6-237 SECTION 662 – RAILROAD TRACK CONSTRUCTION
662.01 DESCRIPTION . This work shall consist of constructing new ballasted track with jointed or
continuous welded rail (CWR); removing and replacing rail; removing and resetting track; removing and replacing ties; raising, aligning, and surfacing track; removing track; instal ling other track material ( OTM ) such as tie plates, anchors, and spikes as required; and de -stressing rail as required in accordance with the CWR program of the Operating Railroad.
662.02 MATERIALS . Materials shall meet the requirements of the following s ubsections:
Aggregate for Railroad Ballast ................................ ................................ .................. 704.03 Railroad Ties ................................ ................................ ................................ .............. 709.04 Rail ................................ ................................ ................................ ............................. 715.0 6 Other Track Material (OTM) ................................ ................................ ..................... 715.0 8
662.03 Submittals .
a.Pre-Construction Submittals . The following information shall be prepared and submitted for review and approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6.
1.Schedule of Materials . A complete schedule of the materials proposed for installation and the source of the material. Information to be provided on rail shall include the rail weight, rail section, rail wear, drilling pattern, typical rail length, date rolled, and the name of the mill where the rail was rolled.
2.Ballast . Source for ballast and gradation analysis of a sample from the ballast source.
3.Relay Rail Source . The source and classification of relay rail per AREMA Chapter 4, Section 3.12 .
4.Relay Rail Tests . Test results for relay rail as specified in Subsection 715.0 6(b)(3) .
5.Ties. Name and address of the facility proposed for disposal of wood ties.
6.Tie Plug Material . Type of tie plug material.
7.Certificate of Compliance . A manufacturer’s certificate of compliance for all materials that are incorporated into the work.
8.Rail Expansion Plan . Plan for rail expansion work inducing the proposed method of rail vibration and the type of mechanical vibratory equipment to be used. 6-238 (9) Thermite Weld Submittals .
a.The type and manufacturer of weld kits.
b.Detailed installation procedures showing proposed quick preheat, self -tapping thermite weld kit, and the method and detailed procedure for making field welds. If there are different types of welds in the Contract (e.g. different sizes or types of rail, compromise joints), a procedure shall be provided for each. Installation procedures submitted shall comply with these provisions and those of the weld kit manufacturer.
c.A detailed list of tools, equipment, and su pplies required to make field welds.
d.Documentation that welders and all other field personnel involved in thermite welding have been trained by the welding kit manufacturer. The documentation shall include the name of the trainee, the location of the tr aining, name of the instructor, and date of the training.
e.Qualification certification for each supervisor and field welder who will perform work under the Contract. Weld supervisors and welders shall be required, when requested by the Engineer, to submi t their qualification certificates throughout the duration of the project.
f.The name of the independent testing entity and certification that the testing laboratory and the persons who will perform ultrasonic testing of field welds have previously tested a minimum of 250 welds.
g.Procedures for inspection and testing of qualification and in -track thermite welds.
1.For ultrasonic testing, a detailed test procedure and description of test equipment, including calibration blocks, that will be used in the t esting process.
2.A form for documenting results of the ultrasonic testing. The form shall include, but not be limited to, identification of test equipment used, calibration, weld number and location, members of the test crew, date and time of test, descr iption of defects, and a recommendation to accept or reject weld.
h.A form for recording field welds for the Contract.
10.Rail Marking . The method of marking rail strings with a permanent method that identifies each rail. 6-239 (b) Post-Construction Submittals . No more than 2 working days following the completion of the work related to the submittal, the following information shall be prepared and submitted for review and approval by the Engineer . The following submittals by the Contractor shall meet the requirements of Subsection 105.0 6.
1.Thermite Weld Submittals .
a.Documentation that the sample thermite welds have been tested and that welds meet or exceed the requirements specified herein.
b.A record of all welds installed under the Contract. This record shall be submitted on the approved Contractor created form and shall include, but not be limited to, the following information for each weld:
1.Weld number, location by track designation and station, and date and time the weld wa s made. Rail identification including section, rail strength and chemistry, heat number, and date rolled.
2.Kit manufacturer and identity of each mold and portion.
3.Weather conditions, and air and rail temperatures.
4.Rail gap.
5.Name of welder, weld supervisor , and Contractor ’s foreman.
6.General notes.
c.Certified ultrasonic inspection results for each field weld.
2.CWR Strings . A record of all CWR strings laid. The record shall indicate the date, the string number, the weight of the rail, the manufacturer, the year, the temperature at which the rail was laid, the mileage location, and whether the string was the north or south r ail (for east/west rail lines) or the east or west rail (for north/south rail lines).
3.CWR Records and Forms . Agency and Operating Railroad CWR records and forms shall be submitted within 48 hours of the completion of work or upon the request of the Operating Railroad or Agency. Records shall be filled out on forms in accordance with the Operating Railroad ’s CWR plan. 6-240 662.04 REMOVAL OF TRACK . Existing rail, anchors, spikes, or other rail fastening devices, bolts, nuts, washers, joint bars, tie plates, concrete ties, wood cross ties, and wood switch ties shall be removed within the limits shown on the Plans.
a.Removal .
1.Rail. Rail meeting the requirements of rel ay rail set forth in Subsection 715.0 6(b) will be deemed to be fit for reuse and shall be stockpiled and protected from damage due to construction operations. The rail shall be reused at the locations indicated on the Plans. When necessary, cutting of rai l shall be performed as specified in Subsection 662.07(c)(10) .
2.Hardware . The Contractor shall remove joint bar bolts, spikes, rail anchors, and any other rail holding devices in a manner that does not damage any existing materials. Flame cutting of bol ts to be removed will be permitted providing the joint bars and rails are not damaged. Existing hardware shall include but not be limited to track spikes, rail anchors, joint bars, tie plates, and shim plates. The Engineer will determine which track hardw are is fit for reuse.
3.Ties. The Contractor shall excavate where necessary for the removal of the existing cross ties.
b.Disposition of Materials .
1.Stacking of Rails for Reuse on the Project .
a.Rails shall be stacked on approved sills a minimum of 6 inches above the ground.
b.Rails shall be stacked with the heads up and with the ends even.
c.Each layer shall be separated by at least three 2 -inch by 4 -inch wood strips evenly spaced along the l ength of the rail.
d.Rail shall be grouped by weight, section, drilling pattern, condition, length, and amount of wear.
e.The weight, section, drilling, and length shall be marked on one of the rails near the mid-height of the stack. These markings shall be painted neatly near one end of the rail. The Contactor shall mark rail ends in yellow designating fit relay rail. The Contractor shall also mark the centerline of each rail length on the rail head in yellow. 6-241 (2) Stacking of Joint Bars, Gage Rods, and Tie Plates for Reuse on the Project .
a.Joint bars, gage rods, and tie plates shall be sorted by section, punching, and condition.
b.Compromise joint bars shall be wired together in pairs, separate from other bars.
3.Rail Anchors Fit for Reuse on the Project .
a.Rail anchors shall be sorted by type and size and placed in kegs, steel drums, or other approved containers.
b.Containers shall be labeled with the rail weight and section.
4.Material to be Scrapped . Existing rail and track hardware removed and not fit for reuse, as determined by the Engineer, as well as any waste material, including ties, shall become the property of the Contractor and shall be removed from the site and disposed of properly at the Contractor’s expense.
662.05 BALLAST HANDLING . The Contractor shall handle ballast in accordance with the requirements
of AREMA Chapter 1, Section 2.5 and the follow ing. Processed ballast shall be handled at the producing plant in such a manner that it does not segregate. Ballast shall be washed prior to loading. Ballast shall be loaded into rail cars or vehicles that are in good order and tight enough to prevent leak age and waste of material, and that are clean and free from rubbish, sand, dirt, or any substance that would foul or damage the ballast. Broken stone for ballast shall be delivered from the screens directly to the rail car (or other vehicle) or to clean bi ns provided for the storage of the output of the crusher.
