 Length: Eight feet six inches.
3.2.25.3.1.1.2 Straightness: A cross tie will be considered straight when a line along a side from the middle of one end to the middle of one end to the other end is everywhere more than 2-3/4 inches from the top and bottom of the tie.
3.2.25.3.2 Contact rail ties:
3.2.25.3.2.1.1 Length: Ten feet.
3.2.25.3.2.1.2 Free of knots greater than 1/2 inch diameter in area of contact rail insulator, i.e., 100 through 110 inches from line end.
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3.2.25.3.2.1.3 AREMA Size 5 requirements apply to contact rail insulator area.
3.2.25.3.2.1.4 Straightness: A contact rail tie will be considered straight when a line along the tip from the middle of one end to the middle of the other end is everywhere more than two inches from both sides.
3.2.25.3.3 Timber ties:
3.2.25.3.3.1.1 Timber ties within Special Trackwork, as shown in the Contract Drawings.
3.2.25.3.3.1.2 Length: As shown in the Contract Drawings.
3.2.25.3.3.1.3 Free of knots greater than 1/2 inch diameter for areas indicated in AREMA.
3.2.25.3.3.1.4 Straightness: A contact rail tie will be considered straight when a line along the top from the middle of one end to the middle of the other end is everywhere more than two inches from both sides.
3.2.25.4 Preservative Treatment:
3.2.25.4.1 All timbers shall be bored for screw spikes. The holes shall be treated with copper naphthenate.
3.2.25.4.2 Ties shall be treated in accordance with the requirements of AWPA Standard C6 for Cross Ties and Switch Ties. Conditioning prior to treatment shall be in accordance with Paragraph 3.2, Boulton Drying Process, of the AWPA Standard C6.
3.2.25.4.3 Immediately following conditioning, the ties shall be pressure treated. The minimum quality control requirements shall be in accordance with AWPA Standard M3. The treating company shall furnish a Certificate of Compliance with this standard, and shall certify the
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treatment according to the foregoing Specification.
3.2.25.4.4 Use only tested and approved preservatives.
3.2.25.4.5 Stamp each treated tie to indicate compliance with these specifications.
3.2.25.4.6 Complete AREMA or AWPA forms for treatment of ties.
3.2.26 PREASSEMBLY:
3.2.26.1 Completely assemble, prior to shipment, the turnouts, crossing diamonds, and crossovers in Contractor’s fabrication shop for inspection by the Contractor’s Quality Control (QC) Staff. For turnouts and crossovers, the direct fixation fasteners will be incorporated into the Work.
3.2.26.2 Fully bolt and assemble rail joints for all turnouts. For inspection, use temporary joint bars with “C” clamps for shop assembly. Install 3/16 inch end post shim where insulated joint bars are indicated. Do not apply adhesive during this process.
3.2.26.3 No bracing, wedging, or support blocking will be permitted to hold components to proper gauge and alignment.
3.2.26.4 Variations from the Authority reviewed Contractor Shop Drawings or any contractual documents will constitute noncompliance and will not be accepted for shipment unless or until proper modification is made and reviewed by the Authority.
3.2.26.5 The contractor must provide assistance to the Authority, without charge, the facilities and assistance to examine the work during its progress, and when the product is finished, to satisfy the Authority that the finished product will comply with the Contract Documents. Provide templates and one yard straight edge or longer, as necessary, to check flangeway, rail end drilling, switch rail planning, and other features of the Work usually checked by templates.
3.2.26.6 Present material for inspection in a safe area away from excessive noise and manufacturing activities. Provide labor to facilitate inspection of the top, side and bottom of frogs and switches.
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3.2.26.7 For inspection and review, match-mark rails in appropriate colors, and sequentially number fasteners. Submit the match-marking and numbering system on the Shop Drawings for the QC Staff before match-marking and numbering commences.
3.2.26.8 Provide COTR with record of the Contractor’s completed turnout inspection checklist prior to WMATA inspection.
4.0 Inspection and Acceptance Testing
4.1 AUTHORITY NOTIFICATION
4.1.1 Notify the Authority in writing not less than 14 days in advance of any scheduled tests or inspections. The Authority retains the right to witness testing and inspections. Do not conduct tests or inspections until authorized by the Authority.
4.2 TESTING LABORATORY:
4.2.1 Perform qualification and production quality control tests using either an independent testing laboratory or a qualified manufacturer’s laboratory reviewed by the Authority. If an independent testing laboratory is selected, it shall be a member of the American Council of Independent Laboratories. If a manufacturer’s laboratory is selected, it shall satisfy the requirements of the American Council of Independent Laboratories’ Manual of Practice - Quality Control System - Requirements for A Testing and Inspection Laboratory, and ASTM E329.
