Chrysler LLCConstruction Standards

12/17/04

SECTION 02725 - RAILROAD WORK

PART 1 - GENERAL

1.1SUMMARY

  1. This Section includes the following:
  2. Engineering fabric
  3. Subballast and ballast.
  4. Railroad ties.
  5. Railroad rails.
  6. Grade crossings.
  7. Insulated track joints.
  8. Related Sections: The following Sections contain requirements that relate to this Section:
  9. Division 2 Section "Earthwork" for filling and rough site work grading.
  10. Division 16 Sections for electric power for electrically interlocked derails.
  1. SUBMITTALS
  2. Product Data: Manufacturer's technical data products provided.
  3. Shop Drawing: Show turnouts complete with switches, frogs, guard rails and switch stands; derail units, fabricated grade, and accessories.
  4. QUALITY ASSURANCE
  5. Codes and Standards: Comply with provisions of the American Railway Engineering and Maintenance of Way Association (AREMA), "Manual for Railway Engineering," and the specified State Department of Transportation “Standard Specifications for Railroad Work” or local authority governing railroad work. Should there be a conflict with these specifications or standards of governing agencies, comply with the more stringent requirements.
  6. Installer Qualifications: An experienced installer competent and experienced in railroad construction of similar scope to that indicated for this Project with a successful construction record of in-service performance.
  7. Connecting Railroad Company Acceptance: Obtain the proper information from the Connecting Railroad Company, before starting work, to insure the Architect and the Owner that the work will be acceptable to all parties concerned upon completion. Deviations from the AREMA specifications will not be permitted without written authority of the Engineering Department of the Connection Railroad Company. When the track work has been completed and before it is put in service, have the installations inspected and approved by the Connecting Railroad Company's Chief Engineer, as track work must conform to their adopted standards and requirements before acceptance will be made by the Architect. This approval, in writing, shall be obtained and presented to the Architect before payment will be made for this work.
  8. No deviations from specifications or documented requirements will be allowed without written authority from the Owner; also final approvals of track work will be made by the Owner, agencies having jurisdiction and Connecting Railroad Company.
  9. PROJECT CONDITIONS
  10. Field Measurements: Verify layout information for railroad tracks shown on the Drawings in relation to the property survey and existing structures. Verify dimensions by field measurements.

