715MISCELLANEOUS METALS

715

7-62SECTION 715 – MISCELLANEOUS METALS

715.01IRON CASTINGS . Iron castings shall meet the following requirements:

shall be true to pattern in form and dimensions, free from pouring faults, sponginess, cracks, blow holes, and other defects in positions affecting their strength and value for the serv ice intended. Castings shall be boldly filleted at angles and the arises shall be sharp and perfect. The surfaces shall have a blemish -free finish. All castings shall be blast -cleaned or otherwise effectively cleaned of scale and sand to present a smooth, clean, and uniform surface. The dimensions of the frames and covers shall substantially conform to the dimensions for cast iron covers and frames as shown in the Contract. The covers shall be flush with the upper surface of the frame when seated. The seati ngs shall be machined or made quiet using a gasket cushioning insert or supported by a three -point triangular suspension. The minimum depth of insertion of the cover into the frame shall be no less than 2 inches. As a minimum, the covers and frames shall m eet the HS-20 loading requirements of AASHTO and the proof load requirements of AASHTO M 306 . Covers shall be identified by the words “STORM SEWER,” “WATER,” “SEWER,” “ELECTRIC,” or others as applicable, in raised cast letters as indicated in the Contract or as directed by the Engineer.

No. 35B, unless otherwise specified.

requirements of ASTM A536, Grade 80 -55-06.

715.02ALUMINUM ALLOY . Aluminum alloy material shall be fabricated from Alloy 6061 -T6

715 7-63 (d) Extruded Bars, Rods, Shapes, and Tubes . Extruded bars, rods, shapes, and tubes shall be in accordance with ASTM B221.

in accordance with ASTM B241 .

requirements .

with ASTM B308 .

ASTM B429 .

requirements of ASTM B211 . Bolt heads shall conform to the requirements of American standard heavy hexagon, ANSI B18.2.1/ANSI B18.2.3.6M . Nuts shall conform to the r equirements of ANSI B18.2.4.6M in accordance with the requirements of ANSI B18.2.1 and ANSI B18.2.2/ANSI B18.2M . Bolt threads shall conform to the requirements of ANSI B1.1/ANSI B1.13M . Both bolts and nuts shall be given an anodic coating at least 0.2 mils in thickness with a dichromate or boiling water seal.

conforming to the requirements of ASTM B209 . Aluminum alloy shims shall be made from alumi num alloy sheet or plate conforming to the requirements of ASTM B209 or ASTM B221 .

715.03STEEL FOR CORRUGATED METAL FORMS . Steel for corrugated metal forms and form

supports shall be in accordance with ASTM A653, Coating Designation G165. Fabrication shall be in conformance with the requirements of ASTM A924 .

715 7-64 715.04 ROOFING SYSTEMS. Roofing systems shall consist of the rafters, roof deck, underlayment materials, roofing panel system, flashing and trim.

709.02

with ASTM D226 , Type II (No. 30 asphalt felt) or as recommended by the manufacturer.

required for the application.

other hardware. Syste ms shall be structural standing seam steel roof panel systems in accordance with ASTM E1514 . Roofing panel systems shall have an uplift rating of UL 90 as determined in accordance with UL 580 and shall accommodate thermal movements for ambient temperature changes of 120°F.

ASTM A653 , Coating Designation G90 with a minimum nominal thickness of 0.0239 inches (16 ounce). Roof panels shall have a two -coat finish consisting of a fluoropolymer top coat and compatible primer in accordance with ASTM A755 on the exposed side of the panel. The top coat shall be green and approved by the Engineer prior to installation . Roof panels shall have a polyester washcoat in accordance with ASTM A755 on the unexposed side of the panel.

Coating Designation G90. Clips shall have a minimum n ominal thickness of 0.064 inches. Panels clips shall be concealed and mechanically connect panels to supports.

be all components required by the manufacturer for the r oofing panel system not otherwise specified herein. Miscellaneous hardware and accessories shall be in accordance with the manufacturer’s recommendations.

