6-309 SECTION 665 – RAILROAD TURNOUT CONSTRUCTION
665.01 DESCRIPTION . This work shall consist of providing new welded railroad turnouts, including a
complete timber switch tie set; connecting the turnout to the existing track, including realignment of existing track, installation of new rail, welds, and compromise welds, as required; raising, aligning, and surfacing turnouts and crossovers; and the removal of turnouts and crossovers.
665.02 MATERIALS . Materials shall meet the r equirements of the following subsections:
Aggregate for Railroad Ballast ................................ ................................ .................. 704.03 Switch Ties ................................ ................................ ................................ ................. 709.04(d) Tie Plugging Material ................................ ................................ ................................ 709.04(e) New Rail ................................ ................................ ................................ .................... 715.0 6(a) Railroad Turnouts ................................ ................................ ................................ ......715.07 Other Track Material (OTM) ................................ ................................ ..................... 715.0 8 New turnouts shall be of the rail section and weights shown on the Plans. Ballast shall be of the type shown on the Plans.
665.03 SUBMITTALS . The following information shall be prepared and submitted for review and
approval by the Engineer . Submittals shall meet the requirements of Subse ction 105.0 6.
a.Fabrication drawings shall be submitted in accordance with the requirements of Subsection 105.06 . All details, dimensions, quantities, parts, specifications, and sections necessary to fabricate and assemble the turnout shall be included i n the submittal.
b.A complete schedule of the materials proposed for installation and the source of the material. Information to be provided on the rail shall include rail weight, rail section, drilling pattern, typical rail length, date rolled, and the name of the mill where the rail was rolled.
c.Sub-assembly component and bolt certificates of origination.
d.Source for ballast and gradation analysis of a sample from the ballast source.
e.Manufacturer’s certificate of compliance for all materials that are incorporated into the work.
f.Manufacturer’s cut sheet of lubricant or graphite for application to switch plates following the cleaning of the plates. 6-310 665.04 TURNOUT CONSTRUCTION REQUIREMENTS . The Contractor shall take special care and precautions when unloading, handling, and installing a turnout package. Care shall be taken to prevent rail bending, switch ties splitting, and loss or damage to associated switch materials. Removal of existing track necessary to install the new turnout sh all be performed in accordance with Subsection 662.04 . The Contractor shall handle ballast in accordance with Subsection 662.05 and shall install bottom ballast in accordance with Subsection 662.06 . Turnout installation shall be performed as follows:
a.Turnout Layout . Pre-plated switch ties, turnout rails, switch, frog, and guard rail (or turnout panels if furnished as such) shall be placed in accordance with the fabrication drawings.
b.Switch Tie Installation . The Contractor shall transport and store switch ties in accordance with AREMA Chapter 30, Section 3.5.11 .
1.New switch ties shall be handled and placed with either a mechanical tie insertion device or tie tongs. The use of picks will not be permitted.
2.The Contractor shall take special car e and vigilance during handling and unloading of switch ties to avoid damage to the ties. Any switch ties damaged during handling or installation shall be replaced by the Contractor at no expense to the Agency.
3.New switch ties shall be placed with the plate side up, square with the line of the rails along the straight route side of the turnout and not skewed. Switch ties shall be spaced in accordance with the fabrication drawings.
c.Rail and Temporary Bolted Joint Installation . Rail and temporary bolt ed joints shall be installed in accordance with the following requirements:
1.Rail layout and joint locations shall be in accordance with the fabrication drawings.
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. 6-311 (3) Tie plates and switch plates shall be free of any dirt and foreign matter prior to rail being installed. Stone dust and extraneous material shall be removed by blowing or brushing off the surface of the tie plate to prevent damage and to ensure proper seating of the rail.
4.When placing rail, regular tie plates shall be square with the rail and switch plate orientation shall be per the fabrication drawings. The should ers of both tie and switch plates (where located) shall bear firmly against the sides of the rail base. Under no circumstances shall the tie plate or switch plate shoulder be allowed under any portion of the rail base. Care shall be taken to ensure that th e rail is fully supported and properly seated on the tie and switch plates.
5.Temporary joint bar assemblies shall be installed with four bolts, as furnished from the fabricator. Joints to be field welded shall be located as specified in Subsection 715. 07(a). Temporary joint bar assemblies shall not be lubricated.
6.Insulated joints shall be located as specified in Subsection 715. 07(h).
7.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.
8.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 m echanical bolt machine and set to apply the required torque. The Contractor shall not use this method to of striking the bars when installing insulated joint bars.
9.Rail clips shall be installed to fasten the rail to the tie plates. Clips shall be drive n until there is an approximately 3/8 -inch gap between the edge of the tie plate and the inner edge of the rear arch of the clip. Clips shall not be overdriven.