4.2.2 The selected laboratory shall use the proper equipment and qualified personnel for the specified tests.
4.3 TESTING EQUIPMENT:
4.3.1 Provide equipment in good operating condition, of adequate capacity and range, and accurately calibrated. Use testing equipment that is in calibration with standards which are certified and traceable to the National Bureau of Standards within one year immediately preceding the test date. Submit copies of calibration certificates with test reports.
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4.4 DOCUMENTATION:
4.4.1 In conjunction with the specified tests, submit the following documents for review to the COTR no later than 30 days after issuance of the Notice to Proceed (NTP):
4.4.1.1 Test report:
4.4.1.1.1 A separate report of test results for each test which includes original data calculations, test procedure references, test equipment identification, test personnel, date of test, specified requirements, actual test results, nonconformance if any, and interpretation of the results. Highlight conformance or deviation in a Report summary.
4.4.1.1.2 Accompany the written test reports with a photographic record of the tests. Include photographs of sufficient clarity to distinguish relevant details as described or referenced in the respective written report.
4.5 QUALITY ASSURANCE/CONTROL:
4.5.1 Quality Assurance Program must be submitted to the Authority as part of the Contractor’s proposal package and must be consistent with ISO 9001. (International Organization for Standardization).
4.5.2 Tolerances: Conform to the AREMA Portfolio of Trackwork Plans - Plan No. 1021-03, Permissible Variations in Completed RBM Steel Frogs; Plan No. 1020- 03, Permissible Variations in Completed Switch Points; the AREMA Specifications for Special Trackwork, Permissible Variations in Dimensions, Fits and Other Physical Attributes , 100-06, Section 7; and the AREMA Specifications for Steel Rails, Section 5, in all aspects unless modified by the Contract Documents and this Specification.
4.5.2.1 Assemble all turnout units and crossover units with plates, clamps, braces and other track material to verify alignment and tolerances as specified. Ballasted Special Trackwork shall be assembled with all ties. After approval by the COTR, match mark all components and package as specified. (See Sections 3.2.27 and 4.1)
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4.5.2.2 The layout rail shall be of section and straightness required by the Specifications, AREMA requirements and within tolerance. The guard rail shall be fully assembled to the layout rail.
4.5.2.3 Contractor quality assurance report shall be provided to WMATA. The report shall be completed and submitted to the COTR for approval prior to shipping any Special Trackwork.
4.5.2.4 After each item of Special Trackwork has been factory assembled and approved by the Contractor, and before special plates have been removed for shipping, all plate locations shall be marked with paint on the rails to facilitate subsequent assembly.
4.5.2.5 Switch point tuck (mating) against the stock rail shall be such that the assembled switch, with minimal bar pressure acting on the switch rail at rod number 1, be such as 25 % or more of the switch point contact length, starting from the tip of the point, shall make positive, firm contact with the ball of the stock rail.
4.5.2.6 Switch point spring back shall be such that the assembled switch, with no pressure acting on the switch rail, the maximum allowable spring back between the switch point and the ball of the stock rail shall be 3/16 inch, measured six inches back from the tip of the point.
4.5.2.7 Test insulated gauge plates and switch rods in accordance with AAR Signal Manual, Part 14.5.3.
4.6 QUALITY CONTROL INSPECTION:
4.6.1 The Contractor and COTR will inspect in accordance with pertinent sections of AREMA, as modified herein.
4.6.2 Acceptance criteria: Failure to meet any pertinent part of AREMA requirements or these specifications constitutes cause for rejection.
4.6.3 Averaging of dimensions, with respect to measurement for size acceptance, is not permitted.
4.6.4 Provide suitable equipment, facilities and assistance required by the COTR to effect inspections.
4.6.5 Inform the COTR when treated wood is ready for inspection.
4.6.6 Do not deliver material until inspected and approved for shipment by the COTR.
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4.6.7 Final inspection and approval of ties will occur as a part of the final inspection of installed ballasted track.
4.7 REFERENCE SPECIFICATIONS: See Section 9.1
4.8 SHOP DRAWINGS AND SUBMITTALS
4.8.1 All drawings and submittals must be provided to the COTR no later than 15 days after issuance of the NTP.
4.8.2 The contractor shall make all working drawings or Shop Drawings that will be required in addition to the furnished drawings; or in addition to other drawings that WMATA may issue in supplementing them. The Shop Drawings shall be delivered to the COTR.
4.8.3 Proposed anti-splitting devices and location in tie.
4.8.4 Proposed manner of which the contractor will mark treated ties to indicate compliance with Specifications. (See Section 3.2.25).