715

7-65Roof panel systems shall have a minimum 2 year manufacturer’s warranty on all components of a

roof panel system, a 20 year manufacturer’s warranty on panel finishes, and a 20 year manufacturer’s warranty on weathertightness. All warranties shall be effective from the date of installation and demonstrate the manufacturer agrees to repair or replace the defective component. Manufacturers shall provide a standard warranty agreement form for each warranty. Sta ndard warranty agreements shall include the owner ’s name, building type, building location, roofing system model, roofing system type, date of completion, Contract amount of material and installation, warranty type, warranty terms and conditions, and signature blocks (for the manufacturer, roofing contractor, and owner).

715.05BICYCLE RACK SYSTEMS . Bicycle rack systems shall be U -shaped, surface mounted, one of

the products listed on the Agency’s Approved Products List , and meet the following requir ements:

specified on the Plans.

715.06RAIL . Rail shall be continuous welded or jointed carbon steel rail

In no case shall new rail be furnished in lengths of less than 39 feet unless approved by the Engineer. The acceptable amount and lengths of short rails shall be as specified in AREMA Chapter 4, Section 2.1.11 .

rail saw. Torch cut rails will not be accepted .

shall be uniform with holes drilled and dressed per AREMA Chapter 4, Section 2.1.12 . Rail drillings shall be as specified in AREMA Chapter 4, Section 3.3 .

drilled.

715 7-66 (2) New Rail, Standard Strength . Standard strength rail shall be in accordance with AREMA Chapter 4 for standard strength rail.

4 for high strength rail.

modified herein.

Section 4.5 to verify that no internal rail defects are prese nt. Each length of rail shall have an attached label with certification information including the rail test date.

be as specified in AREMA Chapter 4, Section 3.3 for current AREMA rail sections. For other rail sections, drilling shall be uniform and match the punching pattern of the joint bars. All holes sha ll be drilled.

rails will not be accepted.

fractures, engine burn fra ctures, head -web separation, piped rail, horizontal split heads, vertical split heads, torch cut rail ends, torch cut bolt holes, or compound or transverse fissures will not be accepted. Relay rail shall be free of shelly spots, head checks, corrugations, bends or kinks, and any other visual defects.

AREMA Chapter 4, Section 3.12 . Limits will be based on the specific AREMA rail section and class of track in which th e rail is to be installed. Relay rail shall only have wear on one side of the head. Rail with wear on both sides of the head will be rejected. For non -AREMA rail sections, wear limits shall be as specified in the Contract. The following limits shall also a pply to relay rail:

715 7-67 715.07 RAILROAD TURNOUTS .

shall be new high strength rail in accordance with Subsection 715.06(a) . The required rail section shall be as indicated on the Plans and all steel work shall us e the same rail section.

Plan 100.

turnout as designated by frog number shall be as specified on the Plans.

and joint layout shall be modified as required to meet the requirements of Subsection

715.07(d) and Subsection 715.07(h) and all joint locations shall clear tie plates by a

minimum of 4 inches to allow for field welding. Additional modifications to joint layout may be required as indicated in the Contract.

Plan 912 except that head block ties shall be 14-feet long when used with low switch stands

24-inches high and 3-foot long connecting rods, and 16-feet long when used with high

switch stands and 6-foot connecting rods.

utilize timber screw spikes to secure all plates. Elastic rail clips shall be utilized to fasten

the rail to the plates. Use of track spikes will not be accepted. Each plate shall utilize a

minimum of four screw spikes. The gage plates shall have all hole positions spiked.

715

prior to field welding

assembly

with 1/2-inch-wide marks locating both sides of each tie. All rail joints shall be match

marked on the head of the rail. Turnouts shall be completely shop assembled for inspection

by the Engineer at the manufacturer’s facility. Following the inspection and any corrective

work required as a result of the inspection, the turnout shall be dismantled. The switch

portion shall be shipped as a panel with remaining switch ties pre-plated and bundled in

groups of four unless otherwise specified in the Contract.

715

AREMA Portfolio Plan 600 and AREMA Portfolio Plan 621.

