SECTION 34 11 32

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Nov 25, 2013 (3 years and 6 months ago)

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RESILIENT
TIES
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FURNISH


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SECTION 34 11 3
2

RESILIENT TIES
-

FURNISH

PART 1
-

GENERAL

1.01

SECTION INCLUDES

A.

This
Technical Specifications

Section

includes specifications for design, fabrication,
testing, loading, handling, shipping and delivery to designated storage sites of resilient ties,
including rubber boots, block pads, rail fasteners, tie pads, rail insulators, and contact rail
insulator ass
embly or
support bracket
assembly
inserts. The following types of resilient ties
are included:

1.

Standard resilient ties.

2.

Long resilient ties.

1.02

RELATED
TECHNICAL SPECIFICATIONS
SECTIONS

A.

Section 01 33 00, Submittal Procedures.

B.

Section 01 33 23, Shop Drawings,

Product Data, and Samples.

C.

Section 01 43 00, Quality Assurance.

D.

Section 01 45 00, Quality Control.

E.

Section 34 05 17, Common Work Results for Trackway.

1.03

MEASUREMENT AND PAYMENT

Delete Articles 1.03A and substitute therefor the following:

A.

Separate measurement or payment will not be made for Work required under this Technical
Specifications Section.

All costs in connection with the Work specified in this Technical
Specifications Section will be considered to be included in the applicable Tr
ack
w
ork Line
Items in the
Price

Schedule
.

1.04

REFERENCE STANDARDS

A.

General:

1.

Submit certification that products furnished conform to the applicable reference
standards and specified requirements.
All AASHTO,
AREMA, ASTM, and
PCI
Standards,
Specifications,
and
tests
;

and other relevant Standards, Specifications, and
tests referenced herein shall be the latest publication as of the date of the bid
documents. The Contractor shall be responsible to keep all such publications up
-
to
-
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date as well as relevant new publ
ications and inform the VTA immediately when any
such updates/new changes occur. If additional expenses result from up
-
dates/changes, the Contractor shall present justification for the expenses in detail to
the VTA for review and approval.


2.

Where any req
uirements of these
Technical Specifications

are more stringent than the
requirements of applicable laws, regulatory requirements, standards, or codes, the
requirements indicated in these
Technical Specifications

shall govern.

B.

American Association of State

Highway and Transportation Officials (AASHTO):

1.

AASHTO T277


Standard Method of Test for Electrical Indication of

Concrete’s Ability to Resist Chloride Ion Penetration
.

C.

American Railway Engineering and Maintenance of Way Association (AREMA):

1.

AREMA Manual


Manual for Railway Engineering (Fixed Properties),


Volume 1,

Chapter 30, Part 4, “Concrete Ties”.

D.

American Society for Testing and Materials (ASTM):

1.

ASTM A167


Specifications for Stainless and Heat
-
Resisting



Chromium
-
Nickel steel Plate, Sheet and Str
ip.

2.

ASTM A536


Ductile Iron Castings.

3.

ASTM A706/A706M


Standard Specification for Low
-
Alloy Steel Deformed


and Plain

Bars for Concrete Reinforcement.

4.

ASTM C31/C31M


Standard Practice for Making and Curing Concrete



Test Specimens in the Field.

5.

ASTM C33


Standard Specification for Concrete Aggregates.

6.

ASTM C39/C39M


Standard Test Method for Compressive Strength of



Cylindrical Concrete Specimens.

7.

ASTM C78


Standard Test Method for Flexural Strength of Concrete


(Using

Simple Beam with Third
-
Point Lo
ading).

8.

ASTM C94/C94M


Standard Specification for Ready
-
Mixed Concrete.

9.

ASTM C114


Standard Test Methods for Chemical Analysis of



Hydraulic Cement.

10.

ASTM C143


Standard Test Method for Slump of
Hydraulic
-
Cement


Concrete.

11.

ASTM C150


Standard
Specification for Portland Cement.

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12.

ASTM C157/C157M


Standard Test Method for Length Change of Hardened


Hydraulic
-
Cement, Mortar, and Concrete.

13.

ASTM C172


Standard Practice for Sampling Freshly Mixed



Concrete.

14.

ASTM C192/C192M


Standard Practice for Mak
ing and Curing

Concrete Test


Specimens in the Laboratory.

15.

ASTM C227


Standard Test Method for Potential Alkali Reactivity of


Cement
-
Aggregate Combinations (Mortar
-
Bar



Method).

16.

ASTM C260


Standard Specification for Air
-
Entraining Admixtures


for Co
ncrete

17.

ASTM C265


Standard Test Method for Water
-
Extractable Sulfate in


Hydrated Hydraulic Cement

Mortar
.

18.

ASTM C295


Standard Guide for Petrographic Examination of



Aggregates for Concrete.

19.

ASTM C359


Standard Test Method for Early Stiffening of



H
ydraulic Cement (Mortar Method).

20.

ASTM C457


Standard Test Method for Microscopical Determination


of Parameters of
the
Air
-
void System in Hardened



Concrete.

21.

ASTM C490


Standard Practice for Use of Apparatus for the



Determination of Length Change of
Hardened Cement


Paste, Mortar, and Concrete.

22.

ASTM C494/C494M


Standard Specification for Chemical Admixtures for


Concrete.

23.

ASTM C586


Standard Test Method for Potential Alkali Reactivity of


Carbonate Rocks for Concrete Aggregates (Rock



Cylinder Me
thod).