PART 2 - PRODUCTS

2.1ENGINEERING FABRIC

  1. Nonwoven pervious geotextile fabric complying with specified standards.
  2. Preferred Product: Supac 10 NP. Subject to compliance with the referenced requirements, provide either this product or a comparable substitute acceptable to the Connecting Railroad Company.
  1. AGGREGATES
  2. Subballast: Approved free draining granular material such as stone or slag screenings, chat or sand meeting the requirements of ASTM D 1241 and meeting the following gradations, MDOT Michigan Series 22A.
  3. Ballast: Hard, clean, crushed stone, crushed hard air-cooled blast furnace slag, crushed or uncrushed gravel as approved. Ballast shall conform to the grading requirements of AREMA / MDOT Size No. 4 (1-1/2 inch to 3/4inch).
  4. cross TIES
  5. 7 inch grade Timber Cross Ties: meeting current AREMA specifications for sawn standard 80 percent oak, 20 percent mixed approved hardwood railroad cross ties pressure treated with a preservative solution 60/40CCTS to a retention of 6 pounds per cubic foot and 100 percent end plated, to the length specified on the Drawings.
  6. Steel Cross Ties: Not less than 8 feet 6 inches long, unspaded, no cant ties for use in concrete encasement. Steel ties used in at grade crossings and within 10 feet thereof shall be not less than 10 feet long unspaded no cant ties for use in concrete encasement.
  7. Preferred Product: North American Railway Steel Tie Corporation (NARSTCO) Type M10. Provide either the named product or a comparable substitute acceptable to the Connecting Railroad Company.
  8. Rail Fastening Clips: Ties shall include clips with hook in shoulders and will be non-insulated or insulated per the Drawings.
  9. Preferred Product: Pandrol Rail Fastenings, Type “e” clip. Provide either the named product or a comparable substitute acceptable to the Connecting Railroad Company.
  10. RAILROAD RAILS
  11. Rails: 132 RE Relay, AREMA Class 3 or better, welded rails in good condition may be available through the Connecting Railroad Company.
  12. Field Welds, Shall conform to current AREMA specifications.
  13. Joint Bars: New or relay, in good condition, of the size, shape and hole punching to fit the rail used. Joint bars shall be six-bolt if required by rails used. Provide compromise joint bars to connect rails to existing rails by the Owner or the Connecting Railroad Company and to new rails by the Connecting Railroad Company where the rail sections are different. Compromise joint bars shall be heat-treated, angle type bars, accurately machined to connect rail sections properly, maintaining the alignment of the gage line.
  14. Track Bolts: New bolts meeting current AREMA Specifications of the size and length to fit the joint bars and rails used. Include a nut and AREA 67 Spec. spring washer with each bolt.
  15. Tie Plates: New or relay in good condition, double shouldered, not less than 7-1/2 inch by 13 inches by 11/16inch, with 8 punched spike holes, designed for the rail section used and to fit the rail base.
  16. Spikes: New meeting current AREMA Specifications, not less than 5/8 inch square and 6 inch long under the head.
  17. Rail Anchors: New one piece heat treated steel meeting current AREMA Specifications, designed to bear against the tie and be driven onto the base of the rail. Rail anchors shall be used according to the standards of the Connecting Railroad Company to fully box anchor ties.
  18. GRADE CROSSINGS
  19. Rubber, Full Depth: Manufactured rubber center and side pads with skid resistant surface attached to properly spaced wood or steel ties using lag bolts or per the manufacturer's instructions and Drawings. Crossing pads shall be sized to suit the rail section being used. Provide steel end deflector plates at the ends of side and center panels for protection from dragging equipment. Flush filled flangeways using either solid flangeway center panels or added rubber flangeway filler strips, by the crossing manufacturer shall be used where indicated on the Drawings.
  20. Products: Provide one of the following:
  21. Hi-RAIL; HiRail Corporation, Inc., Chicago, IL.
  22. Heavy Duty Grade Crossing; OMNI Products Incorporated, Portland, OR.
  23. Cast in place Concrete: As detailed on the Drawings using rubber railseal with specified rail fastening clips.
  24. Products: Provide one of the following:
  25. Performance Polymers Inc., Cambridge, Ont. Canada.
  26. NARSTCO, North American Railway Steel Tie Corporation, Midlothian, TX76065
  27. Precast Concrete: Center and side reinforced full thickness concrete slabs at least eight feet long with skid resistant surface attached to properly spaced steel ties without the need for shims. Rubber pads not more than 1/4 inch thick shall be placed on each tie to resist abrasion prior to placing the concrete slabs. Crossing slabs shall be sized to suit the rail section being used. Rubber filler strips, by the crossing manufacturer, shall be used on each side of each rail to fill the gap between the rail and the concrete slabs. The rubber filler strip on the field side of the rail shall fill the gap to flush with the top of the rail. If filled flangeways are indicated on the Drawings, the rubber filler strip on the flangeway side of the rail shall fill the gap to flush with the top of the rail. Panels at exposed ends of the crossing shall have tapered ends for protection from dragging equipment.
  28. Product: Provide the following:
  29. Improved-Concrete Grade Crossing System; OMNI Products Incorporated, Portland, OR.
  30. INSULATED TRACK JOINTS
  31. Bonded Insulated rail joint plugs shall be provided in tracks and field welded in place where indicated on the Drawings. Joints shall be Bonded Insulated Joint Plugs, 13 feet long, made with 6-hole joint bars for 132 RE rail drilled 3-1/2 inches by 6 inches by 6 inches at 3-3/32 inches above base, with 1 inch “Huck” fasteners and 1/4inch end posts, plug ends blank.
  32. Products: Provide one of the following:
  33. Portec Rail Products (330) 702-5188.
  34. L. B. Foster (412) 928-3502