10.Rail anchors shall not be installed at tie locations which utilize spring clips to fasten the rail to the tie plates. 6-312 (d) Ballasting, Surfacing, Aligning, Tamping, and Dressing of Turnout . Ballasting, surfacing, aligning, tamping, and dressing of the turnout shall be performed in accordance with Subsection 662.07( i) with the following exceptions and additions:
1.The ballast under the switch ties shall be completely and uniformly tamped outward 15 inches from the gage and field sides of each rail. The head block ties supporting the switch stand shall be tamped compl etely to the end of the tie.
2.Upon completion of surfacing, aligning, and tamping, the regular tie plates and various types of switch plates shall bear fully on the tie and the rail, switch points, and frog shall bear fully on the plates. No portion of the various plate shoulders, or stone or any foreign material, will be permitted under the base of rail, switch points, frog, or guard rails. In no case shall the gap between the base of the switch point and the top of the plate exceed 1/16 - inch.
3.The g uard rail flangeway, switch point, frog flangeway, and switch point rod areas shall be cleaned and dressed to allow component parts to function properly. Tie cribs that contain switch rods shall be kept open to provide drainage and prevent build -up of snow and ice in the winter.
4.If, during the installation process, any screw spike becomes damaged, bent, loose, is found to not meet the proper alignment or designated head contact, or is otherwise not functioning as intended, the Contractor shall remove da maged screw spikes. The resulting holes shall be filled with a synthetic tie plugging material as specified in Subsection 709.04(e) and new screw spikes shall be installed. Driving of timber screw spikes with a sledgehammer or spike maul is prohibited. Use of track spikes will not be permitted.
5.The tie cribs shall be dressed such that the ballast does not extend higher than 2 -inches below the top of tie elevation within the limits of the first switch tie ahead of the point of switch to the tie behind th e heel. All tie cribs with switch rods shall be dressed such that the ballast does not extend higher than 6 -inches below top of tie elevation. The profile of the ballast in the vicinity of the switch stand shall not extend higher than 6 -inches below the to p of tie elevation. The ends of the switch ties extending from the first switch tie ahead of the point of switch to the tie behind the heel shall be dressed such that the ballast does not extend higher than 2 -inches below the top of tie elevation. 6-313 (e) Post-Surfacing Adjustments . After all turnout surfacing work has been completed, the Contractor shall check and make any adjustments necessary to turnout gage, frog guard rail facing limits, switch points and stock rails, the switch stand, and the connecti ng rod tension.
1.Graphite or other lubricant as specified in Subsection 715. 07(k) shall be applied to all switch plates following cleaning of the plates.
2.The Contractor shall tighten all loose joints and frog bolts by mechanical means to manufactu rer recommendations.
f.Temporary Joints . The Contractor shall thermite weld temporary turnout joints in accordance with Subsection 662.14 .
g.Construction Tolerances . The new turnout shall be constructed within the tolerances shown in Table 665.04A . TABLE 665.04A – 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 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 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. 1 An exception to this tolerance is the allowable rate of change of elevation within spirals which shall be between 3/8 inch and 1/2 inch over 40 feet. The Contractor shall raise, align, and surface the adjacent existing track to tie into the turnout as specified in Subsection 662.12 . The Contractor shall weld the new turnout rails to existing continuous welded rail in accordance with Section 662 , install ing new rail as required. Rail anchors shall be installed as specified in Section 662 . 6-314 665.05 RAISE, ALIGN, AND SURFACE TURNOUTS AND CROSSOVERS . The Contractor shall raise, align, and surface turnouts and crossovers at the locations indicated in the Co ntract, or as directed by the Engineer. Turnouts and crossovers shall be raised in 2 -inch maximum nominal lifts unless otherwise approved by the Engineer. The completed turnout or crossover section shall conform with Table 665.04A .
a.Turnout and Crossove r Alignment . Turnout and crossover alignment shall be in conformance with Table 665.04A .
b.Turnout and Crossover Surface . Turnout and crossover surface shall be in conformance with Table 665.04A . Each end of the turnout or crossover shall be surfaced a m inimum of 100 feet in each direction.
c.Turnout and Crossover Elevation . The grade shall conform to the Plans. No superelevation shall be added within the limits of the turnout or crossover, unless otherwise shown on the Plans.
d.Ballast . Ballasting, s urfacing, aligning, tamping, and dressing of track shall be performed in accordance with Subsection 665.04(d) and the following:
1.The Contractor shall perform as many raising and surfacing passes as necessary to bring the turnout or crossover surface t o the geometric parameters in Table 665.04A .
2.Final surfacing and aligning shall bring the turnout or crossover to final grade and alignment and shall comply with surface tolerances specified in Table 665.04A . The limit of surfacing shall extend at lea st 100 feet beyond the switch points and at least 100 feet beyond the last long timber on both the straight and diverging track.
e.Post-Surfacing Adjustments . Post -surfacing adjustments shall be performed as specified in Subsection 665.04(e) .