24.

ASTM C617


Standard Practice for Capping Cylindrical Concrete



Specimens.

25.

ASTM C618


Standard Specification for Coal Fly Ash and Raw



Calcined Natural Pozzolan for Use in Concrete.

26.

ASTM C666/C666M


Standard Test Method for Resistance of Concrete to

Rapid

Freezing and Thawing.

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27.

ASTM C856


Standard Practice for Petrographic Examination of



Hardened Concrete.


28.

ASTM C917


Standard Test Method for Evaluation of Cement



Strength Uniformity From a Singl
e Source.

29.

ASTM C1017/C1017M

Standard Specification for Chemical Admixtures for

Use in

Producing Flowing Concrete.

30.

ASTM C1105


Standard Test Method for Length Change of Concrete


Due to

Alkali
-
Carbonate Rock Reaction.

31.

ASTM C1218


Standard Test Method f
or Water
-
Soluble Chloride in


Mortar and Concrete

32.

ASTM C1240


Standard Specification for Silica Fume Used in



Cementitious Mixtures.

33.

ASTM C1260


Standard Test Method for Potential Alkali Reactivity of


Aggregates (Mortar
-
Bar Method).

34.

ASTM C1293


Standard Test Method for Determination of Length



Change of Concrete Due to Alkali
-
Silica Reaction.

35.

ASTM C1524


Standard Test Method for Water
-
Extractable Chloride


in Aggregate (Soxhlet Method).

36.

ASTM C1567


Standard Test Method for Determining the Pote
ntial


Alkali
-
Silica Reactivity of Combinations of




Cementitious Materials and Aggregates (Accelerated


Mortar
-
Bar Method).

37.

ASTM D257


Standard Test Methods for DC Resistance or



Conductance of Insulating Materials.

38.

ASTM D395


Standard Test Methods
for Rubber Property





Compression Set.

39.

ASTM D412


Standard Test Methods for Vulcanized Rubber and



Thermoplastic Elastomers
-

Tension.

40.

ASTM D512


Standard Test Methods for Chloride Ion In Water.

41.

ASTM D573


Standard Test Method for Rubber
-
Deterioration

in an


Air Oven.

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42.

ASTM D1149


Standard Test Method for Rubber Deterioration
-




Surface Ozone Cracking in a
n Ozone

Controlled



Environment
.

43.

ASTM D1411


Standard Test Methods for Water
-
Soluble Chlorides


Present as Admixtures in Graded Aggregate Road



Mixes.

44.

ASTM D1525


Standard Test Methods for Vicat Softening




Temperature of Plastics.

45.

ASTM D1822


Standard Test Method for Tensile
-
Impact Energy to


Break Plastics

and Electrical Insulating Materials.

46.

ASTM D2240


Standard Test Method for Rubber Pro
perty
-

Durometer


Hardness.

E.

Precast/Prestressed Concrete Institute (PCI):

1.

PCI MNL 116


Manual for Quality Control for Plants and Production


of Structural Precast Concrete Products.

2.

PCI Publication


PCI Design Handbook, Precast and Prestressed



Concre
te.

1.05

SUBMITTALS

A.

General: Refer to
Technical Specifications

Section 01 33 00, Submittal Procedures, and
Technical Specifications

Section 01 33 23, Shop Drawings, Product Data and Samples, for
submittal requirements and procedures.

Refer to Section 34 05 17,

Common Work Results
for Trackway, for additional submittal requirements.


B.

Shop Drawings: Submit detailed
Shop Drawing
s

for each type of resilient tie

indicating
all
information necessary for fabrication including
the following:

(
Minimum Contract
Submit
tal (MCS)
34 11 32


1)

1.

Dimensional details of standard resilient ties showing plan, elevation, and cross
sections. Include
tolerances, finishes,
concrete strength and material specifications.

Indicate part numbers.

2.

Location and spacing of reinforcement.

3.

Dimensions
,

tolerances and location of rail fastener
assembly

shoulders,

contact rail
insulator assembly inserts,
and contact rail support bracket inserts.

4.

Detailed
Shop Drawing
s for all
resilient ties

components.


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5.

Detailed
Shop Drawing
s for rail fastener
assembly

and all rail fastener
assembly

components.

6.

Plans and samples to demonstrate conformance with the track tolerance requirements.

C.

Technical Specifications: Detailed technical specifications for
resilient ties and
all
resilient
ti
es

components.

Detailed technical specifications for rail fastener assembly and all rail
fastener assembly components.

(
MCS
34 11 32


2)

D.

Handling, Loading
,

Shipping
, Unloading
,

and Stacking

Procedures:

Submit to VTA for
review and approval the methods
of
handling,
loading,
transporting,
unloading
and stacking
resilient
ties
, including working drawings showing how the resilient ties and fastener
components will be stacked and the stockpile area required
.

(
MCS
34 11 32


3)

E.

Material Sources: Submit list

of sources proposed by the
Contractor

to obtain materials
requiring approval, certifications, or testing.

(
MCS
34 11 32


4)

F.

Rail Fastener
Assembly

Samples: Submit three samples of all rail fastener
assembly

component
s, including
embedded

shoulders,
rail

clips, rail insulators, and tie pads for
review and approval by VTA.

(
MCS
34 11 32


5)

G.

