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Section 1 (Parts 1 - 4) of This Specification Includes Rail Welding by Electric Flash-Butt Welding Method

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Section 1 (Parts 1 - 4) of This Specification Includes Rail Welding by Electric Flash-Butt Welding Method SECTION 05091 RAIL WELDING NOTE: Section 1 (Parts 1 - 4) of this specification includes rail welding by Electric Flash-Butt Welding method. Section 2 (Parts 5 - 8) of this specification includes rail welding by the Thermite Rail Welding method. SECTION 1 - ELECTRIC FLASH-BUTT WELDING PART 1 - GENERAL 1.01 SECTION INCLUDES A. The work specified in this section shall include the fabrication of continuous welded rail (CWR) strings by electric flash-butt welding, including testing, inspection, and qualification of welding and welders. B. The work specified in this section shall also include movement of rail from the manufacturer to the Contractor’s welding plant, from the welding plant to the welded string storage location and from the storage location to the final placement in track location. 1.02 RELATED SECTIONS A. Section 05651- General Track Construction B. Section 05652 - Ballasted Track Construction C. Section 05653 - Direct Fixation Track Construction D. Section 05656 - Running Rail 1.03 REFERENCES A. American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering, Vol. I, Chapter 4, Specification for Fabrication of Continuous Welded Rail (latest addition). B. ASTM E18 C . ASTM E709 (replaced E109) D . ASTM E94 (replaced E142) E. ASTM E164 F . ASTM E709 (duplicate) G. AWS D1.1 1X0000 (11/07) 05091 - 1 H. USNRC Rules and Regulations, Title 10, Atomic Energy, Part 20. I. ASNT SNT-TC-1A Recommended Guidelines for Qualification and Certification of Non- Destructive Testing Personnel. 1.04 SUBMITTALS A. The Contractor shall submit procedures and documentation in accordance with the Section 01300 and as follows. B. Approval of the following items shall be obtained prior to production welding: 1. Identification of welding plant with internal shear and major items of equipment to be used. 2. Standards of welding machine performance as recommended by the manufacturer. 3. Oscillograph record of each qualification weld showing number and duration of preheat impulses, flashing time, upset current time, platen travel during flashing, and platen travel distance for upset cycle. 4. Report of test results of each qualification weld. 5. Schedule showing string number, length, proposed stockpile location and installation location. C. Production weld approval shall be based on these items: 1. Oscillograph records of production welds. 2. Production welding record. D. Deliver five each taper gauges graduated in hundredths of an inch, with cases, to the Engineer. Taper gauges shall become Authority property. E. Deliver four (4) each 36 inch steel straight edges, as manufactured by L. S. Starrett Company of Athol, Massachusetts, or approved equal, to the Engineer. Straight edges shall become Authority property. 1.05 QUALITY ASSURANCE A. The Contractor shall inspect rail for straightness at the manufacturer’s plant. B. Plant Qualification C. General 1. Using the welding plant, personnel and procedures proposed for production welding, make six qualification welds, three for each type of rail. 2. The qualification welds shall be made in the presence of the Engineer. Pieces of the Authority furnished short rails shall be used for making the qualification welds. 3. Weld tests shall provide sufficient detail to establish capability of the welding apparatus to meet specified welding requirements. D. Qualification W eld Testing: The six qualification welds shall be tested by radiography, hardness testing, metallurgical testing and ultrasonic testing in the following manner: 1. Radiography: a. Radiography shall be conducted in accordance with ASTM E94 using short wave length radiation. The use of nuclear by products for radiography shall be in accordance with USNRC Rules and Regulations, Title 10, Atomic Energy, Part 20. The transportation, handling and storage of hazardous materials used in the examination of welds shall be performed only by or 05091 - 2 1X0000 (01/02) under the supervision of a person of proven experience and ability, operating under a proper license. b. Film shall be capable of producing sharp images, and be free of processing and mechanical defects. High speed, coarse-grained film is prohibited. Fine films shall be used covering head, web and each side of base as shown on Exhibit 05091-A. Identify each film by contract number, rail identification, date of test, name of testing agency and the view. c. Acceptance of the weld shall be based on the weld having full penetration, complete fusion and being free of flaws. A letter shall accompany each film plate bearing information given on the film, certifying compliance with ASTM E94 and stating whether or nor the weld satisfies specified requirements. d. Radiograph plates shall be compared to ultrasonic scans to determine the ability of ultrasonic equipment to identify inclusions or other weld defects. If necessary, compare radiograph plates with ultrasonic scans using the ultrasonic reference blocks. Results of this comparison shall be made in a separate report and include recommended ultrasonic equipment to be used and sensitivity requirements. 