PART 3 - EXECUTION

3.1GENERAL

  1. Examination: Verify that in-place construction on which this work is dependent is free of defects, which may influence satisfactory completion and performance of the work. Beginning of installation means acceptance of in-place construction.
  2. Connection to Existing Sidings
  3. Properly connect the railroad sidings to Owner’s existing sidings or the spur extensions of the railroad company's siding outside of Owner's property, as indicated.
  4. Completely remove the existing tracks, or turnouts, and replace with new work, using materials as specified.
  5. Workmanship
  6. Railroad work shall conform to the AREMA design for heavy industrial railroad construction and the State Department of Transportation, or local agency having jurisdiction of railroad work. Specified are AREMA numbers, which shall include latest revisions thereto.
  7. Trackwork on the Connecting Railroad Company's property, and affecting traffic on their lines, shall be done only at times which are approved by the proper authorities of the Connecting Railroad Company. Secure a written permit from the company before beginning any work on the Connecting Railroad Company's property.
  8. Trackwork on Owner's property, which might affect Owners railroad and/or truck traffic shall be done only at times which are approved by the owner, to prevent interference with Owner's operations.
  9. Railroad work shall be performed under the directions of foreman and gang leaders competent and experienced in railroad construction. Work shall conform to and meet requirements of the Connecting Railroad Company.
  10. Before starting work, proper information must be obtained from the Connecting Railroad Company to insure the Architect and the Owner that the work will be acceptable.
  1. TRACK CONSTRUCTION
  2. General
  3. Properly align with instrument tracks. Grade, level, and construct the tracks in accordance with the requirements of the engineering department of the Connecting Railroad Company. Consult the Connecting Railroad Company's engineering department regarding track construction details as may be necessary.
  4. Lay track in conformance with AREMA manual, Vol. I, Chap. 5, Part 4, "Track Construction", Part 5, "Track Maintenance", and Part 3, "Curves".
  5. Roadbed Preparation: Excavating, filling, compacting and rough grading is specified in Division 2 Section “Earthwork". The roadbed will be rough graded to the approximate elevations required for the railroad track work, to provide proper and substantial roadbeds for tracks and for track drainage. Other required earthwork shall be done as part of the railroad track work.
  6. Roadbed Preparation: Include interior and exterior earthwork required to prepare the railroad track road bed, including excavating, filling, compacting and grading to the established elevations and as required for proper, substantial and well drained roadbeds. Longitudinal drainage ditches as required by field conditions shall be provided as part of the work specified. Ditches shall have 24 inch wide bottoms and banks sloped 2 to 1 or flatter, with bottoms sloped to outlets provided by others. Remove surplus earth from the premises. Surplus earth suitable for fills or backfills shall be deposited on the site where directed. Unsuitable material shall be removed from the premises. Materials for fills shall be bank-run sand and gravel, crushed hard blast furnace slag, or other suitable and approved material. Compactfills thoroughly with a 10-ton road roller.
  7. Choke Course Construction: A choke course shall be applied over the graded and compacted earth subgrade to form a base for the subballast when and if the subgrade is too soft for the proper placing of the subballast. This course shall consist of stone screenings placed to a depth of 2 inches, unless indicated otherwise, and not rolled.
  8. Engineering Fabric Installation
  9. Unroll engineering fabric directly on the prepared road bed. Overlap sections at the sides and ends by a minimum of 2 feet. Form angle pleats across the fabric on curves. Avoid large wrinkles.
  10. Torn, cut or otherwise damaged areas shall be overlaid with a patch of the same material, providing a minimum of 2 feet overlap with undamaged material.
  11. Do not operate tracked or wheeled vehicles, nor place ties directly on the fabric.
  12. Subballast and Ballast
  13. The subbase material under the concrete track mats is specified in Division 2 Section “Earthwork.”