662.06 BOTTOM BALLAST INSTALLATION . The depth of ballast required shall be as shown on the
Plans.
a.Inspection of Subbase . The Engineer will inspect and document the condition of the subbase surface upon which the track will be constructed. The Contractor shall remediate and correct any deficiencies as directed by the Engineer.
b.Installation . Installation shall be performed in accordance with AREMA Chapter 5, Section 4.1 . Bottom ballast shall be installed to the underside of the ties to the depths shown in the Contract. 6-242 To the extent practicable, ballast shall be unloaded for use with minimum redistribution and dressing. Care shall be taken when unloading ballast cars to ensure that they are completely unloaded. Railroad ballast shall be distributed so that ample clearance below top of rail is provided for rolling equipment, switches are not fouled, and guard rails are unobstructed. Care shall be taken when unloading and dressing ba llast near open deck bridge approaches.
662.07 TRACK CONSTRUCTION . Ballasted track shall be constructed in accordance with the
applicable sections of AREMA Chapter 5, Part 4 ; AREMA Chapter 5, Part 5; and as specified herein. Ballasted track includes the rail, ties, fastenings, OTM, and ballast. The Contractor shall connect new rail to existing rail sections as indicated on the Plans by the use of standard or compromise joint bars, or by the use of standard or compromise welds whe n connecting to existing CWR.
a.Tie Installation . The Contractor shall transport and store cross ties in accordance with AREMA Chapter 30, Section 3.5.11 .
1.Ties shall be aligned as follows:
a.In double track or main track and passing siding locations, the Contra ctor shall align the ties with the outside (field) end of the tie used as a reference line to align the ties.
b.In single -track locations, the Contractor shall align the north or west end of the tie as a reference line unless otherwise designated by the Engineer.
2.New cross ties shall be handled and placed with either a mechanical tie insertion device or tie tongs. The use of picks will not be permitted.
3.The Contractor shall take special care and vigilance during handling and unloading of cross ties to avoid damage to the ties.
4.New ties shall be placed with the heartwood face down, square with the line of the rails, not skewed and approximately centered about the centerline of track. Ties shall be spaced in accordance with the Contract. 6-243 (b) Tie Plates . Tie plates for timber ties shall be placed prior to setting the rail and shall be used on all ties. Tie plates shall not be placed directly under thermite welds.
1.Tie plates shall be installed centered about the width of the tie, square w ith the rail, with the shoulders bearing firmly against the sides of the rail base. Under no circumstances shall the tie plate shoulder be allowed under any portion of the rail base. Care shall be taken to ensure that the tie plates are well seated on the ties and the rail properly seated on the tie plates. Canted tie plates shall be placed so as to cant the rail inward towards the gage side of the rail. Tie plates with different amounts of cant or flat plates shall not be intermixed except as directed by t he Engineer. This requirement shall also apply to any surfacing within the limits of the project .
2.Tie plates shall be free of any dirt and foreign matter when being installed. Stone dust and extraneous material shall be removed by blowing or brushing o ff the surface of the tie and tie plate to prevent damage and to ensure proper seating of the rail.
3.Pre-plated timber ties may be used, in which case the Contractor shall demonstrate that the completed track gage is correct and within the specified li mits in Subsection 662.07(c) .
c.Rail and Bolted Joint Installation . Rail and bolted joints for new track construction and for removal and replacement of rail shall be installed in accordance with the following requirements. When laying CWR strings or wel ding lengths of rail into CWR, bolted joints may be used for temporary works where applicable and as indicated in the Operating Railroad’s CWR plan.
1.If used, relay rail shall meet the requirements of Subsection 715.0 6(b). Relay rail shall be subject to inspection and acceptance by the Engineer.
2.Rail shall not be dropped on uneven surfaces or left unevenly supported. The unloaded rail shall be placed so that it can be laid with as little handling as possible.
3.The Contractor shall lay th e rail and spike it to the proper gage. At a minimum, every fourth tie shall be gaged on tangents and every third tie shall be gaged on curves. The gage shall be 56 -1/2 inches between points 5/8 inch below the top of the rail on the two inside edges of the rail.
4.Existing track gage shall be at, or within, the limits specified in Table 662.07A . In the event the rail in existing track abutting the new rail is not at or within those limits , gaging shall be performed within existing track for a sufficient length to meet the limits specified in Table 662.07B for rate of change of track gage. The limits of gaging will be determined by the Engineer. 6-244 When correcting gage, all spike pulling a nd driving shall be done on the rail opposite the rail used for lining. Where spikes are pulled, the holes in the ties shall be plugged with tie plugging material meeting the requirements of Subsection 709.04(e) . New spikes shall be driven as specified in Subsection 662.07( g). TABLE 662.07A – EXISTING TRACK GAGE LIMITS Minimum Gage (in.) Maximum Gage (in.) 56-1/4 56-1/2 TABLE 662.07B – EXISTING TRACK GAGE RATE OF CHANGE LIMITS Track Gage Parameter Class of Track 1 2 3 4 The rate of change within 31 feet shall not exceed 1 in. 1 in. 3/4 in. 1/2 in.
5.Joint bars shall be connected before the track is spiked. The fishing surfaces of joints and bolt threads shall be lubricated with an approved corrosion -resistant lubricant in accordance with the manufacturer’s instructions before they are applied. When joint bars are used in temporary works prior to welding, they shall not be lubricated.
6.Rail shall be fully supported on tie plates and bolted.
7.The rail shall be slid into position with lini ng bars or lifted into place with rail tongs. The use of a hammer, maul, or other similar tools to drive the rail into position will not be permitted.
8.Kinked, crooked, or surface -bent rails will not be permitted in the track.
9.Rail shall be cut in a ccordance with AREMA Chapter 5, Section 5.2.4.w .
10.When making bolt holes in the field, all holes shall be made with a rail drill and then chamfered. All chips and burrs shall be removed. Holes shall not be burned with a torch.
a.For rail sections specified in AREMA, the rail drilling pattern shall be as specified in AREMA Chapter 4, Section 3.3 . Rail ends shall be drilled with three holes. 6-245 b. For rail sections not specified in AREMA, the rail drilling pattern shall match joint bars being utilized. If a rail end which is currently drilled requires dri lling for another pattern, the Contractor shall not double drill the new pattern on the existing rail end. The Contractor shall crop off the rail end and then drill the new pattern.
c.When joint bars are used for temporary works prior to welding, the hol e pattern shall be in accordance with the Operating Railroad’s CWR plan.
11.Rail joints shall be installed so that bars are not cocked between the base and head of rail. Joint bars shall be properly seated in the rail.
12.The Contractor shall tighten bolts to the required torque, starting with the two bolts in the middle of the bar and working towards the ends. The Contractor shall strike both bars with a sledgehammer during the tightening process to help seat the bars properly. The Contractor shall then perform a final re -tightening of the two middle bolts. The Contractor shall torque the bolts as required by AREMA for the respective bolt size. All bolts shall be torqued with a mechanical bolt machine and set to apply the required torque. The Contractor shall not use this method to of striking the bars when installing insulated j oint bars.
13.The Contractor shall tamp all ties on which the newly laid rail does not have a full bearing with a mechanical tamper as specified in Subsection 662.07( i). Ties shall be tamped after rail is bolted and laid in tie plates and prior to gaugin g and spiking.
