SPECIAL SPECIFICATION 4196 Railroad Construction

2004 Specifications CSJ 0271-07-274 SPECIAL SPECIFICATION 4196 Railroad Construction 1. Description. Construct railroad tracks including turnouts and other appurtenances, in accordance with this specification, and with Volume 1, Track, of the 2004 American Railway Engineering and Maintenance-of-Way Association's (AREMA) Manual for Railway Engineering, and as shown on the plans. 2. Materials. A. General. For material not designated as second hand, provide new material conforming to this specification. Material designated as second hand may be either new or second hand. Provide straight and true second hand material, in good condition, and free from excess rust, pits, or wear. Test second hand rail for head wear, corrosion, base wear, sweeps, kinks, cracking, delamination, or any other defect including internal metal defects. Ensure the material meets the appropriate specifications indicated below. Provide new material in an unblemished condition, free from defects, rust, or damage. B. Rail. Provide rail meeting the requirements of AREMA Manual Chapter 4, Rail, for 136 RE with properties including Brinell hardness as noted in Chapter 4, Table 2-2 and Table 2-3. For rail on tangent track and on curves of 3 degrees or less provide new 136 RE standard carbon rail. For rail on curves greater than 3 degrees provide 136 RE head hardened rail. Furnish reports of the chemical and mechanical test results to the Engineer. Excluding rail for industry leads, provide continuously shop welded rail and transport in 400 ft. or longer sections to the project site unless shorter sections are required due to curve length, or fit between switches. Perform shop welding meeting the requirements of AREMA Manual, Chapter 4, Section 2.2, Specifications for Fabrication of Continuous Welded Rail (electric flash butt welds). Use the Thermite welding process to field weld joints between sections. Furnish rail for industry leads in lengths of 39 ft. with 11% shorts, varying by 1 ft. increments from 38 ft. down to 25 ft. in length. Submit to the Engineer five copies of a layout showing proposed rail types, continuous welded rail (CWR) lengths, and field welds for approval prior to track construction. Designate on the track layouts the size of compromise joints necessary at locations where proposed rail joins with existing rail. Field verify the sizes of required compromise joints and submit a detailed list to the Engineer before beginning track construction. 1-10 4196

C. Angle Bars, Tie Plates, Track Bolts, and Rail Anchors. 1. General. Unless noted otherwise in this specification, provide new angle bars, tie plates, and rail anchors. 2. Angle Bars. Provide angle bars matching the 136 RE rail and in accordance with AREMA Manual, Chapter 4, Section 1.2, Joint Bars and Assemblies, for six-hole angle bars, drilled in accordance with the plans. 3. Tie Plates. Provide 8-1/2 in. x 16 in. tie plates, inclined, double shoulder for 6 in. base rail as shown on the plans and in accordance with AREMA Manual, Chapter 5, Part 1. Ensure fabrication and workmanship is in accordance with AREMA Manual, Chapter 5, Part 1, Tie Plates, for hot worked, high carbon steel tie plates. Ensure the manufacturer's identity, rail section, and year rolled is visible on top of the field side of the tie plate. Exercise caution to ensure the cant is directed toward the track centerline when installed. Ensure the track is fully plated. 4. Track Bolts. Provide new track bolts with square nuts for 136 RE rail in accordance with AREMA Manual, Chapter 4, Section 2.9, Specifications for Heat-Treated Carbon-Steel Track Bolts, and Carbon-Steel Nuts, latest revision. Furnish 1 in. x 6 in. track bolts. A 200 lb. Keg is considered to consist of approximately 100 bolts, including one nut on each bolt. 5. Rail Anchors. Provide new or reformed rail anchors for 6 in. base rail per AREMA Manual Chapter 5, Part 7, Rail Anchors. Provide rail anchors of the drive-on type, which may be installed either mechanically or by hand. Install Channel-Loc or improved fair anchors, or an approved equal. D. Ties. 1. General. Provide new cross and switch ties and fabricate them from Douglas Fir, Southern Pine, or Oak timber, out of straight grained timber, with opposite faces parallel, with anti-splitting devices applied at ends, and free from defects materially affecting the strength or durability of the ties, and conforming to AREMA Manual, Chapter 30, Part 3, Section 3.1, Timber Cross Ties, latest revision. 2. Treating and Sizing. Provide seasoned ties and handle according to AREMA Manual Chapter 30, Part 3.5. Treat ties with a 50/50 mixture of creosote and petroleum base with a minimum retention of 8 lb. creosote per cubic foo t of timber per AREMA Manual Chapter 30, Part 3, Sections 3.6, 3.7, 3.8, and 3.9 for applicable timber species. Treat field cuts or drilled holes with a compatible preservative before installing, spiking, or bolting. Fabricate timber switch ties from Oak timber in accordance with AREMA Manual Chapter 30, Part 3, Section 2. Install anti-splitting devices meeting the requirements of AREMA Manual Chapter 30, Part 3, Section 3.1. Ensure timber switch ties are well sawn on each side and cut square at the end to the dimensions specified on the plans. For seating tie plates where ties are not properly sawn to provide a plane top surface, adzing is required before treatment. 2-10 4196