Contact Rail Support Bracket Inserts Samples: Submit three samples of contact rail support
bracket inserts for review and approval by VTA
in accordance with the
approved schedule
.

(
MCS
34 11 32


6)

H.

Block Pad Material Certificate: Material certificates demonstrating that the
resilient tie

block pads are made of natural rubber or an equivalent material approved by VTA and
permitting to fulfill all the requirement
s herein.

(
MCS
34 11 32


7)

I.

Block Pad Design Certification: Evidence satisfactory to VTA that the block pad design
will not negatively affect the performance of the proposed
resilient tie

assembly

by the
unavoidable ingress of water into the rubber boot
s during revenue service.

(
MCS
34 11 32


8)

J.

Rubber Boot Material Certificate: Material certificates demonstrating that the
resilient tie

rubber boots are made of
styrene
-
butadiene
rubber

(SBR)

or

an equivalent material
approved by VTA and that the
styre
ne
-
butadiene

rubber
content is at least 50 percent.

(
MCS
34 11 32


9)

K.

Rubber Boot Design Certification:

(
MCS
34 11 32


1
0
)

1.

Evidence satisfactory to VTA that the internal rubber boot wall design will be such
that a 0.02 inch gap between the rubber boot
and the concrete block is maintained
during construction, thereby allowing the concrete block to freely move downward as
the block pad deflects under load during revenue service.

2.

Evidence satisfactory to VTA that the rubber boot wall design will be such th
at
replacing the original rubber boots with maintenance rubber boots having thinner
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walls will permit to achieve the specified
one

inch lateral adjustment of the
resilient
tie

units without compromising the long term performance of the system.

L.

Design Calculations:
Calculations of the concrete block strength, track modulus and
maximum pressure per area exerted by the
resilient tie

units against the encasement
concrete, both vertically and laterally, and a justification that the resulting values
are
compatible with the axle load, train speed and track curvature conditions prevailing on the
project.

(
MCS
34 11 32


1
1
)

M.

Installation Plans:
Submit installation plans for the resilient tie assembly, including a

work
plan
descri
bing

how the proposed
r
esilient tie

assembly

will be installed and
how it will

achieve the performance criteria and dimensional tolerances specified for the completed
track in terms of track gauge, rail cant, horizontal and vertical track alignment,
superelevation in curves and
future vertical and lateral track adjustment.

(
MCS
34 11 32


1
2
)

N.

Test Program Plan: Test Program Plan

in accordance with the requirements herein.

(
MCS
34 11 32


1
3
)

O.

Quality Assurance/Quality Control Plan:
Quality Assurance/Quality Control Plan

in
acc
ordance with the requirements herein
.

(
MCS
34 11 32


1
4
)

P.

PCI MNL 116 Certification: Submit certification that the resilient tie manufacturer’s
operations conform to current industry standards as defined in PCI MNL 116 in accordance
with the requirements

specified herein.

(
MCS
34 11 32


1
5
)

Q.

Manufacturer Experience: Submit documents showing that the resilient tie fabricator has
been regularly and continuously engaged in the manufacture of precast

concrete products
for a minimum of five years and has a p
roven experience in the fabrication of precast
concrete resilient

ties in accordance with the requirements specified herein.

(
MCS
34 11 32


1
6
)


R.

Manufacturer Capacity: Submit documents showing that the resilient tie fabricator has
sufficient production

capacity in accordance with the requirements specified herein.

(
MCS
34 11 32


1
7
)

S.

Concrete Mix Design: Submit the concrete mix design with certified concrete and concrete
components qualification test results for review and approval.

(
MCS
34 11 32


1
8
)

T.

Concrete Resilient Ties Qualification Test Results: Submit the results of each
resilient

tie
and
resilient

tie component qualification test specified herein for review and approval prior
to
resilient

tie production.

(
MCS
34 11 32


19)


U.

Resilient

Ties

Production Test Results: Submit the results of each
resilient

tie and
resilient

tie component production test specified herein for review and approval prior to shipping
resilient

ties.

(
MCS
34 11 32


20)


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V.

Rail Fastener
Assembly

Qualification Test Results: Submit the results of each rail fastener
assembly

and rail fastener
assembly

component qualification test specified herein for
review and approval prior to rail fastener
assembly

production.

(
MCS
34 11 32


21)


W.

Cement Mill
Certificates: Submit cement mill test certificates weekly during
resilient

tie
production.

(
MCS
34 11 32


22)

X.

Rail Fastener
Assembly

Installation Procedures: Submit procedures for the installation and
replacement of rail fastener
assembly

components.

(
MCS
34 11 32


23)


Y.

Formwork Dimensional Compliance Inspection Reports: Submit dimensional compliance
inspection reports for the forms before tie production commences and thereafter every three
months during the production cycle.

(
MCS
34 11 32


24)

Z.

Re
silient

Ties Inventory Records: Submit inventory records of
resilient

ties shipped at the
time of each shipment.

(
MCS
34 11 32


25)

AA.

Resilient

Ties Certificates of Compliance: Submit Certificates of Compliance at the time of
each shipment of
resilient

ties with the Inventory Records. Certificate of Compliance shall
state that the accompanying shipment of
resilient

ties fully complies with all the
requirements specified in this Section.

(
MCS
34 11 32


26)


1.06

GENERAL QUALITY ASSURANCE AND QUALITY CONTR
OL
REQUIREMENTS

A.

General:
M
aintain the quality of materials, components and finished products in
conformance with applicable requirements of
Technical Specifications

Section
01 45 00,
Quality Control
.

