665RAILROAD TURNOUT CONSTRUCTION

665

6-309SECTION 665 – RAILROAD TURNOUT CONSTRUCTION

665.01DESCRIPTION . 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.

665.02MATERIALS . 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.

665.03SUBMITTALS . 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.

All details, dimensions, quantities, parts, specifications, and sections necessary to fabricate and assemble the turnout shall be included i n the submittal.

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.

cleaning of the plates.

665 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:

if furnished as such) shall be placed in accordance with the fabrication drawings.

AREMA Chapter 30, Section 3.5.11 .

or tie tongs. The use of picks will not be permitted.

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.

the straight route side of the turnout and not skewed. Switch ties shall be spaced in accordance with the fabrication drawings.

accordance with the following requirements:

shall be placed so that it can be laid with as little handling as possible.

665 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.

shall be per the fabrication drawings. The shoulders 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.

fabricator. Joints to be field welded shall be located as specified in Subsection 715. 07(a). Temporary joint bar assemblies shall not be lubricated.

Joint bars shall be properly seated in the rail.

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.

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.

rail to the tie plates.

665 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:

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.

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.

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.

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.

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.

665 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.

switch plates following cleaning of the plates.

manufactu rer recommendations.

Subsection 662.14 .

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

665 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 .

Table 665.04A .

665.04A. Each end of the turnout or crossover shall be surfaced a minimum of 100 feet in each

direction.

be added within the limits of the turnout or crossover, unless otherwise shown on the Plans.

accordance with Subsection 665.04(d) and the following:

the turnout or crossover surface to the geometric parameters in Table 665.04A.

alignment and shall comply with surface tolerances specified in Table 665.04A. The limit

of surfacing shall extend at least 100 feet beyond the switch points and at least 100 feet

beyond the last long timber on both the straight and diverging track.

Subsection 665.04(e).

665.06REMOVAL 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.

665.07METHOD 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 accepted work.

665

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.

665.08BASIS 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 complete 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 incidentals 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 be 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

00 Railroad Turnout .......................................................................................Each

08 Railroad Turnout, No. 8 ............................................................................Each

10 Railroad Turnout, No. 10 ..........................................................................Each

00 Removal of Railroad Turnout ...................................................................Each

00 Remove and Reset Railroad Turnout ........................................................Each

665.0500 Raise, Align, and Surface Turnout ............................................................Each

50 Raise, Align, and Surface Crossover ........................................................Each

667

6-316SECTION 667 – OTHER TRACK MATERIAL

667.01DESCRIPTION . 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.

667.02MATERIALS . Materials shall meet the requirements of the following subsections:

Other Track Material (OTM) ................................ ................................ ..................... 715.0 8

667.03SUBMITTALS . 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.

the fabrication drawings shall indicate all bolt hole locations.

667.04JOINT 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:

the bar has been compromised.