14.Ties under compromise bars shall be spaced at 18 inches on center, with a tie directly under the rail end of the lighter of the two rail sections being joined. Hardwood ties meeting the requirements of 49 C.F.R. § 213.109 for non -defect ive crossties shall be used under compromise joints. When using temporary compromise joints as part of rail change -out or turnout change -out programs, it is permissible to use track shims to support the joint until the shims and compromise joints are remov ed the next day. The ties shall be tamped to support any permanent compromise joints left in the track. Shims to support permanent compromise joints will not be permitted.
15.A minimum 12 foot stagger shall be maintained between bolted joints on opposit e rails, unless otherwise indicated on the Plans.
16.Bolted joints, including temporary joints in connecting strings of continuous welded rail, shall not be installed on bridges, nor shall they be installed on roadbed approaches within 300 feet of the b allast walls at either end of the bridge.
17.Insulated joints shall have a 4 -foot to 5 -foot stagger. 6-246 (18) Any mismatched rail ends at joints which exceed 1/8 inch either vertically on the rail head or horizontally on the gage side of the rail head shal l be corrected. The rail end mismatch shall be measured after the standard or compromise joints have been applied and tightened. If mismatched rail ends already contain rail end batter (due to the larger rail having been struck by wheels), the amount of ra il end batter shall be taken into account when calculating the mismatch. Mismatches shall be corrected by changing joint bars and bolts, by being built-up with weld material on the offending rail, or by substituting a different piece of rail. The length of ramp required for this procedure will be calculated as the ramp slope, which shall be the rail end mismatch measurement (in thousandths of an inch) divided by 0.012.
19.Additional requirements for laying and adjustment of CWR are specified in Subsectio n 662.07(d) and Subsection 662.07(e) .
d.Temperature Requirements for Laying CWR . CWR shall be laid within the preferred rail laying temperature (PRLT) range in accordance with the requirements of the Operating Railroad’s CWR plan. Laying and adjustment p rocedures for CWR will be dependent on the maximum and minimum rail temperatures expected. If CWR is laid at rail temperatures above the maximum preferred rail laying temperature, the CWR shall be adjusted within 48 hours after being installed. If CWR is laid at rail temperatures below the minimum preferred rail laying temperature, rail heaters shall be used to bring the rail temperature within the PRLT range. The rail temperature of any CWR string laid shall be measured with an accurate and reliable rai l thermometer placed on the base of the rail near the web. The thermometer shall be designed for measurement of rail temperature and shall be placed away from the wind and out of direct sunlight.
e.Adjustment of CWR . CWR rails shall be laid without expansion gaps. To lay CWR which is below the minimum preferred rail laying temperature, the rail shall be heated to the preferred laying temperature with a propane rail heater. The rail shall be heated directly following it being laid or vibrated. The temperature of the rail will determine the amount of heat required. On the base of the rail next to a tie plate which has been set to proper gage and spiked, the exact distance the rail will need to expand based on the diffe rence between the current rail temperature and the PRLT shall be marked. The rail string shall be marked at each quarter point and at the end. 6-247 The rail shall be vibrated by a mechanical vibrator to ensure proper rail movement in accordance with the appr oved rail vibration plan. In no case will the Contractor be permitted to simultaneously apply mechanical vibrations and heat to perform rail expansion. Under no circumstances shall the rail be vibrated by using spike mauls, sledgehammers, or other types of hammers or tools to strike the rail. Equipment such as hydraulic rail pullers may be used to expand the rail to the proper PRLT equivalent length. Adjustment of CWR shall occur after all work specified in Subsection 662.07( i) has been completed.
f.Welding of Rail . Welding of CWR strings in the field shall be either by thermite welding or in - track electric flash -butt welding. Electric flash -butt welding shall be performed in accordance with the requirements of AREMA Chapter 4, Section 3.10 and AREM A Chapter 4, Section 3.11 . Thermite welding shall meet the requirements of AREMA Chapter 4, Section 3.13 and Subsection
662.14 .
Field welds shall be completed using in -track electric flash -butt welding to connect continuous welded rail strings, connect tur nouts to adjacent rail strings, weld shop -fabricated rails containing bonded insulated joints into track, and weld shop -fabricated transition/compromise rails into track. Thermite welding shall be used within turnouts, for compromise welds, and at other lo cations noted on the Plans or designated by the Engineer. Excessive rail grinding of the weld that causes a depression on the head and or gage face of the rail after a weld is completed will not be accepted. The weld shall be cut out beyond the heat affect ed zone and replaced. The Engineer will visually inspect welds for visible defects, such as any incomplete portion or inclusions. The weld will be rejected and shall be replaced if it contains these defects.
1.A minimum 12 -foot stagger shall be maintain ed between welds and bolted joints unless otherwise specified.
2.The end of a CWR string in one rail shall not vary from the end of a CWR string in the opposite rail by more than 100 feet. 6-248 (g) Track Spiking Requirements .
1.Ties shall be pre -bored with a tie boring machine prior to installing spikes.
2.Rail holding spikes shall be started with the head pointed toward the rail and driven vertically and square with the rail and driven so as to allow 1/8 inch to 3/16 inch in the space between the underside of the head of the spike and the top of the base of the rail. Opposite holes on the gage and field side of the rail shall be used for rail holding spikes. The rail holding spiking arrangement shall be in accordance with Table 662.07C unless otherwise specified in the Contract.
3.Plate holding spikes shal l be started with the head pointed toward the rail and driven vertically so the head has full bearing against the tie plate. Plate holding spiking arrangements shall be in accordance with Table 662.07C unless otherwise specified in the Contract. TABLE 662.07C – TIE SPIKING TABLE Degree of Curve Tie Spiking Arrangement Main and Siding Track Yard and Industrial Track 0°-00' to 2° -00' 0°-00' to 2° -00' 2 rail holding and 0 plate holding 2°-01' to 6° -00' 2°-01' to 13° -00' 2 rail holding and 1 plate holding – 1 field side 6°-01' and greater 13°-01' and greater 2 rail holding and 2 plate holding - 1 field side and 1 gage side
4.On each tie, spikes on the gage side of the running rail shall be placed across from each other and spikes on the field side of the running rail shall be placed across from each other. Spikes on the field side shall be placed in the hole on the north or we st side of the plate. The spiking pattern shall be held consistent through the limits of work.
5.Spikes shall not be overdriven or straightened while driving. Spikes shall not be bent against the rail. Spikes which are bent while being driven shall be discarded and replaced. No spikes shall be driven against the end of joint bars. No spikes shall be driven in a slot in a rail joint. 6-249 (6) The Contractor shall not remove track spikes once driven, unless directed by the Engineer. If spikes are pulled, the ties shall be plugged with synthetic tie plugging material meeting the requirements of Subsection 709.04( e). Track spikes may be driven thr ough tie plugging material. The Contractor shall remove and replace any tie where the tie plugging material is not completely and tightly filling the track spike hole or where the tie plugging material is not properly holding a driven track spike.
7.Defective tie plates shall be culled by the Contractor.
h.Rail Anchors . Rail anchors shall be applied in the pattern as shown in AREMA Chapter 5, Section 5.4. The rail anchor pattern shall be spaced approximately uniformly along the rail length. To avoid ti e skewing, the anchors shall be applied against the same tie on opposite rails. Rail anchors shall have full bearing against a sound tie. New rail anchors shall firmly grip the bottom of the rail to which they are applied to provide longitudinal rail restr aint. Rail anchors shall not be installed at ties which support rail joints, where they will interfere with bond wire, boot legs, insulated joints, and other signal or track appliances. Rail anchors shall be installed manually or with standard anchor machi nes. For track constructed with jointed rail, rail anchors shall be installed immediately after rail is laid. All rail laid in a given day shall be fully anchored on that same day. Unless otherwise specified, the Contractor shall anchor CWR in accordance with the following and the CWR program of the Operating Railroad:
1.For the first and last 200 feet of each string, including connections as noted on the Plans, rail anchors shall be applied and boxed at every tie in both directions, including where joints are to be field welded. For the remainder of the string, rail anchors shall be applied and boxed at every second tie for restraint in both directions.