Frogs and frog plates shall be in accordance with AREMA Portfolio Plan 622 for No. 8 frogs and

AREMA Portfolio Plan 623 for No. 10 frogs.

width. Frog guard rail assemblies and guard rail plates shall conform to AREMA Portfolio Plan

502 and AREMA Portfolio Plan 504, except the separator and end blocks shall be designed to allow

for the adjustment of the flangeway width by use of removable shims. When used with unworn

rails, the width of the flangeway shall be adjustable in a range from 1-1/2 inches to 1-7/8 inches.

risers for screw spikes in accordance with AREMA Portfolio Plan 112. Switch points shall be in

accordance with AREMA Portfolio Plan 112 and AREMA Portfolio Plan 221, Detail 5100. Stock

rails shall be in accordance with AREMA Portfolio Plan 112 and AREMA Portfolio Plan 221.

The stock rail extensions ahead of the point of switch shall be modified as follows: the straight

stock rail shall extend 12-feet ahead of the point of switch and the bent stock rail shall extend 6-

feet ahead of the point of switch.

Bolted heel block assemblies shall be in accordance with AREMA Portfolio Plan 221, Detail 1125.

Vertical, adjustable, insulated switch rod and clip assemblies shall be in accordance with AREMA

Portfolio Plan 222.

Adjustable, boltless stock rail brace assemblies shall be in accordance with AREMA Portfolio Plan

224.

Insulated gage plates shall be used at the point of switch and on the first and third ties ahead of the

point of switch. Gage plates shall be in accordance with AREMA Portfolio Plan 112 and AREMA

Portfolio Plan 223. Switch plates shall be in accordance with AREMA Portfolio Plan 112 and

AREMA Portfolio Plan 224. Turnout plates shall be in accordance with AREMA Portfolio Plan

112. Transition plates shall incorporate 1:80 rail cant and be used where rail transitions from 1:40

cant to no cant.

715

for unrestricted use. All switch stands shall be supplied complete with a connecting rod assembly

and both the stand and the connecting rod assembly shall meet the requirements of AREMA

Portfolio Plan 251.

Inside switches shall be low mast with trihandle and the target shall be yellow/green. Mainline

switches shall be high mast with trihandle and the target shall be red/green.

The switch stand and connecting rod assembly, including bolts, nuts, washers, and cotter pins,

shall be of the proper size to fit the switch and switch stand.

the rail section compatible with the frog and switch points used. At field weld locations, rails shall

be furnished with only the hole furthest from the end of the rail drilled.

715.08(f)

Insulated joints shall be located so as to be suspended within the tie cribs and have a stagger

distance between the two insulated joints that is a minimum of 32 inches and a maximum of 56

inches.

and screw spikes shall conform to Subsection 715.08(e). Spring clips for use at temporary (to be

welded in the field) and insulated joints need not be identical in design to those used on a standard

rail. Clips used at joint bars shall have similar performance characteristics, shall be made by the

same manufacturer, and shall be capable of being installed into identical shoulders as the standard

rail clip. All switch ties shall be pre-drilled with a pilot hole prior to installing screw spikes.

Driving of timber screw spikes with a sledgehammer or spike maul is prohibited.

shall come furnished pre-plated from the fabricator unless otherwise specified in the Contract.

be specifically manufactured for this application.

715

OTHER TRACK MATERIAL (OTM)

Figure 5-1-5, with Punching A – 8 Spike Holes.

Figure 5-1-7, with Punching A – 8 Spike Holes.

rails to be connected and have no defects.

used. Each plate shall have 8 holes punched for 5/8-inch track spikes. Four of the

holes shall be punched for rail holding spikes and four holes punched for the use of

plate holding spikes.

addition to being judged defective due to improper fit, they may be deemed

defective for any of the following reasons:

and shall have the same plan area and spike hole configuration as the tie plates.

Spikes shall meet the dimensional requirements of AREMA Chapter 5, Section 2.2. The material

of the spikes shall meet the requirements of AREMA Chapter 5, Section 2.1.

