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. 6-270 (e) Layout Plan . A site -specific plan showing schematically the track layout, rail sections to be used, location of joints, location of welds, location of compromise joints or compromise w elds, and connections to existing rails.
f.Precast Concrete Panels .
1.Fabrication drawings detailing cross tie spacing and placing prior to installation. The manufacturer shall submit fabrication drawings within 15 working days after onsite field measurements are taken by the manufacturer. Fabrication drawings shall show details of crossing surface, and for other materials in related sections and production quality control documentation. The fabrication drawings shall include a full cross section v iew of the panels on cross ties, a plan view of panels in the track, and a detail of the flangeways. The fabrication drawings shall also indicate data on panel weights, loading specifications, lifting eye specifications, and any other applicable informatio n.
2.Manufacturer’s drawings showing mounting details for the existing or proposed precast concrete railroad grade crossing panels crossing surface, and for other materials in related sections and production quality control documentation.
3.Manufactur er’s printed installation instructions.
4.Manufacturer’s standard warranty.
g.Rubber Rail Seal .
1.Product data sheet.
2.Manufacturer’s installation requirements.
663.04 Construction Requirements .
a.General Requirements .
1.The crossing shall be installed in accordance with AREMA and the MUTCD .
2.Track work at highway crossings shall be closely coordinated with signal system installation and highway grading, drainage, and paving work, so that paving between tracks and adjac ent to tracks can be accomplished in a single operation with highway paving. 6-271 (3) Where necessary to open crossings to highway traffic before final precast concrete panel installation and paving is completed, temporary panels or paving may be required. The Contractor shall ensure that temporary panels and pavement surfaces are properly maintained to avoid adverse highway traffic loads to the track structure. Any temporary paving shall be completely removed and the surfaces restored before final paving.
b.Removal of Track . Track removal shall conform to Subsection 662.04 .
c.Underdrain . Underdrain shall be installed in accordance with Section 605 at the locations shown on the Plans. Underdrain flushing basins shall be installed at the upstream end of the underdrain and at intermediate points as required to provide cleanout access points no more than 200 feet apart.
d.Track Construction . Ballasted track shall be constructed in accordance with Section 662 and the following.
1.All rail within grade crossings shall be CWR.
2.Connections to existing rail sections shall be completed as shown on the Plans.
a.Standard joint bars shall be installed in accordance with Subsection 667.04 .
b.Compromise joint bars shall be installed i n accordance with Subsection 667.05 .
c.Field welded joints shall be installed in accordance with Subsection 662.07(f) . Welds that fall within the area of the rubber rail seal shall be ground down to the profile of the rail.
3.Track construction within t he limits of the crossing shall be completed, with track lined and surfaced to final horizontal and vertical location, and with ballast tamped and dressed, before the embedded rubber rail seal interface is installed. The embedded rubber rail seal shall be installed in accordance with the manufacturer ’s procedures and requirements.
4.Where practical, track should be placed in service and as many train movements as possible allowed to traverse the crossing prior to establishing final line and surface, so as to attain the optimum ballast compaction in the crossing.
e.Bituminous Concrete Pavement . The Contractor shall install bituminous concrete pavement in accordance with Section 406 , as directed by the Engineer. The Contractor shall coordinat e the installation of new pavement with the embedded rubber rail seal manufacturer’s installation requirements. 6-272 (f) Precast Concrete Grade Crossing Panels . Precast concrete grade crossing panels shall be installed in accordance with AREMA Chapter 5, Secti on 8.2 ; AREMA Chapter 5, Section 8.3 ; and the manufacturer’s recommendations.
g.Rubber Rail Seals . Rubber rail seal shall be installed between the field and gage sides of the rail and the adjacent crossing surface and shall be compatible with the railroa d grade crossing for which it is to be installed. The Contractor shall install rail seals level, in accordance with the manufacturer’s recommendations and as directed by the Engineer. The elastomeric interface shall provide a tight fit with the rail to m inimize moisture infiltration and facilitate easy installation on both tangent and curved track. The ends of each piece of elastomeric interface shall be precision cut to ensure straight square ends.
h.Install bituminous concrete pavement transitions at each end of the gage panels as indicated on the Plans.
663.05 Precast Concrete Panel Grade Crossing Repair .
a.This work shall consist of fastening existing precast concrete railroad grade crossing panels in accordance with the manufacturer’s recommenda tions, including furnishing and installing all hardware required to reattach the existing panels at a railroad -highway crossing, at the location indicated in the Plans.
b.This work includes fastening existing precast concrete railroad grade crossing pane ls that are loose, including the removal and resetting of the panel as necessary to complete the work per the manufacturer’s recommendations. The Contractor shall be responsible for any damage to the existing panel, the elastomeric interface , and any other railroad facilities, and shall repair all damage caused by their operations at their own cost.
c.The existing 1/8 -inch elastomeric bearing pad shall be removed and reinstalled between the t op of the timber cross tie and bottom of the concrete panels.