2.Where CWR joins convent ional jointed rail, all rail, except that supporting the rail joint, shall be box anchored for 200 feet in each direction.
3.Anchored ties shall have four anchors per tie.
4.If joints have been eliminated by field welding, it will be permissible to re move anchors on every second tie. 6-250 (5) Where CWR connects to jointed rail, the Contractor shall anchor the first six jointed rail lengths at every third tie in both directions.
6.Through turnouts and other special track work connected to CWR, rails sha ll be anchored in accordance with the following:
a.On each side of the turnout every tie shall be box anchored wherever possible (i.e. when anchors are applied to one rail, anchors are also required on the opposite rail of the same side). Rail anchors sh all be applied on the gage side of the rail except where insufficient clearance restricts the use of the anchor or application tool, in which case anchors may be applied from the field side of the rail where clearance permits.
b.In addition to the straig ht side, the diverging side shall be anchored a sufficient distance to prevent rail movement from disturbing the switch point and frog.
c.Every cross tie shall be box anchored for 200 feet ahead of the head block ties and 200 feet past the frog on each tr ack on each side of the turnout.
7.Every tie shall be box anchored for a distance of at least 300 feet back from the abutment at either end of a bridge.
i.Ballasting, Surfacing, Aligning, Tamping, and Dressing of Track . The depth of ballast required shall be as shown on the Plans. Track shoulders shall be a minimum of 12 inches. Work shall be performed so that the track alignment, surface, and elevation will be maintained after tamping.
1.Ballasting . Following the installation of the track on the compacted bottom ballast, ballast shall be distributed in advance of the track surfacing in sufficient quantity to properly surface, align, tamp, and dress the track to the required ballast cross section.
a.To the extent practicable, ballast shall be unloaded for use with minimum redistribution and dressing. Care shall be taken when unloading ballast cars to ensure that they are completely unloaded.
b.Railroad ballast shall be distributed so that ample cle arance below the top of rail is provided for rolling equipment.
c.Care shall be taken when unloading and dressing ballast near open deck bridge approaches. 6-251 d. The Contractor shall avoid pulling sod, vegetation, and other foreign material onto the track structure or shoulders for the purpose of tamping or dressing the ballast sections. Any sod, vegetation or foreign matter inadvertently pulled in shall be removed by the Contractor prior to tamping.
2.Surfacing and Aligning . The Contractor shall perform as many raising and surfacing passes as are needed to bring the track into the tolerances specified in Table 662.07D while meeting the following requirements. The Contractor shall consider overhead clearances where present.
a.Track surfacing shall be per formed using methods that will prevent undue bending of the rail, straining of the joints, and damaging or loosening the fastenings. The amount of track lift in a single operation shall neither exceed 4 inches nor endanger the horizontal or vertical stabil ity of the track. The track shall be raised such that the lift required to reach the final surface shall not be less than 1 inch nor more than 3 inches. The final raising and aligning operations shall fill cribs to the top of tie and the shoulders with bal last. A minimum of 2 inches of clearance shall be provided between metallic portions (non -rail) of the track structure and ballast. Particular attention shall be given to the tamping of ties not attached to the rails, to ensure that they maintain firm bear ing against the base of the rail, without admitting ballast between the rail and tie. No portion of the tie plate shoulder, or stone, or any foreign material shall be permitted under the base of rail.
b.Any cross tie on which the tie plate is not tight ag ainst the rail base (down tie) shall be thoroughly cleaned of ballast in the rail seat area, the tie raised to firm bearing against the rail, and re -tamped until the tie plate is bearing firmly against the rail base.
c.Final surfacing and aligning shall bring the track to final grade and alignment and shall comply with the construction tolerances specified in Table 662.07D .
3.Tamping . Tamping shall be accomplished using an electromatic squeeze -type vibratory tamping ma chine having at least sixteen tools, on traversing work heads, per tie. The work heads shall be capable of penetrating cemented or fouled ballast in the event that providing a smooth transition requires tamping existing track. A uniform squeeze shall be ap plied to all tools and the tools shall remain perpendicular to the tie during the entire tamping cycle. The tamping tools shall have sufficient length and head and face area, based on the manufacturer’s specifications, to compact the ballast under the tie. The tamper shall be capable of tamping both ballasted open track and ballasted special trackwork. The tamper shall be capable of automatic lift, level, and alignment of tangent and curved track, as well as turnouts. 6-252 a. All ties, including ties under a r ail joint, shall receive a minimum of two separate insertions of the vibratory tamper. Tamping tools shall be inserted simultaneously inside and outside of both running rails on opposite sides of the same tie. The ballast under the tie shall be completely and uniformly tamped from 15 inches inside of the rail to the end of the tie. The tamping tools and limit switches shall be set to avoid damage to the track structure directly beneath the ballast layer.
b.The Contractor shall t amp the center of the tie on ly if approved by the Engineer. When the tamping operation is completed, all cribs shall be filled in.
4.Dressing . After ballasting and surfacing operations are completed, the track work shall be dressed by utilizing a ballast regulator to provide the b allast section shown on the Plans. Following dressing, the ballast shall be flush with the top of tie and cribs shall be full. There shall be no ballast material left on the base of the rails, tie plates, or top of the ties.
5.Damaged Track Spikes . If d uring the raising, aligning and surfacing operations any track spikes become damaged, loose, or are otherwise not functioning as intended, the Contractor shall remove damaged spikes, fill the resulting holes with synthetic tie plugging material specified i n Subsection 709.04(e) , and drive a new spike in accordance with Subsection 662.07( g).
6.Damaged Ties . If during the raising, aligning, and surfacing operations any ties become damaged such that the ties are defective as defined in 49 C.F.R. § 213.109 , the damaged ties shall be removed and replaced with new ties and fastenings at no additional expense to the Agency.
j.New Ballasted Track Construction Tolerances . Trackwork shall be constructed as shown on the Plans and meet the alignment of the existing tracks to which it will be connected. The final track alignment shall be continuous throughout and with in the tolerances specified in this Subsection. The actual centerline of track shall be within ± 1/4 inch of the locations indicated on the Plans. The top of rail elevation shall be within ± 1/4 inch of the elevations indicated on the Plans. The Contractor shall perform a conventional survey to measure the horizontal and vertical alignment, track geometry, superelevation, and gage of the as -built track. The as -built alignment shall be compared to the design alignment indic ated on the Plans. The track shall be within the tolerances shown in Table 662.07D . Any deviations above the allowable specified shall be corrected at no cost to the Agency. 6-253 TABLE 662.07D – TRACK SURFACE AND ALIGNMENT CONSTRUCTION TOLERANCES Track Surface and Alignment Parameter Maximum Allowable Construction Tolerance Deviation from uniform profile on either rail at the mid -ordinate of a 62 -foot chord shall not exceed 1/4 in. Deviation from zero cross level at any point on tangents or the specified elevation on curves shall not exceed 1/8 in. The difference in cross level between any two points less than 62 feet apart on tangents or curves shall not exceed 1/4 in. Deviation from uniform alignment at the mid-ordinate of a 62 -foot chord on tangent and curved track shall not exceed 1/4 in.
k.Final Track Inspections . If the initial as -built survey indicates deviations in excess of those specified in Table 662.07D , the Contractor shall perform an additional conventional survey after correcti ve action has been performed to bring the track to within tolerances for final surface, alignment, gage, cross level, and superelevation. Track inspections shall be performed in the presence of the Engineer. The Contractor shall notify the Engineer 7 calen dar days in advance of requesting any track inspection. Track deviations, as disclosed by the inspection described above, which exceed tolerances specified herein shall be corrected by the Contractor at no additional cost to the Agency. Additional inspecti ons are required to ensure the corrections have been made. Traffic shall not be permitted upon the newly installed track section until the track has been accepted by the Engineer.