B.

Quality Assurance/Quality Control Plan:
E
stablish, imp
lement, and maintain a detailed
Quality Assurance/Quality Control Plan in conformance with applicable requirements of
Technical Specifications

Section
01 43 00, Quality Assurance, and
Technical Specifications

Section
01 45 00, Quality Control
. The Quality

Assurance/Quality Control Plan shall
include at least the following elements:

1.

Resilient Ties:

a.

Material specifications; certificates of compliance.

b.

Formwork.

c.

Setting of embedded shoulders for running rails and
embedded inserts for
contact rail bracket supp
ort
s
.

d.

Placing reinforcing steel.

e.

Proportioning of concrete mix. Mixing, transporting, placing, consolidating,
and surface finishing.

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f.

Curing details.

g.

Identification.

h.

Quality control production testing procedures and frequency.

i.

Inspection procedures.

j.

Vendor
(sub
-
Contractor
) surveillance.

k.

Corrective action and disposition of defective or rejected
resilient ties

and
resilient tie components
.

l.

Delivery protection and handling.

m.

Acceptable quality levels and sampling plans.

2.

Rail Fasteners:

a.

Material specifications;
certificates of compliance.

b.

Process control.

c.

Quality control production testing procedures and frequency.

d.

Inspection procedures.

e.

Vendor (sub
-
Contractor
) surveillance.

f.

Corrective action and disposition of defective or rejected

rail fastener

assemblie
s and f
astener
assembly
components
.

g.

Delivery protection and handling.

h.

Identification.

i.

Acceptable quality levels and sampling plans.

C.

Tie Production Testing Facilities:

1.

Except for testing to detect potential deleterious reactions, a
ll
tie production
inspection an
d testing shall be performed at the precasting plant by qualified
manufacturer's personnel approved by VTA. The plant shall use the proper
equipment and qualified testing personnel for the tie testing and inspection described
herein. Tie testing and insp
ection equipment and personnel shall be subject to
approval by VTA. VTA, or an independent witness designated by VTA, will monitor
the operations at the precasting plant to ensure that the inspections and tests are being
performed in accordance with appro
ved procedures and in compliance with these
Specifications.

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2.


Production testing to detect potential deleterious reactions shall be
performed by
the

qualified
,

independent testing service

performing qualification testing as specified in
Articles 1.06D and 1.06E herein.


D.

Tie Qualification Testing Service:

1.

General: All tie and rail fastener assembly design qualification inspection and testing
shall be performed by a qualified
,

independent
testing service
approved in writing by
VTA in advance of any inspection and testing,
employed by and at the expense of the
Contractor
. The selected laboratory shall employ the proper equipment and qualified
testing personnel for the tie and rail fastener a
ssembly testing and inspection
described herein. Tie and rail fastener assembly testing and inspection equipment and
personnel shall be subject to approval by VTA. VTA, or an independent witness
designated by VTA, will monitor the operations at the preca
sting plant to ensure that
the inspections and tests are being performed in accordance with approved procedures
and in compliance with these
Technical Specifications
.

2.

Agreement:
S
ubmit one copy of the
Contractor
’s agreement with the testing service
to VT
A for approval
. The agreement shall specify that the testing service is directly
responsible to VTA; that all subsequent communication between the Testing Services
and the
Contractor

regarding the work under this Contract shall be through VTA
; and
that
the agreement shall run for the duration of the Contract and can be terminated
only by VTA.

3.

Responsibility for Independent Testing Service: The performance of the independent
testing service is entirely the responsibility of the
Contractor
. Any substand
ard
conditions discovered after independent testing and inspection shall be repaired or
replaced, at no additional cost to
VTA
.

E.

Specialized Testing Services: All
production and qualification
testing to detect
potential
deleterious
reaction
s

appropriate fo
r the concrete design mix
shall be performed by
qualified independent laboratories

as follows
:

1.

ASTM C295 Standard Guide for Petrographic Examination of Aggregates for
Concrete. For qualification of innocuous aggregates proposed for use in the
production o
f the
resilient

ties.

2.

ASTM C856 Standard Practice for Petrographic Examination of Hardened Concrete.
For qualification of the concrete proposed for use in the production of the
resilient

ties.

3.

ASTM C1260 Standard Test Method for Potential Alkali Reactiv
ity of Aggregates
(Mortar Bar Method). Expansion limit, 0.08% at 16 days after casting.

4.

ASTM C1293 Standard Test Method for Determination of Length Change of
Concrete Due to Alkali
-
Silica Reaction. Expansion limit, 0.04% at one year.

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5.

ASTM C1105 Standard Test Method for Length Change of Concrete Due to Alkali
-
Carbonate Rock Reaction. If carbonate rocks are identified by petrographic
examination per ASTM C295, then this method should be used for qualification of
the concrete proposed fo
r use in the production of the
resilient

ties.

6.

ASTM C1567 Standard Test Method for Determining the Potential Alkali
-
Silica
Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated
Mortar
-
Bar Method). For qualification of the concre
te proposed for use in the
production of the
resilient

ties.

7.

ASTM C666 Standard Test Method of Resistance of Concrete to Rapid Freezing and
Thawing Procedure A. Rapid Freezing and Thawing in Water. Durability factor not
less than 90% at 300 cycles.

8.