The Department may require, at its option and expense, an independent laboratory inspection of ties before creosote treatment. If ties are found to be acceptable and free of excessive checking, stamp them with an identifying mark that is not obscured by the end plate or s-iron. A secondary inspection will be conducted by the Department at the project site to ensure that no damage occurred to the ties during transportation or handling. During the secondary inspection, the Department will again check each tie for the degree of checking that has occurred. If, in the opinion of the inspector, excessive checking has occurred, the tie(s) will be rejected. 3. Minimum Dimensions. For track except industry leads and under concrete crossing panels, provide timber cross ties that are 7-in. grade, 7 in. x 9 in. in cross section, and 9 ft. 0 in. long, in conformance with AREMA Manual, Chapter 30, Part 3, Section 3.1, Timber Cross Ties. For industry leads, timber cross ties may be 7 in. grade, 7 in. x 9 in. in cross section, and 8 ft. 6 in. long, in conformance with AREMA Manual, Chapter 30, Part 3, Section 3.1, Timber Cross Ties. For ties under concrete crossing panels, provide timber cross ties that are 7-in. grade, 7 in. x 9 in. in cross section, and 10 ft. 0 in. long, in conformance with AREMA Manual, Chapter 30, Part 3, Section 3.1, Timber Cross Ties. Provide switch ties of the dimensions shown on the switch tie layout plans. 4. Shakes. A shake is a separation along the grain, most of which occurs between the rings of annual growth. The maximum allowable shake is one third the width of the tie in length, provided it does not extend nearer than 1 in. to any surface. 5. Splits. A split is a separation of the wood extending from one surface to an opposite or adjacent surface. In unseasoned crossties, the maximum split is 1/8 in. wide or 4 in. long. In a seasoned crosstie, the maximum split is 1/4 in. wide or longer than the width of the face across which it occurs. Install anti-splitting devices on hardwood ties. 6. Slanting Grain. Except in woods with interlocking grain, a slant in grain in excess of 1 in 15 is not permitted. 7. Straightness, Score Marks, and Parallel Sides. A tie is considered straight when a straight line along a side from the middle of one end to the middle of the other end is everywhere more than 2 in. from the top and the bottom of the tie. A tie is not well hewed or sawed when its surfaces are cut into with score-marks more than 1/2 in. deep or when its surfaces are not even. The top and bottom of a tie is considered parallel if any difference in the thickness at the sides or ends does not exceed 1/2 in. 3-10 4196

E. Spikes. Provide new 5/8 in. x 6 in. high carbon steel track spikes in accordance with AREMA Manual, Chapter 5, Part 2, Track Spikes. F. Lock Washers. Provide high power spring lock washers 1/16 in. greater diameter than the bolt furnished by the Contractor. G. Ballast. For railroad ballast material, supply crushed granite stone in conformance with AREMA Manual, Chapter 1, Part 2, Ballast. Provide a gradation conforming to AREMA Number 4. H. Gage rods. For gage rods, provide Racor Non-Insulated Figure 3882-C, or approved equal, complete with lock washer under the nut. Gage rods may be secondhand. I. Turnouts. Provide new turnouts and construct them in accordance with the railroad common standard drawings as noted on the plans. J. Compromise Rail Joints. Provide joints consisting of one left-hand and one right-hand bar, with each end conforming to rail sections and bar punch as shown on the plans. Provide alternately oval and round bolt holes to fit joint bar punch. Joints may be secondhand. Weld compromise joints in continuously welded rail (CWR) installations. K. Grade Crossings. Provide concrete panels for grade crossings conforming to special specifications for concrete panel grade crossings. 3. Construction. A. Clearing, Grading, and Ditching. Perform clearing, grading, excavation, and embankment for the preparation of railroad subgrade in accordance with Item 100, Preparing Right of Way, Item 110, Excavation, and Item 132, Embankment except as modified by this Item. B. Lime Stabilization of Subgrade. Stabilize the subgrade in accordance with Item 260, Lime Treatment (Road Mixed), to the lines, grades, and thickness as shown on the plans. C. Track Construction. Ensure the track construction, laying, and surfacing are supervised by experienced personnel skilled in railroad track construction. 1. Placing Sub-Ballast. Place sub-ballast conforming to and in accordance with Item 247, Flexible Base. Use Type A, Grade 1 flexible base. 2. Ties. Lay ties heart side down and construct the track upon the sub-ballast before the ballast is unloaded and applied. Ties may be delivered and unloaded from railroad cars operating on adjoining tracks, tracks to be built, or by trucks operating over the compacted sub-ballast. Do not allow the truck wheels on the track subgrade except on areas protected by the sub-ballast layer. Lay ties at right angles to the center line of the track. Handle ties with tongs or a tie spacing bar, and never strike them with maul, hammer, or other tool. 4-10 4196