662.08 REMOVE AND REPLACE RAIL . The Contractor shall remove existing jointed rail and furnish
and install replacement jointed rail or CWR at locations shown in the Plans. The Contractor shall supply and install new joint bar bolts, washers, nuts, track spikes, and as many new joint bars, tie plates, rail anchors an d welds as necessary to complete this work. Relay rail shall be subject to inspection and acceptance by the Engineer prior to installation. Relay rail shall meet the requirements of Subsection 715.0 6(b). 6-254 Existing rail and track hardware shall be removed within the limits shown on the Plans. Existing rail and track hardware shall be removed and disposed of as specified in Subsection 662.04 . Any material damaged or lost due directly to the Contractor’s operations shall be replaced at the Contractor’ s expense. Sufficient ballast shall be removed from the cribs for adzing and anchor application. On ties that require adzing, the ties shall be adzed to get a full and even bearing for new tie plates. Excessive adzing shall be avoided. The adzed surface sh all be parallel to the top of the ties. All spike holes shall be plugged in accordance with Subsection 662.07( g)(6). All newly adzed surfaces shall be coated with a preservative meeting the requirements of AWPA Standard M4 in accordance with Subsection 726 .01. The replacement rail and joint bar assemblies shall be installed in accordance with Subsection 662.07(c) . Additional requirements for laying and adjusting CWR are specified in Subsections 662.07(d) and Subsection 662.07(e) . Rail shall be laid on tie p lates as specified in Subsection 662.07(b) . Rail shall be spiked as specified in Subsection 662.07( g) and anchored as specified in Subsection 662.07( h). CWR shall be welded in accordance with Subsection 662.07(f) and Subsection 662.14 . After rail installat ion is completed, the ballast shall be dressed in accordance with Subsection 662.07( i)(4).
662.09 REMOVE AND RESET RAILROAD TRACKS . The Contractor shall remove and reset existing
jointed rail track as shown in the Contract or as directed by the Engineer. The Contractor shall furnish new joint bars, joint bar bolts, washers, nuts, track spikes, and rail anchors. Existing rail, ties, and track hardware shall be removed and stockpil ed for reuse within the limits shown on the Plans in accordance with Subsection 662.04 . New ballast shall be installed as required in accordance with Subsection 662.05 , Subsection 662.06 , and Subsection 662.07 . Track shall be reconstructed to the alignmen t and profile shown on the Plans using existing rail, ties, and new track hardware in accordance with Subsection 662.07 . The Contractor shall surface, align, tamp, and dress the track as specified in Subsection 662.07( i).
662.10 REMOVE AND REPLACE CROSS TIES. The Contractor shall remove existing cross ties,
properly dispose of all removed cross ties, and install new cross ties, including tie plates and tie attachment hardware, as detailed in the Contract and as directed by the Engineer. The size of the rep lacement ties shall be as indicated on the Plans. The Contractor shall clean the tie surfaces sufficiently to permit the identification of defective cross ties. The Contractor shall remove only those cross ties designated by the Engineer as being defective . Cross ties shall be removed in such a manner that the existing line and surface of the rails is not disturbed. The crib shall be excavated sufficiently to allow for the installation of the new cross tie without jacking or otherwise disturbing the rails. 6-255 New cross ties shall be installed in accordance with Subsection 662.07(a) , except ties shall be spaced in accordance with the existing spacing, unless otherwise noted in the Contract. Ties shall be plated as specified in Subsection 662.07(b) . Existing rail anchors which affect the installation of a new tie plate shall be removed and reinstalled. Ties shall be spiked as specified in Subsection 662.07( g) with the following additional requ irements:
a.All replacement ties shall be spiked to the existing track gage provided the existing gage is at, or within, the limits specified in Table 662.07A . The Contractor shall be responsible for gaging if the existing track gage is not within the above limits. Limits of gaging shall extend to the limits of tie replacement in the Contract.
b.Spiking shall be deferred until either of the following condition s is satisfied when a tie is to be installed on an existing joint:
1.Where the rail joint requires a new rail joint assembly, the assembly shall be fully installed.
2.Where the rail joint assembly requires bolt replacement, the bolts shall be replaced and fully tightened. After the installation of the cross ties, tie plates, track spikes, and rail anchors, the Contractor shall replace the ballast that was removed for this operation. The Contractor shall tamp the ballast as specified in Subsection 662. 07(i). If the existing rail is CWR, the rail shall be thermally adjusted in accordance with Subsection 662.07(d) and Subsection 662.07(e) .
662.11 REMOVE AND REPLACE BRIDGE TIES . The Contractor shall remove all existing bridge ties,
properly dispose of all removed existing bridge ties, and install new timber bridge ties, including tie plates and tie attachment hardware, as detailed in the Plans and as directed by the Engineer. Installation of new timber bridge ties required to complete the wor k shall be performed in accordance with AREMA Chapter 7, Section 1.7.8 ; AREMA Chapter 7, Part 4 ; and AREMA Chapter 15, Section 8.3 . Holes for bolts connecting bridge ties to stringer top flanges shall be drilled the same diameter as the bolt. Bridge tie to stringer top flange connectors shall be installed in accordance with the manufacturer ’s instructions. 6-256 All field cut ends and connection holes in timber members shall be treated with a field -applied preservative treatment meeting the requirements of AWPA Standard M4 in accordance with Subsection 726.01 . Tie plates shall be installed on all new ties in accor dance with Subsection 662.07(b) .
662.12 RAISE, ALIGN, AND SURFACE TRACK . The Contractor shall raise, align, and surface track
at the locations indicated in the Contract, or as directed by the Engineer. The completed track section shall conform with Table 662.12A for the FRA class of track as defined in the Contract. The track shall be raised in 2 -inch maximum nominal lifts unless otherwise approved by the Engineer.
a.Track Alignment . The track alignment shall be in conformance with Table 662.12A .
b.Track Surface . The track surface shall be in conformance with Table 662.12A . TABLE 662.12A – ALLOWABLE TRACK SURFACE AND ALIGNMENT MAINT. DEVIATIONS Track Surface and Alignment Parameter Class of Track 1 2 3 4 The runoff in any 31 feet at the end of a raise shall not exceed 2-5/8 in. 2-1/4 in. 1-1/2 in. 1-1/8 in. Deviation from uniform profile on either rail at the mid -ordinate of a 62 -foot chord shall not exceed 2-1/4 in. 2 in. 1-5/8 in. 1-1/2 in. Deviation from zero cross level at any point on tangents or the specified elevation on curves shall not exceed 2-1/4 in. 1-1/2 in. 1-1/4 in. 1 in. The difference in cross level between any two points less than 62 feet apart on tangents or curves shall not exceed 2-1/4 in. 1-5/8 in. 1-1/2 in. 1-1/4 in. Deviation from uniform alignment at the mid-ordinate of a 62 -foot chord on tangent and curved track shall not exceed 3-3/4 in. 2-1/4 in. 1-1/4 in. 1 in.
c.Track Elevation . Superelevation and grade shall conform to the Plans. 6-257 (d) Ballast . Ballasting, surfacing, aligning, tamping , and dressing of track shall be performed in accordance with Subsection 622.07( i) with the following modifications:
1.Where tie plates do not exist (only if permitted in Contract or as directed by the Engineer) the Contractor shall tamp the tie up tight so that it is in full contact with the base of the rail. No portion of the tie plate shoulder, stone, or any foreign material shall be permitted under the base of rail at these locations.