Du
ggan Concrete Expansion Test. As indicated in AREMA Manual, Chapter 30, Part
4, Section 4.2.3 Expansion limit, 0.15% at 20 days.

F.

Testing Equipment: Testing equipment shall be in good operating condition, of adequate
capacity and range, and accurately cal
ibrated. Testing equipment calibration shall be
certified and traceable to recognized national standards such as the National Institute of
Standards and Technology. Testing equipment shall be calibrated in accordance with the
requirements of the approved
Quality Assurance/Quality Control Plan.

G.

Qualification of Testing Personnel: Personnel shall be qualified by virtue of prior
experience
and/
or training

as specified by ASTM, AASHTO, PCI and AREMA
.

H.

Test Program Plan:

1.

A test program plan shall be prepared id
entifying the approach for accomplishing
each of the specified tests. The test program plan shall be prepared for approval by
VTA prior to the start of Work. A detailed narrative shall be prepared for each test
and inspection specified describing the tes
t set
-
up; equipment, and instrumentation
that will be used; procedure to be implemented; and the anticipated, as well as
acceptable test results. Drawings showing all significant components of the test
equipment shall be included, as necessary, to describe

the test set
-
up and procedure.
Pertinent testing drawings included in standard specifications may be referenced in
lieu of actual drawings. The test program plan shall include the test sequencing.

2.

Equipment specifications, and calibration methods for all
testing equipment used to
perform testing and inspection shall be included in the test program plan. The plan
shall indicate the calibration certificates that will be submitted with the test reports.

3.

Identity and qualifications of personnel who will perfor
m testing and inspection shall
be included in the test program plan. Also include certification records for personnel
who will perform nondestructive testing.

4.

The test plan shall include a description of the testing facilities and a layout of the test
equi
pment that will permit the efficient performance of the testing.

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5.

The plan shall include the proposed format for reporting test data.

6.

The projected schedule for test procedure submittals, test executions, and test results
reports submittals shall be include
d in the test program plan.

7.

The test program plan shall address qualification testing and production testing
separately.

8.

The test program plan shall be prepared by the organization performing the tests and
inspections.

The independent testing service shall prepare the qualification test
program plan. The resilient tie manufacturer shall prepare the production test
program plan.

9.

After approval of the test program plan, any proposed changes shall be approved by
VTA prio
r to implementing the change.

I.

Test Reports:

1.

Test reports with the test results of each test specified herein shall be submitted.
Separate test reports shall be submitted for qualification and production tests. Test
reports shall be submitted in bound vol
umes. The test results shall not be submitted
until complete.

2.

The test reports shall include test name, identity of test sample, test procedure
references, specified requirements, actual test results, non
-
conformances if any, and
interpretation of the res
ults. The format for the test report shall be arranged so that
the data is presented in an orderly manner.

3.

Standard, computer
-
generated, test reports may be used upon approval by
VTA
.
Such reports shall be supplemented, as required, to provide all infor
mation, and test
and inspection results specified herein.

4.

Copies of calibration certificates shall be submitted with the initial test reports. If test
equipment is recalibrated while Work is being performed on this Contract, calibration
certificates shall

be submitted for the recalibrated test equipment with the test reports
of the first tests performed after recalibration. In lieu of submitting calibration
certificates, the Contractor may maintain the certificates at its facilities available to
VTA

at al
l times during the performance of the Contract and for a three
-
year retention
period thereafter.

J.

VTA Notification:
VTA reserves the right to witness any or all qualification and production
tests and inspections.
VTA shall be notified in writing not less t
han
14

Days

in advance of
dates scheduled for any tests or inspections.

1.07

R
ESILIENT
T
IE

QUALITY ASSURANCE AND QUALITY CONTROL
REQUIREMENTS

A.

Qualifications of Fabricator:

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1.

Resilient ties

shall be produced in a plant or production facility by a fabricator who
has been regularly and continuously engaged in the manufacture of precast concrete
products for a minimum of five years. In addition, the fabricator shall have
proven

satisfactory exp
erience in the fabrication of precast
resilient ties

similar to the
specified
ties for a minimum of five years.

2.

Fabricator shall have sufficient production capacity to produce the required number
of ties
within the time specified to meet the milestone and
production completion
dates
in accordance with the
specified
quality requirements.

3.

The fabricator shall furnish certification that all aspects of the yard operation,
including materials testing, storage, and handling conform to the quality control
requirem
ents herein, and to current industry standards as defined in PCI MNL 116.

4.

Current certification by PCI throughout the fabrication period will be accepted as
evidence of conformance with this requirement.

5.

Certification by a qualified, independent consultant

or laboratory will also be
accepted as evidence of conformance with this requirement. Initial certification shall
be based on a plant inspection of yard operations and quality control procedures.
VTA shall be notified prior to the inspection and may atten
d. At least two follow
-
up
inspections shall be performed during the production run, and each certificate of
conformance submitted to VTA.


B.

Tolerances: Fabricate
resilient ties

within the tolerances indicated and specified. When not
indicated or specified

i
n Table 1.

When not indicated or specified,
conform to tolerances
specified in
AREMA

Manual.


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Table 1


Resilient

Tie Dimensional Tolerance

Dimension

Tolerance

Nominal Length

±1/4”

Width of Bottom

±1/8”

Width of Top at Center of Rail Seat

±1/8”

Maximum Top Corner Chamfer

1 inch by 45 degrees.