If ties are not sawn correctly, hand adz them so that the tie plates have full bearing on the tie, and the rail has full bearing on the tie plate. Keep adzing on the tie to a minimum. Install switch ties in accordance with the plans. In main line, ladder, and runaround tracks, use 7-in. grade timber ties and space them on 19-1/2 in. centers. In industry spur tracks, use 7-in. grade timber ties and space them on 22 in. centers. 3. Tie Plates. Ensure turnouts and tracks are fully tie plated. To avoid unnecessary spiking, apply tie plates as the rail is laid. Place tie plates on the exact center of the tie and with the entire shoulder in contact with the base of the rail. Exercise caution to ensure that the cant is directed toward the center of the track center line when installed. Ensure the surface of the tie is free of dirt, shavings, or other material when applying the tie plate. 4. Rail. Unload, store, or distribute rails along the roadbed in such a manner as to prevent damage. Do not use rails less than 15 ft. long except for temporary closures. Lay rails and adjust them for optimum laying temperature per procedures outlined in AREMA Manual, Chapter 5, Part 5. Apply rail anchors immediately behind laying of continuous welded rail (CWR). Fully anchor the rail laid each day before competing the day's work. Lay and adjust CWR prior to field welding the joints. Ensure field welded joints have the date, welding crew, and rail temperature placed, using weatherproof paint, on the field side of the rail next to the weld. Furnish the Owner with a record of the welds made, the locations, and the above information. Provide Thermite welds meeting the requirements of AREMA Manual Chapter 4, Part 2, Section 5. Perform field welding by the Thermite welding process using preformed, factory-made molds. Supply a complete description of the Thermite weld procedure including the manufacturer's trade name and field welding process. Before beginning rail welding, provide certification that each welding crew is experienced and qualified in the process. Perform welding under the direct supervision of an experienced, qualified welding foreman or supervisor. In addition, arrange for a manufacturer's representative to observe and approve the process being performed by crews. Cut rails with a saw or chisel, in a square cut perpendicular to the vertical and horizontal line of the rail. Drill holes in blind ends of rail with an approved track drill, align the holes perpendicular to the web of the rail, and ensure the drilled 5-10 4196

holes are the same diameter as the existing holes in the rail. Cutting rails or drilling holes in cut rails by means of acetylene or electric torch is not permitted. Apply rail joints before spiking the track. Attach joint bars to one rail end before the rail ends are abutted in laying. Orient the rail in a vertical position and in approximate alignment when the joint bars are applied by tightening the middle bolts and working towards each end. Use six specified bolts, with specified lock washers, in each joint. Ensure joint angle bars and joint compromise bars accurately fit the rail. A medium blow with a maul to assure contact surfaces are in contact is permitted while the bolts are being tightened to a required tension of 20,000 lb. to 30,000 lb. After raising the track to its final elevation, check the bolts and retighten bolts that do not have the specified tension. Ensure the length of bolts allows a minimum of two threads of the bolts to be exposed beyond the end of each nut. 5. Spiking. Perform spiking with an approved spike maul or spiking machine and exercise caution to prevent striking the rail. Replace rails damaged by spike maul or machines at no expense to the Department. Plug existing spike holes, including holes where spikes will be replaced, with specified tie plugs. Drive the plugs flush with the top of the tie and cut any portion of the plug that remains above the surface flush with the top of the tie. First, spike the right-hand rail going away from the switch points, or the outside rail on curves, in position in its proper relation to the lined end of ties. Then, spike the opposite rail to true gage (4 ft. 8-1/2 in.). On tangent track, and on curves less than 1 degree, 30 minutes, apply one gauge side and one field side rail spike on each tie plate (2 spikes per plate). On curved track ranging from 1 degree 30 minutes to less than 4 degrees, use two gauge side rail base spikes, one field side rail base spike, and one field side hold down spike for a total of 4 spikes per plate. On curved track ranging from 4 degrees to 8 degrees, use two gauge side rail base spikes, one field side rail base spike, one field side hold down spike, and one gauge side hold down spike for a total of 5 spikes per plate. Stagger spikes so that the outside and inside spikes are on opposite sides of the tie. Ensure the inside spikes on both rails are on the same side of the tie. Double spike both the inside and outside rail on curved track having a degree of curvature greater than 10 degrees, 0 minutes on inside of rail. Start and drive spikes vertically with the face of shank in full contact with the base of the rail and drive them so that it is not necessary to straighten them during driving. Using a maul to straighten spikes started crooked is not permitted. Pull spikes started crooked, plug the holes, and re-drive the spikes. Drive spikes so as to 6-10 4196