2.The Contractor shall pe rform as many raising and surfacing passes as necessary to bring the track surface to the geometric parameters in Table 662.12A for the designated FRA class as indicated in the Contract.
3.Final surfacing and aligning shall bring the track to final grade and alignment and shall comply with surface and superelevation tolerances specified in Table 662.12A for the designated class of track.
4.In the event that the work required to comply with the designated FRA class of track results in a situation where there is greater than allowable deviations in the runoff of the top of rail elevations due to meeting the existing grade at a highway grade crossing, bridge, or turnout, the Contractor shall s urface out of face consistent with designated FRA class of track requirements and tolerances or as directed by the Engineer. Such work shall be incidental to the Contract.
e.Loose Joint Bolts . All loose joint bolts shall be tightened by mechanical means.
f.Thermal Adjustment . If the existing rail is CWR, the rail shall be thermally adjusted in accordance with Subsection 662.07(d) and Subsection 662.07(e) .
662.13 TEMPORARY RAIL CONNECTIONS . The Contractor shall furnish and install temporary
connections between the new rail and existing rail to allow for the passage of a train (during work periods of non -exclusive and interruptible access) and at the end of an exclusive occupancy period. The closure rail shall be connected to the new rail by a compromise joint if the rails are of different sections. The connection rail shall have a full number of bolts and spikes.
a.On tangents, the minimum length of the closure rail shall be 16 feet.
b.On curves or spirals, the minimum length of the closure rail sha ll be 19 -1/2 feet. 6-258 662.14 THERMITE WELDING .
a.Quality Control . The thermite welding process shall be performed by trained and experienced personnel. The training shall include specific training provided by the welding kit manufacturer. Training shall include classroom and hands -on instruction with the course curricu lum set by the manufacturer. The Contractor shall provide for a representative of the welding kit manufacturer to be on call with 2 working days’ notice to assist in case any unusual problems arise in the field. The welding kit manufacturer shall be prep ared to provide for laboratory testing needed to solve a problem and shall have the capability of tracking their kit materials backward through the chain of production.
1.Thermite Weld Qualification Inspection and Testing . Prior to performing thermite welding, the weld kit, weld procedure , and each welding crew shall be qualified as specified below. Welding crews shall prepare, in accordance with the approved method and procedure for thermite field welding, at least three s amples of a thermite weld. Each welding crew shall perform at least one of each type of sample weld. Sample welds shall join two pieces of each type of running rail used in the Contract, each a minimum of 30 inches and a maximum of 36 inches in length. Sample weld testing and inspection shall be performed by an approved certified independent testing laboratory. The Engineer may audit operations to ensure that inspection and tests are being performed in accordance with the specified procedures. The Contrac tor shall test three sample welds. A manual ultrasonic test shall be performed on all sample welds from each type of rail as specified in Subsection 662.14(a)(2) . Sample welds shall be ultrasonically inspected in accordance with ASTM E164 . Acceptance crite ria for this test shall be as specified in Subsection 662.14(a)(2)e. and Subsection 662.14(a)(2)g . Approval of the weld kit, welding process, and welding crews will be contingent upon all sample welds satisfying the specified requirements. Should any sampl e weld fail to satisfy the specified requirements, the welding process, the welding crew, or both, will not be qualified for the work. A supervisor shall be employed for each welding crew who has been trained and certified for performing thermite field wel ding by the manufacturer supplying the weld kits. Should the supervisor of the welding crew be replaced during the work, the welding crew shall be re-qualified under the new supervisor. If the Contractor changes the manufacturer of the welding kits or weld ers during the work of the Contract, the sample weld testing shall be completed again. 6-259 (2) Field Weld In -Track Testing . During field welding, all field welds shall be hand tested and inspected as specified herein. All welds shall be ultrasonically tested by a certified testing laboratory as specified in this s ubsection. Thermite welds shall be visually and dimensionally inspected as soon as the weld has been completed. Manual ultrasonic testing of thermite welds in track designated as in -revenue service sh all be completed within 24 hours of weld completion. Manual ultrasonic testing of thermite welds in track designated as out -of-revenue service shall be completed within 30 days of the date of welding but in all cases prior to the resumption of train operat ions. The ultrasonic testing calibration process shall be able to permit detection of defects of size, type, and location described under the acceptance criteria. The test procedure and equipment shall include, but not be limited to, the following:
a.Calibration .
1.Calibration shall be performed by the Contractor when starting work and at least every hour.
2.Recalibration shall be performed by the Contractor if there is a change in probes or cables.
b.Web Test .
1.The Contractor shall use two 45° probes placed on top of the rail in pitch - catch configuration.
2.The Contractor shall scan from the top to the bottom of the weld with both probes.
3.The Contractor shall scan the top and bottom edges of the weld with a single probe.
4.The Contractor shall scan from both sides of the weld. 6-260 c. Head Test .
1.The Contractor shall use two 45° probes placed on sides of the rail head in pitch -catch configuration.
2.The Contractor shall scan across the weld with both probe s, angling them up and down to cover the entire cross -section of the weld.
3.The Contractor shall scan each vertical edge of the weld with a single probe.
4.The Contractor shall scan from both sides of the weld.
d.Base Test .
1.The Contractor shall use a 70° probe.
2.The Contractor shall place the probe on top of the base far enough back from the center of the weld so that the beam is following the path as defined in the approved test procedure.
3.The Contractor shall move toward and away from the weld , angling the probe from side to side.
4.The Contractor shall scan both sides of the base and from both sides of the weld.
5.The test crew shall fully document their findings on the approved Contract form.
e.Ultrasonic Acceptance Criteria .
1.Welds shall be free of defects. No defect in the weld of any size will be accepted in the head, web, or base of the rail.
2.The Engineer may perform random manual ultrasonic tests of field welds.
f.Physical Inspection .
1.The Contractor shall visually and dimensionally inspect each field weld to determine conformance with the alignment and finishing tolerances specified herein. 6-261 2. When the weld is made and the molds and risers are removed, the weld shall be checked for obvious failures such as an inco mplete weld.
3.Once the weld has been ground and the weld temperature is less than 200°F, physical inspections shall be made by the Contractor to verify acceptance criteria.
g.Physical Acceptance Criteria . The welds shall meet the following criteria in o rder to be considered acceptable by the Engineer during the physical inspection.
1.The weld shall have no visible voids, rat holes, nicks, or gouges in surfaces which have been ground.
2.The weld collar in the web zone and base of the rail shall not be g round except to remove notches created by upset conditions. Sharp protrusions and gouges shall be blended into the rail and weld collar contour to eliminate possible stress risers.
3.Combined vertical offset and crown camber at top of rail, at rail temper ature of 200°F or less, shall not exceed 0.060 inch es. No dip camber will be allowed.
4.Combined horizontal offset and horizontal kink camber at the side of the rail head, at a rail temperature of 200°F or less, shall not exceed 0.060 inches.
5.A finished deviation of not more than + 0.010 inches or - 0.00 inches from the parent section of rail head surface will be allowed.
6.Weld straightness tolerances shall be as shown in AREMA Chapter 4 .
h.Defective Welds . Defective welds shall be cut out and replaced with a 19 -1/2 foot section of new or like relay rail, and welded in place, at no additional cost to the Agency.
i.Final Ultrasonic Testing . Final ultrasonic testing shall be performed by an on -track detector car. 6-262 (b) Thermite Welding .