2. Hardness testing: a. Hardness testing shall be in accordance with current AREMA “Specification for Fabrication of Continuous W elded Rail” (latest edition) and “Specification for the Quality Assurance of Electric Flash-butt Welding of Rail.” b. The hardness test shall be performed in accordance with ASTM E18, using a 150kgf diamond sphere conical penetrator. Hardness and location shall be recorded. 3. Metallurgical Tests: a. A one foot specimen of each weld shall be sectioned longitudinally through the centerline of the rail. Each specimen shall be etched to enable observation of the hardness pattern, metallurgical properties and the heat affected zone. b. An acceptable weld as determined by the metallurgical test shall meet the following criteria: 1) Steel shall consist of fine-grained pearlite structure with small interlamellar spacing. 2) The hardness pattern in the etched section shall have a uniform distribution. 3) The heat affected zone shall be parallel and fully extended on both sides of the weld. 4) The weld joint shall be planar. 5) Uniform zone of plastic deformation resulting from upset operation shall extend equally on both sides of the weld point. c. An 8x10 black and white photograph and a description of the metallurgical properties including grain structure and distribution shall be submitted. 4. Ultrasonic test, slow bend test and magnetic particle test in accordance with the AREMA Manual (latest edition). 5. All test samples are to be permanently marked for identification and returned to the Engineer at the completion of testing. 1.06 DELIVERY, STORAGE AND HANDLING A. It shall be the Contractor’s responsibility to make all arrangements for shipment and handling of the rail. The Contractor shall: 1. Coordinate unwelded rail stick movement from the manufacturer’s plant to the welding site by rail and truck as necessary. 2. Obtain any required permits from state, regional or local jurisdictions. 3. Make arrangements for loading, unloading and stacking rail sticks. 1X0000 (11/07) 05091 - 3 B. Handle and store rail so that it is not damaged either before or after welding. 1. Stacking of sticks shall be as approved by the Engineer and layers shall be separated by wood lathing. 2. Rail shall be handled in a manner that prevents damage to fasteners, rail and structures. 3. Rail shall not be dropped or dragged on the trackbed. The use of rollers is required. PART 2 - PRODUCTS 2.01 RAIL FOR CONTINUOUS WELDED RAIL A. Rail for the Work shall be furnished by the Contractor in accordance with WMATA Standard Specification Section 05656, Running Rail. PART 3 - EXECUTION 3.01 PREPARATION FOR WELDING A. The welding plant shall be set up on Authority property as approved by the Engineer. B. Rail welding shall be in accordance with the current AREMA Manual “Specification for Fabrication of Continuous Welded Rail” (latest edition), “Specification for the Quality Assurance of Electric Flash-butt Welding of Rail” and as specified herein. C. Rail for installation in this Contract shall be welded in accordance with a string schedule approved by the Engineer. Strings should be not less than 720 feet in length in order to minimize field connections, unless shorter strings are required to satisfy conditions of rail type or installation. Each string shall be of only one rail type; standard or head hardened rail. D. Rails shall be welded using an electric flash butt welding plant equivalent to the Chessie System plant at Russell, KY or Amtrak Plant at New Haven, CT. An equivalent portable plant may be set up within the contract area. E. Rail Inspection Prior to Welding 1. Inspect each rail end prior to welding for deviations from lateral line in either direction and for upsweep, downsweep or droop. 2. Rail with upsweep, downsweep or droop and rail failing to comply with the tolerances shown on Exhibit 05091-B shall be cut back a sufficient distance to achieve the required alignment. Rails shall be cut clean and within 1/32 inch of square by means of rail saws or abrasive cutting discs. 3. Torch cutting of rail is prohibited. Cutting shall be done at no additional cost to the Authority. F. Rail End Preparation for Welding: Immediately prior to welding, all rail ends shall be wire brushed to remove mill scale or other dirt which might hinder the flow of electric current. G. Alignment in Weld Machine: 1. Alignment of the rail in the welding machine shall be done on the head of the rail. 2. Vertical alignment shall provide for a flat running surface within 0.01 inch between the abutting rail ends. 3. Horizontal alignment shall distribute head width differences evenly between each side of the head. No horizontal offset shall exceed 0.03 inch on either side of the head. No horizontal offset shall exceed 0.10 inch on either side of the base of the rail. 05091 - 4 1X0000 (01/02) 3.02 WELDING OF RAILS A.
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