715

the requirements of AREMA Chapter 5, Part 7.

compatible with the rails to be connected and have no defects such as pitting or excessive

rust.

ties, meet the requirements of AREMA Chapter 30, Appendix 30-A-2 and shall have a

successful service history of at least 20 years on either commuter rail, intercity passenger

rail, or freight rail within the United States.

capable of being driven and removed parallel to the rail manually with a sledgehammer, a

specially purposed tool for installing and removing the clips, or through mechanical means.

provide longitudinal restraint and resistance to rail rollover. The nominal toe load applied

shall be 2,750 pounds with a working deflection of 7/16 of an inch. The surface area in

contact with the rail shall be 0.82 square inches. The rail seat clamping force with two clips

installed on one tie plate shall be 5,500 pounds.

inserted into the tie plate shoulder, rear arch, heel which bears with the field side of the tie

plates, front arch, and toe which bears on the rail base.

the spring clips, with raised rail shoulders to prevent lateral movement of the rail. Tie plates

shall meet the requirements of AREMA Chapter 5, Section 1.1. Plates shall incorporate

1:40 cant. Tie plates shall be suited for 5-1/2 inch or 6-inch rail bases as applicable. Tie

plates shall contain four 1-inch round holes located at the corners of the plate and two

11/16-inch square holes, one each on the gage and field sides of the plate centered between

the round holes.

AREMA Chapter 5, Section 10.1 and AREMA Chapter 5, Section 10.2.

715

be installed. Joint bar bolts and nuts shall meet the material requirements of AREMA

Chapter 4, Section 3.5.

be connected and have no defects.

section, as indicated in the Contract, and be of proper design for the rail sections to be

connected.

requirements of AREMA Chapter 4, Section 3.4.

they fit properly, are premanufactured and are compatible with both rails which are to be

connected. Relay bars will be subject to inspection and approval by the Engineer.

the rail exactly. No-hand joint bars and 4-hole joint bars will not be acceptable unless

approved by the Engineer.

inspection and acceptance of compromise rail joint assemblies by the Engineer shall always

be conditioned upon the fact that the final acceptance cannot be given until the assembly

is installed in its final position. In addition to being deemed defective due to improper fit,

compromise rail joint assemblies may be deemed defective for the following reasons:

715

connected.

Chapter 4, Section 3.5.

consist of two joint bars of same general configuration as 6-hole standard joint bars

conforming to the dimensional requirements of the selected rail section. Insulated joint bars

shall have a rolled, heat-treated steel core surrounded by uniform, single pour, polymeric

insulation material and be designed for use in installations requiring insulated signal joints.

Bar, end post, and bushing insulation material shall be impervious to oil, grease, and water,

and with electrical resistance characteristics equal to or greater than fiber insulation

meeting the requirements of AREMA Chapter 4, Section 3.9. Insulated joints shall be

resistant to abrading, cracking, cutting, spalling, and fatigue failure under impact loads,

and shall exhibit deflection characteristics comparable to standard steel rail joints.

Insulated joints shall be complete with bars, 3/16-inch end posts, bushings, and washer

plates and high strength bolts.

Bolts, nuts, and flat washers shall conform to the chemical and mechanical requirements

of ASTM F3125, Grade A490 and having Class 2A and Class 2B thread fit. A positive

means for maintaining the tension in the bolts through in-service vibrations shall be

provided by a prevailing lock nut complying with ASME B18.16.6 and IFI-101. Bolt holes

shall be located and sized in conformance with the rail drilling pattern specified in AREMA

or as directed by the Engineer. Flat washers, if required, shall be hardened ASTM F3125,

Grade A325 or Grade A490, and tempered carbon steel.

Insulated joints shall be suspended. Tie plates for supported insulated joints shall be

polymer.

715

totaling 19-1/2 feet in length (minimum length of one side of the plug rail is 8 feet) and

conforming to the dimensional requirements of the selected rail section. Rail shall meet the

requirements of Subsection 715.06.

Joint bars shall be fabricated from quenched carbon steel conforming to AREMA Chapter

4.

Joint bars shall be full contact bars conforming to the dimensional requirements of the

selected rail section. Joint bars shall be smooth and straight. The inside face of joint bars

shall be coated with pre-bonded insulating material, smooth, with no branding or stamping.

The Contractor shall supply end posts and high strength bolts.

Fabrication tolerances shall be in accordance with AREMA Chapter 4, Section 3.8.