  14. Subballast shall be a minimum of 8 inches deep and shall extend the full width of the roadbed. Subballast shall be compacted to a minimum of 95 percent of its maximum dry density.
  15. Ballast shall be a minimum of 8 inches deep under bottoms of wood ties. Ballast for exterior tracks shall be level with tops of ties.
  16. Ballast for interior tracks shall be laid level, extending from wall to wall of the track well (and flush with tops of ties) (to indicated elevation to form subbase under the bituminous concrete trackwell paving). Tracks shall be properly surfaced and lined.
  17. Use care to insure even distribution of track ballast and proper drainage and to eliminate ruts that may form water pockets. Insert ballast in convenient lifts, not less than two in all.
  18. Use care, particularly on final lift, to assure track structure being in accurate compliance with established cross level, line and grade, and in full accordance with construction stakings. Retamp ballast and re-drive spikes of ties not giving full bearing support to rails. Thoroughly power tool or pick tamp ballast under each tie from each end on both sides of the tie to a point 15 inches inside each rail. Carefully fill remaining center portion and shovel tamp the ballast. Thoroughly tamp ballast under switch ties throughout their length. Give tamped ballast a final dressing of track ballast, with shovels or ballast forks, to specified elevations, side slope and toe line. Covering ballast with sand or other fine grained material will not be permitted.
  19. Wood Tie Placing
  20. The minimum number of ties used per length of rail shall be as follows:
  21. Use the best ties as joint ties and carefully place for proper joint support and to suit the length of joint bars used. Space the remainder of ties evenly. Do not distribute ties on subgrade roadbed before it is properly finished and ready for receipt of track structures. Do not distribute ties on engineering fabric before it is covered with subballast. Remove ties not meeting specifications from the job site.
  22. Handle ties carefully to avoid splitting or bruising. Do not use picks, spike mauls, sledges, or shovels in handling and placing ties. Move ties only with tongs to minimize any damage incidental to handling. Place ties so center of tie will coincide with center line of track. Lay ties at right angles to track with the face up and heartwood face down. When it is impossible to detect which the heartwood face, lay tie with the widest face is down. Clean bottoms of rails, tie plates and bearing surfaces of ties before laying rails.
  23. Rail Laying
  24. Lay rails to the standard 4 feet 8-1/2-inch gauge on tangents, and on curves up to 14 degrees. On curves greater than 14 degrees, widen the gauge 1/8 inch for each increment of 2 degrees of curve, to a maximum of 4 feet 9-1/4 inches.
  25. Allow for expansion at rail joints by installing rail expansion shims of wood or metal in conformance with table in AREMA manual, Vol. I, Chap. 5, Part 5, Section C, "Laying".
  26. Control handling of rails, by crane or by hand, to avoid breakage or other damage. Lay relay rail so best side of head forms gauge side of rail as laid. Precurverails for curves 15 degrees or over to true radius throughout the entire rail length without kinks or offsets.
  27. Lay rails with joints staggered not more than one foot from center of opposite rail whenever possible.
  28. Lay relay rail so best side of head forms gauge side of rail as laid.
  29. Do not use a torch for cutting track rail or for burning bolt holes or other like purposes. Use proper tools such as rail saw, rail chisel, and rail drill.
  30. Joint Bar (Splice Bar) Installation: Clean foreign material from bars. Oil bars and properly install with full number and correct size of bolts, nuts and nut locks, properly fitted against rails and firmly held by two track bolts during rail laying operations. Full bolting may be completed in connection with track surfacing. Insofar as practical, keep rail joints out of driveway and roadway crossing areas. Connect rails of different section by properly fitted compromise joints.
  31. Track Bolt Installation: Install track bolts with nuts alternately on inside and outside of the rails. Tighten bolts by track wrench, power driven preferred, before spiking track. After track has been put into service and before acceptance of the work, check bolts and tighten if required.