Depth at Center of Rail Seat

+1/4”,
-
1/8”

Distance between the inside faces of the embedded shoulders

+0”,
-
1/8”

Resilient

Tie Rail Seat Cant

1 in 40

±
5 degree

Resilient

Tie Rail Seat Differential Tilt

±
1/16 inch in a width of 6
inches

Rail Seat Plane

±1/32”

C.

Resilient Tie Inspections and Tests:

1.

Vertical Load Test:

a.

Prior to the test, a minimum of ten 24,000
-
pound vertical loading cycles shall
be applied downward at the center of the rail head midway between the
resilient
tie

units to ensure the proper seating of all components. The vertical position of
the rail head
after the seating procedure shall be used as reference for all
measurements taken during the test. A vertical load increasing in increments of
2,000 pounds to a maximum of 24,000 pounds at a rate of no less than 100
pounds per minute and no more than 1,000

pounds per minute shall be applied
downward at the center of the rail head midway between
resilient tie

units. For
each increment of load, the vertical deflection of the rail head at each
resilient
tie

unit shall be measured to the nearest 0.001 inch and
shall be recorded. The
load shall be removed and the final position of the rail head shall be measured
and recorded. The values for vertical loads versus deflection shall be plotted on
a graph.

b.

The average spring rate of the
resilient tie

units shall be be
tween 85,000 pounds
per inch and 150,000 pounds per inch for loads between 4,000 pounds and
12,000 pounds per rail seat. One minute after the removal of the maximum
load, the rail head shall return to within 0.05 inch of the reference position. The
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resilie
nt tie

components shall not exhibit evidence of failure such as slippage,
yielding or fracture.

2.

Lateral Load Test:

a.

Prior to the test, a minimum of ten 14,000 pounds vertical loading cycles shall
be applied downward at the center of the rail head midway bet
ween the
resilient
tie

units to ensure the proper seating of all components. The position of the rail
head after the seating procedure shall be used as reference for all measurements
taken during the test. A vertical load of 14,000 pounds shall then be app
lied
downward at the center of the rail head midway between the
resilient tie

units.
A lateral load, increasing in increments of 1,000 pounds to a maximum load of
6,000 pounds, at a rate of no less than 100 pounds per minute and no more than
1,000 pounds p
er minute, shall be applied horizontally to the rail head at a point
0.625 inches below the top of the rail midway between
resilient tie

units in a
direction normal to the vertical load. The lateral displacement of the rail head
shall be continuously measu
red throughout the loading sequence at a point
0.625 inches below the top of the rail at each
resilient tie

unit. The vertical and
lateral loads shall be removed and the final position of the rail head shall be
measured at each rail seat and recorded. The
recorded values for lateral loads
versus displacement shall be plotted on a graph.

b.

The lateral displacement of the rail head when fully loaded shall not exceed
0.250 inches from the original gauge line. The difference between the original
and final positio
ns of the rail head shall not exceed 0.062 inches. At no time
during the test shall a
resilient tie

component exhibit evidence of failure such as
slippage, yielding or fracture.

3.

Lateral Restraint Test:

a.

A static vertical load of 5,000 pounds shall be applie
d to the rail head midway
between the
resilient tie

units. A lateral load shall then be applied at the base of
the rail normal to the vertical load midway between the
resilient tie

units
increasing in increments of 500 pounds from zero to 14,000 pounds at
a rate of
no less than 100 pounds per minute and no more than 500 pounds per minute.
The lateral displacement of the rail head and rail base at each
resilient tie

unit
shall be measured to the nearest 0.001 inch and shall be recorded after each
increment o
f loading.

b.

The lateral displacement of the rail head when fully loaded shall not exceed
0.125 inch from the original gauge line and the lateral displacement of the rail
base shall not exceed 0.010 inch from the original gauge line. At no time during
the te
st shall a component exhibit evidence of failure such as slippage, yielding
or fracture.

4.

Longitudinal Restraint Test:

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a.

A load shall be applied longitudinally to the rail at its base increasing in
increments of 500 pounds at a rate of no less than 100 pounds

per minute and
no more than 500 pounds per minute. Load increments shall be maintained
constant for at least one minute before increasing the load to the next increment.
The load shall be increased in these increments until slippage occurs between
the
res
ilient tie

units and the rail. The longitudinal displacement of the rail shall
be measured relative to the
resilient tie

unit nearest the load application point
and recorded continuously to the nearest 0.001 inch from the time of initial
loading, through r
ail slippage, to the time of rail unloading. The values for
longitudinal load versus displacement shall be plotted on a graph.

b.

The longitudinal load at slippage shall be equal to or greater than
5,000

pounds.
At no time during the test shall a
resilient
tie

component exhibit evidence of
failure such as slippage, yielding or fracture except for the slippage between the
rail fasteners and the rail.

5.

Vertical and Lateral Repeated Load Test:

a.

A vertical load shall be applied to the rail head midway between
resilient tie

units to produce a vertical downward load of 20,000 pounds. A lateral load
shall be applied to the gauge side of the rail head midway between
resilient tie

units to produce a load normal to the vertical load of 8,000 pounds. A second
lateral
load shall be applied to the field side of the rail head midway between
resilient tie

units to produce a load normal to the vertical load of 5,000 pounds.
The lateral loads shall be applied 0.625 inch below the top of the rail. Three
million cycles of vert
ical and gauge side lateral loading shall be applied first.
Then three million cycles of vertical and field side lateral loading shall be
applied. The load cycle frequency shall be regulated to prevent the temperature
of the components from exceeding 160 d
egrees
F
ahrenheit
.

b.