Insulating material shall be of a high pressure, laminated design, impervious to oil, grease,

and water, with electrical resistance characteristics equal to or greater than fiber insulation,

and meeting the requirements of AREMA Chapter 4, Section 3.9. The end posts shall

project 1/4 inch (± 1/16 inch) below the base of rail and shall be 3/16 inch thick.

Bonded insulated joints joined together with adhesive and with six high-strength, 1 inch

diameter bolts. Bolts, nuts, and flat washers shall conform to chemical and mechanical

requirements of ASTM F3125, Grade A490 and having Class 2A and Class 2B thread fit.

A positive means for maintaining tension in bolts through in service vibrations shall be

provided by a prevailing lock nut complying with ASME B18.16.6. The bolt hole location

and size shall conform to drilling for rail as specified in AREMA. Flat washers, if required,

shall be hardened ASTM F3125, Grade A325 or Grade A490, and tempered carbon steel.

hardware required for installation of new timber shall meet the requirements of AREMA

Chapter 7, Section 1.6. All connection hardware shall be galvanized in accordance with

ASTM A153 unless otherwise noted.

715

nuts and washers.

washers.

steel open deck stringers. Bridge tie anchor and hook bolt dimensions shall be as

indicated on the Plans.

be free from burrs and cracks of any size and shall have a workmanlike finish.

The Brinell hardness of bridge tie anchors shall be greater than 390 and less than

430 when tested using ASTM E10. No cracks of any size in the steel macrostructure

will be allowed. Tie anchors shall have a slotted bolt hole to accommodate

variations in the thickness of the top flange.

length.

shall be formed with an integral flat washer provided with a hole in the washer to

permit nailing it to track crossties. The integral washers of the nuts shall be capable

of retaining the nuts in place when the bolts are tightened and provide an even

bearing surface on the track crossties.

Connection assemblies shall have a successful in-track service record on freight

railroads within the United States of at least 20 years.

associated attachment hardware shall be in accordance with AREMA Chapter 7, Section 1.7.8 and

as specified in the Contract.

716

7-77SECTION 716 – BITUMINOUS CONCRETE MIXTURES

716.01GENERAL REQUIREMENTS . Bituminous concrete mixtures shall be produced in accordance

with an Agency approved mix design, using aggregates and asphalt binder from Agency approved sources, at an approved bituminous concrete production facility . Asphalt binder for bituminous concrete mixtures shall meet the requirements of Subsection 702.0 1. WMA technologies and anti -strip additives, if used, shall meet the requirements of Subsection 702.03 and Subsection 702.04 , respectively. Aggregates for b ituminous concrete mixtures and recycled asphalt materials (RAM) shall meet the requirements of Subsection 704.10 and Subsection 704.2 2, respectively.

716.02BITUMINOUS CONCRETE MIXTURES

in this subsection shall be submitted in accordance with the Agency’s Bituminous Concrete Policy Manual . No paving of a mix design shall be started until the Contractor has submitted, and the Agency has approved the mix design, including cold feed gradations, mixing times, the percentage of each ingredient, including asphalt binder , the job mix formula (JMF ) from such a combination, and the optimum mixing and compaction temperatures. The design shall also include the control limits for quality control. A copy of all design test data used in developing the mix design, including graphs, may be required with t he submittal of the mix design or at any time when directed by the Agency. The stockpile gradation data shall be derived by wet sieve analysis. Coarse aggregates for Superpave shall be furnished with at least three stockpiles for mixes with a nominal maxi mum aggregate size (NMAS) greater than or equal to 1 inch (25.0 mm), two stockpiles for mixes with a NMAS greater than or equal to 1/2 inch (12.5mm) and greater than 3/8 inch (9.5 mm), and one stockpile for mixes with a NMAS less than or equal to 3/8 inch (9.5 mm). No change in the JMF may be made without Agency approval. The Agency may approve changes in the design’s JMF or discontinue use of the design if placement, finishing, or compaction characteristics are determined to be unsatisfactory. At the time that the mix design is submitted, the Contractor shall provide batched asphalt mixture to the Agency, for determining asphalt ignition oven calibration, in accordance with the Agency’s Bituminous Concrete Policy Manual .