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 MTR-19-XXX-EQ SP-1 DIRECT FIXATION FASTENERS 05675-2 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. MTR-19-XXX-EQ SP-2 DIRECT FIXATION FASTENERS 05675-3 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 MTR-19-XXX-EQ SP-3 DIRECT FIXATION FASTENERS 05675-4 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 MTR-19-XXX-EQ SP-4 DIRECT FIXATION FASTENERS 05675-5 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. MTR-19-XXX-EQ SP-5 DIRECT FIXATION FASTENERS 05675-6 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