d.The field side flangeway shall be 2 -1/2 inches (± 1/4 inch) wide from the ball of rail to the panel. The filler shall be flush and level with the top of panel. The gage flangeway filler shal l be 2 -3/4 inches to 3 inches maximum from the ball of rail to concrete panel in standard 56 -1/2-inch gage for tangent track. 6-273 663.06 METHOD OF MEASUREMENT . The quantity of Reconstruct Railroad -Highway Grade Crossing to be measured for payment will be on a lump sum basis for each crossing installed in the complete and accepted work. The quantity of Precast Concrete Panel Grade Crossing System to be measured for payment will be on a lump sum basis for each crossing installed in the complete and accepted work. The quantity of Precast Concrete Panel Grade Crossing Surface Repair at the location specified to be measured for payment will be for each precast panel repaired in the complete and accepted work. The quantity of Rubber Rail Seal to be measured for payment will be the number of linear feet of rail seal installed in the complete and accepted work. Field and gage side seals will be considered a single installation unit and will not be measured separat ely.
663.07 BASIS OF PAYMENT . The accepted quantity of Reconstruct Railroad -Highway Grade Crossing
at the location specified will be paid for at the Contract lump sum price. Payment will be full compensation for removal and disposal of existing materials ; excavation; furnishing, transporting, handling, and installing the materials specified including rubber rail seal, spikes, tie plates, other track material, underdrain, geotextile; temporary paving on roadways; and for furnishing all labor, tools, equipm ent, and incidentals necessary to complete the work. Where required, underdrain carrier pipe and all appurtenances, such as joints, bends, and caps, underdrain flushing basins, material used for backfilling voids created by the removal of unsuitable materi al below subgrade, all associated excavation, backfill, geotextile fabric, and outletting of underdrain to the existing drainage swale will not be paid for directly but will be considered incidental to Reconstruct Railroad - Highway Crossing. Restoring roadw ay surfaces, emulsified asphalt used in the treatment of surfaces prior to placing permanent pavement, and furnishing and placing final roadway pavement will be paid for separately under the appropriate Contract items. The accepted quantity of Precast Conc rete Panel Grade Crossing System at the location specified will be paid for at the Contract lump sum price. Payment will be full compensation for furnishing, transporting, handling, and installing the materials specified, including precast concrete panels with elastomeric flangeway filler, elastomeric bearing pads, and other track material; and for furnishing all labor, tools, equipment, and incidentals to complete the work. 6-274 The accepted quantity of Precast Concrete Panel Grade Crossing Surface Repair at the locations specified will be paid for at the Contract price for each panel. Payment will be full compensation for furnishing the necessary hardware, removing, and installing the panel with the associated materials specified, including the protection and reuse of the elastomeric flangeway filler, elastomeric bearing pads, and other track material; and for furnishing all labor, tools, equipment, and incidentals to complete the work. Where not incidental to Reconstruct Railroad -Highway Grade Crossing, th e accepted quantity of Rubber Rail Seal will be paid for at the Contract unit price per linear foot. Payment will be full compensation for furnishing, transporting, handling, and placing the materials specified and for furnishing all labor, tools, equipmen t, and incidentals necessary to complete the work. Payment will be made under: Pay Item Pay Unit 663.0100 Reconstruct Railroad -Highway Grade Crossing ................................ .......Lump Sum 663.0200 Precast Concrete Panel Grade Crossing System ................................ .......Lump Sum 663.0250 Precast Conc rete Panel Grade Crossing Surface Repair ........................... Each 663.0270 Rubber Rail Seal ................................ ................................ ....................... Linear Foot 6-275 SECTION 664 – RAILROAD SIGNALS
664.01 DESCRIPTION . This work includes designing, furnishing and installing new railroad -highway
active warning systems with new metered power services, traffic preemption interconnection where indicated on the Plans, and testing of equipment, material, hardware, and all nece ssary appurtenances specified or required to provide a safe and operating automatic highway crossing warning systems (AHCWS) as specified in this section and as indicated on the Plans.
664.02 MATERIALS . Materials shall meet the requirements of the followi ng subsections:
Sand Borrow and Cushion ................................ ................................ ......................... 703.03 Dense Graded Crushed Stone for Subbase ................................ ................................ 704.06 Electrical Conduit ................................ ................................ ................................ ......752.0 6 Automatic Highway Crossing Warning System (AHCWS) ................................ ......781.03
664.03 Submittals .
a.Pre-Installation 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.Catalog Cut Sheets . Catalog cut sheets and descriptive literature for all material as specified herein.
2.Working Drawings . Working drawings, including, but not limited to, the following:
a.Fabrication drawings for the assembly of automatic highway crossing warning layout, including detailed bills of material. Fabrication drawings shall include detailed drawings of signal masts, cantilever gates, shelters and cases, and their respective foundations.
b.Design calculations in accordance with the AREMA C&S Manual for signal masts, cantilever gates, and their respective foundations.
c.Detai led installation drawings for each layout indicating the location and sizes of the new wiring.
d.Drawings showing the proposed size and equipment layout of the housing, including rack, lighting, convenience outlet arrangement, and exhaust fan mounting and location.
Source: Vermont Standard Specifications for Construction, 2024 Edition. Pages 1043–1048 of 1,380.