allow 1/8 in. to 3/16 in. space between the underside of the head of the spikes and the top of the base of the rail. Immediately after completing track surfacing, settle spikes in place with the underside of the head of the spike contacting the top of the base with a minimum of pressure. 6. Gage. Place track on tangent and around curves to true gage (4 ft. 8-1/2in.). Gage track with an all-metal track gage tool. Spike the line side of track well ahead of gaging. Gage track on every third tie. Place the track gage perpendicular to the rails, and ensure contact points are against rail before the spikes are started. Use a bar to hold the gage rail in its proper position against the contact face of gage, and drive the spikes so that their faces are in contact with the rails and so that the gage can be removed without force. Fully box anchor the track every other tie except within 200 ft. of any bolted joint, turnout, or on curves greater than or equal to 3 degrees where it is required to fully box anchor every tie. D. New Turnouts. Furnish and construct new turnouts complete, out of 136 RE rail and in accordance with AREMA Manual, Chapters 4 and 5, these specifications, and as shown on the plans. Install new turnouts complete in place except those noted on the plans to be installed by railroad forces. After turnouts are completely installed (surfaced, lined, and dressed), oil the switches and adjust them so that the points fit properly and the switches throw easily, in accordance with provisions of the AREMA Manual. E. Track Surfacing. 1. Placing Ballast. Install and fully spike ties before unloading the stone ballast. Unload the stone ballast by opening one or more center or side dump cars, allowing the required amount of ballast to flow out as the train is moved along slowly. If ballast cars do not have attached plows, place ties or some other suitable plow, in front of the car wheels to prevent derailments. Derailments are the sole responsibility of the Contractor. Rerail derailed cars or equipment and repair damage to cars, equipment, and track at no expense to the Department. Ensure the track is capable of supporting railroad cars without damaging rail or the subgrade when delivering ballast in railroad cars. Before placing ballast, regrade and compact sub-ballast damaged during ballast hauling or Contractor operations. 2. Surfacing. After distributing ballast evenly across the track cross section, use jacks or tampers with integral jacks, to raise the track. Do not raise the track more than 4 in. at a time. Use either hand held or machine-mounted pneumatic or electric tamping tools. 7-10 4196

Obtain the Owner's approval before using tamping, lining, jacking, and dressing equipment. Place ballast to raise the track to within 4 in. of the final grade and compact. Construct the final lift by jacking the track to the exact elevation and grade as shown on the plans and as provided by grade stakes set at 50 ft. intervals. The initial 4 in. of ballast may be placed by truck or similar equipment, spread, and compacted by rollers or vibratory compactors before placing track material. Thoroughly tamp the ballast from 15 in. inside either rail to the ends of the ties. Leave the tie centers untamped. Set the depth for mechanical tampers below the bottom of the tie to ensure proper tamping. Always use two tamping tools opposite each other on the same tie. Start the tampers from a nearly vertical position and work downward past the bottom of the tie, after which slant the tool inward to force ballast under the tie. Give special attention to tamping of joint ties. Adjust the squeeze pressure on mechanical tampers so equipped, to suit the type of ballast being tamped to ensure that the ballast is tamped throughout portions of the track tie over which the live load is distributed. After bringing track to true surface, elevation and grade, give it a final lining and place it in true alignment. After placing in true alignment, give the ballast section its final shape by means of a ballast regulator equipped with track broom. Resurface the track as needed to meet cross level, profile grade, and alignment criteria after a maximum of three fully loaded trains have traversed the project area. Give special consideration to ensuring proper ballast compaction at turnouts. Ensure tangent track is cross level. The maximum deviation from the established cross level is 1/8 in. Provide superelevation and runoffs on curves in accordance with the typical sections and plans. The maximum deviation from profile grade and horizontal alignment is 1/8 in. in 50 ft. Maintain the inside rail on a curve at the prescribed grade and provide the proper superelevation by raising the outer rail. Obtain approval by the Owner for all work and obtain acceptance by the railroad company before allowing trains to operate over the track. F. Gage Rods. Install gage rods after the track is in its final alignment and is surfaced and dressed. Apply one gage rod between the first two track ties ahead of the turnout. Tighten gage rods until the clip and hooked end of the gage rod is firmly against the base of the rail, leaving the track in true gage. G. Concrete Panel Grade Crossings. Install concrete panel grade crossings in accordance with special specifications for concrete panel grade crossings. H. Relocating Existing Turnouts. Where indicated on the plans, relocate the existing turnouts of size and type shown. Inspect, together with Engineer, the existing turnouts and document the existing condition before performing any work. Remove the turnout together with its ties and other track material, from the existing track in one piece, from the point of the switch to the end of long ties as a minimum, and carefully lift and install 8-10 4196