  32. Tie Plate Installation
  33. Use tie plates under each rail on each cross tie and each switch tie not protected by switch plates, frog plates, or guard rail plates.
  34. Install plates squarely with shoulder snug against rail. Cocked tie plates will not be permitted.
  35. Spiking: Spike rails fully. Use two spikes, diagonally located, at each rail on each tie. Start spikes and drive vertically with face of shank in contact with the rail and square with rail so that face of spike will have full hold on rail base. Damage to tie timber fiber must be minimized. Goosenecks or Drawing of rail in spike driving will not be permitted. Do not strike spikes after head is down to snug contact with rail base. Reset spikes after traffic has settled tie plates into the tie. Use care not to overdrive. Do not adjust rail gauge by striking with maul or other tool.
  36. Final Acceptance: Before final acceptance, track shall be spotted and accurately lined, to remove irregularities of cross level, surface or line caused by settlement or compaction of ballast following traffic loading. Bolts shall be retightened, if necessary, to bring to full tension and spikes shall be set down to full rail contact.
  37. Insulated Track Joint Installation
  38. Joints shall be installed at locations indicated on the Drawings as required to enable the Connecting Railroad Company to properly connect the signal light and bell systems for the railroad tracks.
  39. If gauge rods are used at rails between insulated joints, they shall be of the insulated type.
  40. Individual rails mounted on ties shall be completely isolated from each other to insure proper operation of the signal system.
  41. Double shoulder poly tie plates shall be utilized.
  42. Rails between insulated joints shall be bonded by the Connecting Railroad Company to provide electrical circuit to operate the signal system.
  43. grade crossing installation
  44. General: Install grade crossings in roads and other paved and unpaved areas both inside and outside of the buildings as indicated on the Drawings. Grade crossings shall be of the type indicated on the drawings.
  45. Prefabricated Crossings: Install in accordance with the manufacturer's instructions.
  46. Cast in place Concrete:
  47. Grout: Notify Contractor responsible for providing and placing grout when ties are to be placed so ties can be set before grout hardens.
  48. Steel Tie and Rail Installation: After concrete track mat has been placed and has hardened, install steel ties on beds of grout so ties are full bedded with no voids under ties. Attach steel rails thereon to the finished track elevation.
  49. Flangeways: Install flangeway crossing guard members, including blocks and bars, along both rails, using materials specified. When joints in bars are necessary, make joints at center line of a spacing block and weld both ends of bars together.
  50. Exposed Ends: At exposed ends of the crossing mat, the concrete above the bottom of the rail shall be tapered at a 45 degree angle toward the crossing for protection from dragging equipment.
  51. Bituminous Concrete: Install flangeway crossing guard members, including blocks and angles, along both rails, using materials specified. When joints in bars are necessary, make joints at center line of a spacing block and weld both ends of angles together.
  52. TRAINMEN’S WALKWAYS
  53. General: Provide walkways along each side of the new and relocated railroad tracks on the Owner's property, which do not run through paved areas.
  54. Construction: The railroad track roadbed shoulders shall be widened. Provide and place and compact walkway aggregate to form walkways. Grade top surfaces on a slight slope from track ballast shoulders out to outer line of widened roadbed shoulders. Where two tracks are near to each other, fill the track ballast trough between with walkway material as specified above and dress surfaces with a 2 inch crown along center line between tracks.
  55. SIGNS
  56. Install permanent signs required, such as crossing, clearance, derail, and other safeguards required for the safe operation or protection of the railroad installation. Signs shall be installed on permanent, galvanized steel posts meeting the requirements of the Connecting Railroad Company.
  57. CLEANING
  58. Upon completion of the work, the site shall be cleared of equipment, surplus materials and debris, and such material shall be satisfactorily disposed of off the site.

END OF SECTION