665.06 REMOVAL OF TURNOUTS AND CROSSOVERS . Existing turnouts and crossovers shall be
removed within the limits shown on the Plans. All materials removed shall become the property of the Contractor and shall be removed from the project site and properly disposed of, unless otherwise stated in the Contract.
665.07 METHOD OF MEASUREMENT . The quantity of Railroad Turnout; Railroad Turnout, No. 8;
and Railroad Turnout, No. 10 to be measured for payment will be the number of each turnout installed in the complete and acc epted work. 6-315 The quantity of Removal of Railroad Turnout to be measured for payment will be the number of each turnout removed in the complete and accepted work. The quantity of Remove and Reset Railroad Turnout to be measured for payment will be the number of each turnout removed and reset in the complete and accepted work. The quantity of Raise, Align, and Surface Turnout and Raise, Align, and Surface Crossover to be measured for payment will be the actual number of turnouts or crossovers aligned and surfaced in the complete and accepted work.
665.08 BASIS OF PAYMENT . The accepted quantity of Railroad Turnout; Railroad Turnout, No. 8; and
Railroad Turnout, No. 10 will be paid for at the Contract unit price per each. Payment will be full compensation for furnishing and installing the turnout, including all required welding, and for furnishing all materials, labor, tools, equipment, and incidentals necessary to compl ete the work. The accepted quantity of Removal of Railroad Turnout will be paid for at the Contract unit price per each. Payment will be full compensation for removing the existing turnout, and for furnishing all materials, labor, tools, equipment, and in cidentals necessary to complete the work. The accepted quantity of Remove and Reset Railroad Turnout will be paid for at the Contract unit price per each. Payment will be full compensation for removing and resetting the existing turnout, and for furnishing all materials, labor, tools, equipment, and incidentals necessary to complete the work. The accepted quantity of Raise, Align, and Surface Turnout and Raise, Align, and Surface Crossover will be paid for at the Contract unit price per each. Payment will b e full compensation for furnishing all materials, labor, tools, equipment, and incidentals necessary to complete the work. All loose joints and frog bolts shall be tightened by mechanical means and included in the item for Raise, Align , and Surface Turnout or Raise, Align, and Surface Crossover. Geotextile, subballast, and ballast will be paid for separately under the appropriate Contract items. Payment will be made under: Pay Item Pay Unit 665.0100 Railroad Turnout ................................ ................................ ....................... Each 665.0108 Railroad Turnou t, No. 8 ................................ ................................ ............ Each 665.0110 Railroad Turnout, No. 10 ................................ ................................ .......... Each 665.0200 Removal of Railroad Turnout ................................ ................................ ...Each 665.0300 Remove and Reset Railroad Turnout ................................ ........................ Each 665.0500 Raise, Align, and Surface Turnout ................................ ............................ Each 665.0550 Raise, Align, and Surface Crossover ................................ ........................ Each 6-316 SECTION 667 – OTHER TRACK MATERIAL
667.01 DESCRIPTION . This work shall consist of removing and replacing joint bar sets, installing
compromise rail joint assemblies to connect two abutting rails of differing sizes, installing conventional poly or bonded insulated joints, and removing and replacing tie plates.
667.02 MATERIALS . Materials shall meet the requirements of the following subsections:
Other Track Material (OTM) ................................ ................................ ..................... 715.0 8
667.03 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.Fabrication drawings of all track material components. For joint bars and compromise joint ba rs, the fabrication drawings shall indicate all bolt hole locations.
b.Manufacturer’s certificate of compliance for all materials that are incorporated into the work.
c.For insulated joints, the following submittals are required:
1.Catalog cuts or o ther manufacturer’s descriptive literature on insulated joints and fasteners.
2.Manufacturer’s field installation (to include bolt torque) and test procedures.
3.Locations where rail cutting and welding is required for insulated joints.
4.Fabrica tion drawings, including fabrication details, for insulated joints.
d.Shop drawings and catalog cuts for all assembly hardware for bridge tie connections.
667.04 JOINT BAR SETS . All defective joint bar sets identified by the Engineer shall be removed an d
acceptable similar replacement bar sets (assemblies) installed. If one or both joint bars are defective, both joint bars shall be replaced. Joint bars may be deemed defective and rejected by the Engineer for the following reasons:
a.Cracks, breaks, or other flaws that impair the proper functioning of the bar or where integrity of the bar has been compromised.
b.Bolt holes with wear which prevents a snug fit of the bolt assembly.
Source: Vermont Standard Specifications for Construction, 2024 Edition. Pages 1083–1089 of 1,380.