The
resilient tie

units shall withstand three million cycles of load application in
each direction with no evidence of failure. Upon visual inspection, no
component of the
resilient tie

units shall exhibit evidence of failure such as
sli
ppage, yielding, abrasion, or fracture during the test. Unacceptable elastomer
degradation is defined as the inability of the
resilient tie

unit to meet the post
fatigue tests outlined in Figure 1,
Resilient Tie

Qualification Testing Sequence.
Adjusting or

tightening of components shall not be permitted at any time during
the test.

6.

Voltage Withstand Test:

a.

The concrete slab shall be grounded. A direct current potential of 15 kV (or as
high as achievable with the testing equipment if built
-
in safety features
do not
permit to reach 15 kV) shall then be applied to the rail head for one minute.

b.

The elastomer shall withstand this test with no visible damage such as splits,
cracks, pinholes or fracture.

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7.

Electrical Resistance and Impedance Tests:

a.

The concrete slab s
hall be grounded. A direct current potential of 750 volts DC
shall be applied to the rail head for three minutes. The resistance shall be
measured with an accuracy of plus or minus two percent.

b.

The rail pad and rail insulators shall be removed from the as
sembled test
configuration and immersed in distilled water for 70 hours at 95 degrees
F
ahrenheit
. After removal from the water immersion, without drying, and with
no portion of the soaked materials or
resilient tie

units at a temperature below
95 degrees
F
ahrenheit
, the soaked materials shall be reinstalled. With the
concrete slab grounded, 750 volts DC shall be applied to the rail head for three
minutes. A potential of 50 volts AC shall then be applied to the rail head for
three minutes for each increment
of measurement for frequencies from 20 Hz to
10 kHz, in increments of 20 Hz up to 100 Hz, 200 Hz up to 1,000 Hz, and 2,000
Hz up to 10 kHz. The calculated impedance shall be based on plus or minus
two percent accuracy and recorded for each frequency increm
ent.

c.

The minimum resistance for 750 volts DC shall be 10 megohms when dry and 1
megohm when wet. The minimum impedance for any frequency between 20 Hz
and 10 kHz with 50 volts AC shall be 10,000 ohms.

D.

Block Pad Inspections and Tests:

1.

Flatness Control:

a.

A
full block pad shall rest on a flat, level and smooth control surface. A
straight, rigid rule shall be laid across the top surface of the pad along its length.
The rule shall rest across the pad without compressing it.

b.

The flatness shall be controlled at a

minimum of three locations: one inch from
each edge and at the centerline of the pad. The procedure shall be repeated with
the rule placed along the width of the pad. If visible deformations exist in other
locations, these locations shall be verified as w
ell in accordance with the same
procedure.

c.

No gap or pocket between the rule and the top surface of the pad shall exceed
0.02 inch in depth or 0.80 inch in length.

d.

The vertical distance measured from the bottom edge of the rule on either side
of the pad (l
engthwise and widthwise) and the control surface shall be in
accordance with the thickness dimension and tolerance specified in the
approved drawing of the block pad.

2.

Static Deflection Measurement:

a.

This test shall be performed at room temperature (68 degr
ee
F
ahrenheit
) on a
complete block pad.

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b.

The loads shall be transmitted to the block pad through a rigid plate. This plate
shall be suitably reinforced to provide accurate pad deflection measurements.
Prior to the application of a load, the plate shall rest

with all its weight on the
pad.

c.

Gauges, positioned at the corners of the loading plate, shall be used to measure
the deflection of the pad.

d.

The block pad shall be subjected to ten preloading cycles between 0 and 12,000
pounds. Preloading shall be applied
at a rate of
5,000

+
1,000

pounds

per
minute and the load shall be maintained for 60 + 15 seconds before unloading.
The pad shall remain free from load for 60 + 15 seconds between preloading
cycles.

e.

The gauges shall be set to zero within 180 + 30 seconds a
fter the last preloading
cycle and loading shall begin immediately thereafter.

f.

Loading shall be applied at a rate of
5,000

+
1,000

pounds
/minute and the
deflection shall be measured within 60 + 15 seconds after loading is completed.

g.

The pad shall be subjec
ted to a loading of 12,000 pounds. The deflections
measured by the gauges shall be recorded.

h.

The deflection of the block pad (average of the four readings) shall correspond
to: 0.105 inch + 0.012 inches.

3.

Dynamic Spring Rate:

a.

The dynamic spring rate at room

temperature (68 degrees
F
ahrenheit
) measured
under loads cycled between near zero and 12,000 lbs at a frequency of 20 Hz
shall not differ from the static spring rate at room temperature as measured
according to Static Deflection Measurement herein, by mor
e than 20 percent.

b.

The static spring rates measured at 120 degrees
F
ahrenheit

and 15 degrees
F
ahrenheit

shall not differ from the static spring rate measured at 68 degrees
F
ahrenheit

by more than 20 percent under the load specified in Static
Deflection Mea
surement herein.

c.

The static spring rate measured at 68 degrees
F
ahrenheit

after an artificial heat
aging at 160 degrees
F
ahrenheit

during 72 hours shall not differ from the static
spring rate measured before the artificial heat aging in accordance with Static
Deflection Measurement herein, by more than 30 percent.

d.