4.8.5 Certificate of Compliance with AWPA Standard M3 for the treatment.
4.8.6 Shop Drawings for Special Trackwork components shall be in CADD and PDF, including the following:
4.8.6.1 Split Switches, including stock rails
4.8.6.2 Insulated switch rods, including clip assemblies
4.8.6.3 Closure rails, turnout rails and connecting rails as shown in the Contract Drawings.
4.8.6.4 Frogs and frog guard rails
4.8.6.5 All special plates for direct fixation Special Trackwork, including details of components
4.8.6.6 Complete layouts and details for turnouts, double crossover, and crossing diamonds
4.8.6.7 NOT USED Manganese housing
4.8.6.8 NOT USED Cast rail stops and housing chairs
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4.8.7 Product Data: The procedure to be used in the depth hardening of frog castings. Submit the following:
4.8.7.1 Certificates of material compliance required by AREMA and this Specification.
4.8.7.2 Test reports of chemical analyses, Brinell hardness, electrical insulation, and other tests required by AREMA and this Specification.
4.8.7.3 Frog depth hardening results.
4.8.8 A certified copy of reports on the analyses and tests required by referenced ASTM specifications.
4.9 PACKAGING:
4.9.1 The turnouts shall be packaged as follows:
4.9.1.1 One switch panel, extending from the beginning of the turnout unit ahead of the point of switch.
4.9.1.2 The remainder of the turnout as follows:
4.9.1.2.1 Frog with associated plates and hardware.
4.9.1.2.2 Guard rails.
4.9.1.2.3 Closure rails and turnout rails and connecting rails.
4.9.2 Identification Numbers:
4.9.2.1 As shown in the Contract Drawings, each turnout has an identification number. This number shall be stamped on a metal tag and the tag affixed to each panel and separate component bundle.
4.9.2.2 Tags shall be made of corrosive-resistant metal such as anodized aluminum or brass. Fastening nails shall be of the same material as the tags. Numbers shall be stamped in characters 2 inch minimum in height. Tags shall be a minimum of .050 inches thick, 1-1/4 inches wide and two inches long.
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4.9.3 NOT USED Single Crossover packaged as follows:
4.9.4 Double Crossovers packaged as follows:
4.9.4.1 Four turnouts per one double crossover as shown in the Contract Drawings.
4.9.4.2 One package for each center frog, with plates.
4.9.4.3 One package for each end frog, with plates
4.9.5 Ties 0, 1, 2, 3 and all contact rail ties may be bundled, tagged and shipped separately from the switch panel to facilitate transportation.
4.9.6 Package and label parts and replacement materials in moisture-proof containers suitable for shipment and storage.
4.9.7 Attach copies of shipping list in the package and so that the list is readable from the exterior of the package.
5.0 Safety Certification N/A
6.0 Warranty
6.1.1 There shall be a 1 year warranty on all materials and workmanship. See Special Provision #14 for additional warranty provisions.
7.0 Training N/A
8.0 Delivery Schedule Delivery of the Special Trackwork shall be made to the West Falls Church Rail Yard, 7251 Idylwood Rd., Falls Church, VA 22043. Delivery must be made no later than 45 days after the Notice to Proceed. Hours of delivery shall be between 8:30 a.m. and 2:00 p.m. Monday through Friday only exclusive of legal holidays in the District of Columbia. The contractor shall
SPN- 0024 K08 No. 10 K08 Turnout Yards Rev. 1 - 1/8/2013 Page 20 of 21 notify WMATA of material deliveries 48 hours in advance. Please contact Mr. Kevin Morris at (202) 365-3458 for delivery instructions
Delivery Days Item # Description Turnout Switch Machine Switch From Notice Switch Numbers Hand Location Type To Proceed No. 10 Double 1A LH Left 1 45 Crossover, 40’-6” 1B LH Left 1 1 Track Centers, 3A RH Right 1 Type 1 Ballasted 3B RH Right 1
8.1.1 WMATA will inspect the materials after delivery to determine that they are of proper quantity and that they are in satisfactory condition on arrival. The contractor shall replace or supply any products that have been damaged or do not meet specification requirements at his expense.
9.0 Appendices
9.1 REFERENCE DOCUMENTS AND SPECIFICATIONS
9.1.1 Reference Specifications:
9.1.1.1 Except as modified in the Contract Documents, design, manufacture, test, assemble, inspect, ship Special Trackwork in accordance with the American Railway Engineering and Maintenance-of-Way Association (AREMA), Portfolio of Track work Plans, and the AREMA Manual for Railway Engineering.
9.1.1.2 Except as modified in the Contract Drawings, use rail in the Special Trackwork conforming to the requirements of the AREMA Manual for Railway Engineering, Chapter 4, Part 2, Specifications for Steel Rails, High Strength Rail, and as specified.
9.2 CONTRACT DRAWINGS
9.2.1 Contract Drawings “Special Trackwork Procurement Drawings” are attached separately to this RFP will be provided on separate disc upon request to interested vendors.
9.2.2 DRAWINGS: TW2010-16 TW201O-17 TW2010-18 TW2010-19 TW2010-20 TW2010-21 TW2010-22 TW2010-23
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