it in the location shown on the plans. Exercise caution in removing, lifting, handling, and placing the turnout to prevent damage to any of the existing turnout materials. Correct damage caused by or resulting from the Contractor's work to the satisfaction of the Engineer, at no expense to the Department. Replace damaged material resulting from the Contractor's work with new material in accordance with this specification and at no expense to the Department. 4. Measurement. A. Railroad Granite Ballast. Ballast material will be measured by the net ton. The weight will be based on the volume of ballast material computed in place between the top of sub-ballast surface, and the lines, grades, and slopes of the accepted ballast shown on the plans by the method of average end areas. This is a plans quantity measurement Item. The quantity to be paid is the quantity shown in the proposal unless modified by Article 9.2, Plans Quantity Measurement. Additional measurement or calculations will be made if adjustments of quantities are required. No measurement will be made for thickness or width exceeding that shown on the typical section or provided on the plans. B. Railroad Turnouts (Complete In Place). New turnouts will be measured by each turnout complete in place, as measured from the point of switch to the last long tie, including ties, split switch, frogs, switch stand, guard rails, stock rails, connecting rods, ties, targets, and other track material necessary to complete the turnout. Where two turnouts join to form a crossover between adjacent tracks, the railroad will provide and install one turnout per crossover as noted on the plans and will provide and install the 25 ft. long ties required, but the Contractor provides the necessary rails, ties, and other track material as necessary to complete track approaches, turnout, and crossover construction in accordance with the plan documents. C. Railroad Relocate Turnout (Complete in Place). Existing turnouts relocated will be measured by each turnout relocated as measured from the point of switch to the last long tie, including ties, split switch, frogs, switch stand, guard rails, stock rails, connecting rods, ties, targets, and other track material associated with the existing turnout. D. Railroad Open Track Construction. Track constructed complete in place, including ties, rails, and other track material, will be measured by the foot along the center line of track, excluding turnouts from the point of switch to the last long tie. E. Loose Ties. Additional ties provided for use by the Railroad in connecting the new track to the existing track will be measured by each tie provided and stockpiled as indicated in the plans. 5. Payment. A. Railroad Granite Ballast. The work performed and materials furnished for ballast material in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for RR Granite Ballast. The price is full 9-10 4196

compensation for furnishing, placing, and tamping ballast in accordance with this specification and the plans including labor, tools, equipment, and incidentals necessary. B. Railroad Turnouts (Complete In Place). The work performed and materials furnished in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for "RR Turnouts (Complete in Place) of the type and size specified. The price is full compensation for materials, labor, tools, equipment, Thermite welding, and incidentals including lining, leveling, tamping, and compacting the ballast as needed to complete the turnout installation to the line, grades, and sections shown on the plans. C. Railroad Relocate Turnout (Complete in Place). The work performed and materials furnished in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for RR Relocate Turnout (Complete in Place) of the type and size specified. The price is full compensation for materials, labor, tools, equipment, Thermite welding, and incidentals including lining, leveling, tamping, and compacting the ballast as needed to complete the turnout installation to the line, grades, and sections shown on the plans. D. Railroad Open Track Construction. The work performed and materials furnished for constructing track sections complete in place in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for RR Open Track Construction. The price is full compensation for materials, labor, tools, equipment, and incidentals including 136 RE rails, ties, and other track materials (including rail angle bars, tie plates, tie bolts, rail anchors, gage rods, spikes, lock washers, and compromise joints), installation, laying of ties, Thermite welding, assembling and attaching fittings, spiking, lining, leveling, tamping, and compacting the ballast as needed to complete construction to the line, grades, and sections shown on the plans. Sub-ballast will be paid for under Item 247, Flexible Base. E. Loose Ties. The work performed and materials furnished for providing additional ties for use by the Railroad in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for Loose Ties. The price is full compensation for materials, labor, and incidentals needed to stockpile the ties as indicated in the plans. 10-10 4196