1.General Requirements . Thermite welds shall be made with approved weld kits. Thermite welds shall be made to join jointed rail or CWR. Thermite welds will be required in turnouts and in areas of bituminous concrete pavement crossings to eliminate rail joints. The ends of rails to be welded shall be saw -cut. Torch cutting of rails will not be allowed. If plug rails are required to meet the requirements, or to replace a defective we ld, the minimum length of the plug rail shall be 19 -1/2 feet. Thermite welds shall not be located within the following areas in standard track work. In the case of special trackwork, some exceptions will be allowed with the approval of the Engineer.
a.Within 8 feet of the center of any bolted, bonded, or insulated joint.
b.Within 2 feet of a thermite weld in the opposite rail. Thermite welds shall be staggered a minimum of 4 tie cribs from any thermite or flash butt weld in the opposite rail.
c.Within 6 inches of any hole drilled in rail.
d.Within 9 inches of a weld which has been cut out.
e.Within 4 inches of a tie plate. If necessary, ties shall be spaced to provide this clearance prior to the welds being made.
f.Within 10 feet of the roadway surface of a grade crossing.
g.A minimum of 16 feet from any existing weld in the same rail on tangent (19 -1/2 feet on curves) or as directed by the Engineer.
h.On open deck bridges or timber structures.
2.Weld Quality . Weld quality shall be as specified in this section.
3.Welding Requirements . The Contractor shall use approved kits that are self -tapping and require minimum preheating. Rail ends shall be saw -cut at right angles to the rail. The surface of the rail shall be cleaned for a length of approximately 6 inches from each end, so that the surface of the rail is free of all grease, dirt, loose oxide, scale, and moisture. Burrs and lipped metal which would interfere with the proper fit of molds shall be removed. 6-263 Rails shall be aligned wi th respect to alignment prior to welding. Proper rail end alignment shall be achieved by the use of an alignment device designed and manufactured for this purpose. In no case will the use of track jacks or track spikes be allowed for rail end alignment. Striking of rail with blunt tools, such as a maul, is prohibited with the exception of brass hammers. The Contractor shall ensure that rail ends are secured against longitudinal, vertical, lateral, or twisting movement during and immediately after the weld ing process. Rail pullers or expanders shall be used to prevent movement. Rail clips or anchors shall be installed if there is a chance of longitudinal movement. At the time of field welding, the rail gap shall be as specified by the manufacturer of the weld kit. A hydraulic rail puller or expander shall be used to establish the proper rail end gap at all thermite weld locations. Field welds shall not be made when the ambient temperature is below 40°F or during inclement weather such as rain, mist, sleet, o r snow unless approved by the Engineer and in compliance with the Operating Railroad’s CWR plan. The weld shall not be subjected to a sudden strain by releasing hydraulic pressure too quickly. The rail puller or expander shall be left in place until the rail has cooled to below 500°F. Any movement of the rail before the weld has cooled to at least 500°F may result in the failure of the weld. When welding rail in track on lines in service, sufficient time to complete weld ing shall be allowed so that the surface finish and temperature of the welded joint will permit safe operation of scheduled trains without delay to service. The temperature of the welded joint shall be 200°F or less before rail traffic is allowed to pass over the weld. When welding rails in track on lines in service, the Contractor shall ensure that rail fastenings and anchors are properly installed prior to restoration of service. Thermite field welds shall be made in accordance with and shall not deviate fr om the manufacturer’s recommendations and AREMA Chapter 4 . 6-264 a. The weld shall be trimmed and ground to meet the following requirements and as otherwise specified by the manufacturer:
1.The weld shall be finished to the tolerances specified.
2.A rail shear, specifically designed for the purpose, shall be utilized to remove weld upset. Use of a saw, cutting torch, or other handheld devices is prohibited.
3.A rail profile grinder specifically designed for the purpose shall be used to finish grind the top and sides of the weld. Use of a handheld grinder is prohibited.
4.The weld collar in the web zone and base of rail shall not be ground except to remove notches created by upset conditions, sharp protrusions, and gouges. These shall be blended into the rail and weld collar contour to eliminate possible stress risers. Defects visible to the unaided eye shall be removed by grinding. If removal by grinding cannot be accomplished without damaging rail, the weld shall be removed. Precautions shall be taken to avoid excessive pressure during grinding of a weld in order to prevent overheating of the rail surface.
5.Finish grinding shall only be performed when the weld temperature is less than 200°F.
6.Overheating of rail when grinding shall be avoided. Onc e the weld has cooled to below 200°F prior to grinding, the temperature rise due to grinding shall not exceed this temperature.
7.Welds shall be ground before the heat leaves the weld. Heat shall not be re - introduced into the sides of the weld where it wi ll be ground.
8.Finish rail grinding on the top and sides of the weld shall be completed prior to the operation of trains over the weld.
4.Weld Identification . Weld identification shall be marked on the field side of rail using a permanent metal marker and the required information shall be recorded in conformance with these specifications.
5.Records . The Contractor shall prepare a record for each weld completed and submit the records as specified in Subsection 662.03 . 6-265 662.15 METHOD OF MEASUREMENT . The quantity of Railroad Ballast to be measured for payment will be the number of tons placed in the complete and accepted work, as determined based on vehicle loads. A load ticket shall be furnished to the Engineer for each load delivered to the job site. The quantity of Remove and Replace Bridge Ties of the size specified in the Contract to be measured for payment will be the number of existing bridge ties removed and replaced in the complete and accepted work. The quantity of Remove and Replace Cross Ties of the size specified in the Contract and as directed by the Engineer to be measured for payment will be the number of existing cross ties removed and replaced in the complete and accepted work. The quantity of Remove and Replace Switch Ties to be measure d for payment will be the total linear feet of existing switch timbers removed and replaced in the complete and accepted work. The quantity of Remove and Replace Jointed Rail to be measured for payment of the type specified will be the number of linear fee t of rail installed in the complete and accepted work. Individual rails will be measured separately. The quantity of Remove and Reset Jointed Railroad Track to be measured for payment will be the number of linear feet of track removed and reset in the complete and accepted work. Individual rails will not be measured separately. Measurement will be along the centerline of the track. The quantity of Remove Railroad Track to be measured for payment will be the number of linear feet of track removed in the complete and accepted work. Individual rails will not be measured separately. Measurement will be along the centerline of the track. The quantity of Ballasted Track Construction with Jointed Rail to be measured for payment will be the actual number of linear feet of track constructed to final grade in the complete and accepted work. Individual rails will not be measured separately. Measurement will be along the centerline of the track. The quanti ty of Ballasted Track Construction with CWR to be measured for payment will be the actual number of linear feet of track constructed to final grade in the complete and accepted work. Individual rails will not be measured separately. Measurement will be alo ng the centerline of the track . The quantity of Remove Jointed Rail and Install CWR to be measured for payment of the type specified will be the number of linear feet of track installed in the complete and accepted work. Individual rails will not be measu red separately. Measurement will be along the centerline of the track. 6-266 The quantity of Raise, Align, and Surface Track to be measured for payment will be the number of linear feet of track raised, aligned, and surfaced to final grade in the complete an d accepted work. Individual rails will not be measured separately. Measurement will be along the centerline of the track. The Contractor shall perform as many raising and surfacing passes to achieve final grade or as directed by the Engineer to bring the t rack to the designated design standard as indicated in the Contract. Multiple passes will not be measured separately for payment. The quantity of Gaging Track to be measured for payment will be the number of linear feet of track gaged. Measurement will be taken along the centerline of the track.
662.16 BASIS OF PAYMENT . The accepted quantity of Railroad Ballast will be paid for at the Contract
unit price per ton. Payment will be full compensation for furnishing, transporting, handling, testing, placing, an d tamping the materials specified, and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work. The accepted quantity of Remove and Replace Bridge Ties will be paid for at the Contract unit price per each. Payment will b e full compensation for furnishing, transporting, handling, and placing the material specified, including removal and disposal of old ties, furnishing and installing tie plates where required, furnishing new ties, spikes, and tie plugging material as requi red, and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work. The accepted quantity of Remove and Replace Cross Ties will be paid for at the Contract unit price per each. Payment will be full compensation for furnishi ng, transporting, handling, and placing the material specified, including excavation, removal, and disposal of old ties, furnishing and installing tie plates where required, furnishing new ties, spikes, and tie plugging material as required, and for furnis hing all labor, tools, equipment, and incidentals necessary to complete the work. Railroad Ballast will be paid for separately. The accepted quantity of Remove and Replace Switch Ties will be paid for at the Contract unit price per linear foot . Payment wil l be full compensation for furnishing, transporting, handling, and placing the material specified, including excavation, removal, and disposal of old ties, furnishing and installing tie plates where required, furnishing new ties, spikes and tie plugging ma terial as required, and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work. Railroad Ballast will be paid for separately. The accepted quantity of Remove and Replace Jointed Rail will be paid for at the Contract unit price per linear foot of rail. Payment will be full compensation for removing existing rail, tie plates, joint assemblies, track spikes, and rail anchors; furnishing, transporting, distributing, handling, and installing the materials specified, including jointed rail, tie plates, spikes, and other miscellaneous materials; and for furnishing all labor, tools, equipment, and incidental necessary to complete the work. 6-267 The accepted quantity of Remove and Reset Jointed Railroad Track will be paid for at the Contract unit price per linear foot of track. Payment will be full compensation for supplying new rail hardware, removing, handling, and resetting rail, ties, and rail hardware, and for furnishing all labor, tools, equipment, and incidentals necessary to co mplete the work. The accepted quantity of Remove Railroad Track will be paid for at the Contract unit price per linear foot of track. Payment will be full compensation for furnishing all materials, labor, tools, equipment, and incidentals necessary to com plete the work. The accepted quantity of Ballasted Track Construction with Jointed Rail will be paid for at the Contract unit price per linear foot of track. Payment will be full compensation for furnishing, transporting, distributing, handling, and instal ling the materials specified, including jointed rail, tie plates, spikes, and other miscellaneous materials, and for furnishing all labor, tools, equipment, and incidental necessary to complete the work. Railroad Ballast will be paid for separately. The ac cepted quantity of Ballasted Track Construction with CWR will be paid for at the Contract unit price per linear foot. Payment will be full compensation for furnishing, transporting, distributing, handling, and installing the materials specified, including CWR, tie plates, spikes, and other miscellaneous materials, and for furnishing all labor, tools, equipment, and incidental necessary to complete the work. The costs for thermite welding, all preparation and training activity will not be paid separately but shall be considered incidental to this item. Railroad ballast will be paid for separately. The accepted quantity of Remove Jointed Rail and Install CWR will be paid for at the Contract unit price per linear foot. Payment will be full compensation for removing existing rails; installing new CWR; installing OTM such as tie plates, anchors, and spikes; scrapping of non -salvaged track materials; de - stressing rail as required; and for furnishing all labor, tools, equipment, and incidentals necessary to complete the work. Thermite welding will be considered incidental to this item. The accepted quantity of Raise, Align, and Surface Track will be paid for at the Contract unit price per linear foot. Payment will be full compensation for furnis hing all materials, labor, tools, equipment, and incidentals necessary to complete the work. Verification surveys, corrections of track deviations, and re - inspections shall be considered incidental to this item. Tightening of all loose bolts within the lim its of this item shall be considered incidental to this item. Multiple passes will be considered incidental to the actual length of track feet raised, aligned, and surfaced to final grade. Railroad Ballast will be paid for separately. The accepted quantity of Gaging Track will be paid for at the Contract unit price per linear foot. Payment will be full compensation for furnishing all materials, labor, tools, equipment, and incidentals necessary to complete the work. Replacing missing spikes with new track s pikes will be considered incidental to this item. The cost of temporary rail connections will be considered incidental to the other Contract items of this section. 6-268 Payment will be made under: Pay Item Pay Unit 662.0010 Railroad Ballast ................................ ................................ ......................... Ton 662.0110 Remove and Replace Bridge Ties ................................ ............................. Each 662.0120 Remove and Replace Cross Ties ................................ ............................... Each 662.0130 Remove and Replace Switch Ties ................................ ............................. Linear Foot 662.0200 Remove and Replace Jointed Rail ................................ ............................ Linear Foot 662.0250 Remove and Reset Jointed Railroad Track ................................ ............... Linear F oot 662.0300 Remove Railroad Track ................................ ................................ ............ Linear Foot 662.0350 Ballasted Track Construction with Jointed Rail ................................ .......Linear Foot 662.0360 Ballasted Track Construction with CWR ................................ ................. Linear Foot 662.0400 Remove Jointed Rail and Insta ll CWR ................................ ..................... Linear Foot 662.0410 Raise, Alig n, and Surface Track ................................ ............................... Linear Foot 662.0450 Gaging Track ................................ ................................ ............................ Linear Foot 6-269 SECTION 663 – RAILROAD -HIGHWAY GRADE CROSSINGS
663.01 DESCRIPTION . This work includes rehabilitation of existing railroad -highway grade crossings
and construction of new full depth bituminous concrete or precast concrete railroad -highway grade crossings, including furnishing all required materials and necessary incidental s in accordance with the Contract and as directed by the Engineer.
663.02 MATERIALS . Materials shall meet the requirements of the following subsections:
Aggregate for Railroad Ballast ................................ ................................ .................. 704.03 Cross Ties ................................ ................................ ................................ ................... 709.04( c) Corrugated Polyethylene Pipe (CPEP) ................................ ................................ ......710.03 Polyvinyl Chloride (PVC) Plastic Pipe ................................ ................................ ......710.05 New Rail ................................ ................................ ................................ .................... 715.06(a) Relay Rail ................................ ................................ ................................ ................... 715.06(b) Other Track Material (OTM) ................................ ................................ ..................... 715.0 8 Bituminous Concrete Mixtures ................................ ................................ .................. 716.02 Geotextile under Railroad Ballast ................................ ................................ .............. 720.03 Precast Concrete Grade Crossing Systems ................................ ................................ 781.01 Rubbe r Rail Seal ................................ ................................ ................................ ........ 781.02
663.03 SUBMITTALS . The following information shall be prepared and submitted for review and
approval by the Engineer . Submittals shall meet the requirements of Subsection 105.0 6.
a.Work Plan . A site specific plan for work to be undert aken at each crossing, including construction staging, any proposed temporary paving or temporary detours, and material storage sites. The work shall comply with the approved traffic control plan.
b.Shop Drawings . Shop drawings showing details of crossin g surface and for other materials in related sections and production quality control documentation.
c.Inspection Procedures . Procedures for inspection of track prior to placing it in service for train operation.
d.Continuous Welded Rail (CWR) Maintenan ce Plan or Temperature Adjustment Plan . If construction affects existing CWR, the Contractor shall submit a plan (CWR Maintenance Plan) for maintenance of the Operating Railroad’s neutral temperature in accordance with their CWR program or submit a plan to adjust the CWR to the Operating Railroad’s neutral temperature.
Source: Vermont Standard Specifications for Construction, 2024 Edition. Pages 1011–1042 of 1,380.