The static spring rate measured at 68 degrees
F
ahrenheit

after 3 milli
on fatigue
loading cycles between near zero and 12,000 lbs shall not differ from the static
spring rate measured before the beginning of the fatigue test in accordance with
Static Deflection Measurement herein by more than 20 percent. The cycling
rate shal
l ensure that overheating of the block pad does not occur.

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4.

Acoustic Stiffness Ratio Test:

a.

A block pad shall be subjected to the static spring rate test and the load versus
deflection curve shall be plotted between 5,000 and 12,000 pounds.

b.

The block pad s
hall then be subjected to incremental preloads between 5,000
and 12,000 lbs and the corresponding acoustic dynamic spring rate shall be
recorded in the 50
-
250 Hz frequency range.

c.

The acoustic dynamic spring rates measured under the above preloads at 100
Hz

shall be divided by the corresponding static spring rates measured under the
same preloads and the resulting average dynamic to static ratio shall not exceed
2.0.

5.

Ozone Test:

a.

The block pad material shall be exposed to 25pphm ozone for 168 hours at 104
deg
rees
F
ahrenheit

in accordance with ASTM D1149.

b.

No cracks shall be apparent under a magnification of 7 after exposure.

6.

Porosity Test:

a.

This test shall be performed at 68 degrees
F
ahrenheit
.

b.

The initial weight (P0) of the block pads shall be measured and reco
rded.

c.

The block pad shall be submerged in distilled water and compressed between
two flat steel plates until the distance between the steel plates and therefore the
thickness of the compressed block pad reaches 2/3 of the initial pad thickness.
The block p
ad shall remain compressed during one minute. The block pad shall
then be unloaded and maintained free of load for another minute. This cycle
shall be repeated three times before the block pad is removed from the water.

d.

The block pad shall be superficially

dried and their weight P1 shall be measured
and recorded immediately thereafter.

e.

The difference between P1 and P0 shall not exceed 0.07 ounces for any of the
block pads tested.

E.

Rubber Boot Inspections and Tests:

1.

Measurement of the Shore A Hardness:

a.

The S
hore A hardness of the boot material shall be measured according to
ASTM D2240, indentation hardness of rubber and plastics by means of a
durometer. Measurements shall be made at five points on the upper surface of
the boot base.

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b.

The average of the measur
ed Shore A values must fall between 70 and 80.

2.

Measurement of the Ultimate Strength and Elongation at Break:

a.

Twelve samples (six longitudinal and six transversal) shall be cut from the base
of the boot according to ASTM D412, method A, die C. The thicknes
s of the
samples shall correspond to that of the base of the boot.

b.

The ultimate strength and the elongation at break shall be measured on six
samples (three longitudinal and three transversal).

c.

The remaining six samples (three longitudinal and three transv
ersal) shall be
artificially aged according to ASTM D573 for 72 hours in an oven maintained
at a temperature of 212 degrees
F
ahrenheit

plus

3 degree
F
ahrenheit
. The
ultimate tensile strength and the elongation at break shall be measured after
cooling the
samples at room temperature (
plus
68 degrees
F
ahrenheit
) for not
less than sixteen hours.

d.

For each set, the median value of the three measures shall be recorded and the
values shall meet the following:

1)

Minimum tensile strength of the initial section before

ageing 1740 psi and
1450 psi after ageing.

2)

Minimum elongation at break before ageing 250% and 180% after
ageing.

1.08

RAIL FASTENER
ASSEMBLY

QUALITY ASSURANCE AND QUALITY
CONTROL REQUIREMENTS

A.

Rail Fastener
Assembly

Inspections and Tests:

1.

Rail Fastener Shoulder
Tests:

a.

Rail Fastener Shoulder
Pull
-
O
ut Test: The
Rail Fastener
Shoulder Pull
-
Out
Test

shall be performed on each
rail fastener assembly
shoulder as indicated in
Figure 4 to determine the ability of shoulders to resist tension. An ax
ial load P
of 8000 pounds shall be applied to each shoulder separately and shall be held
for not less than three minutes
, during which time a visual inspection shall be
made to determine if there is any slippage of the shoulder or any cracking of the
concr
ete
. The embedded shoulder shall not move and the concrete shall not
crack, as observed by visual inspection. Separation of laitance surrounding the
shoulder will not be cause for rejection.

Inability of the shoulder itself to resist
the 8000 pounds load
without permanent deformation shall also constitute
failure of this test.

b.

Rail Fastener Shoulder Torque Test: Following successful completion of the

Rail Fastener

S
houlder
P
ull
-
O
ut
T
est, the
Rail Fastener
Shoulder T
orque
T
est
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shall be performed on each
ra
il fastener assembly
shoulder. A torque of 250
foot
-
pounds shall be applied about the vertical axis of the shoulder by means of
a calibrated torque wrench and a suitable attachment to the shoulder. The torque
shall be held for not less than 3 minutes. Abil
ity of the shoulder to resist this
torque without rotation, cracking of concrete or permanent deformation shall
constitute passage of this test.

2.

Rail Fastener Uplift Test:

a.

The configuration for the rail fastener uplift test is a single
resilient tie

unit
r
igidly restrained from uplift displacement with a rail section fully fastened to
the
resilient tie

unit in accordance with the contractor's installation instructions.
The rail fasteners from the second
resilient tie

unit shall be removed. The load
applicat
ion point on the rail shall be centered between the installed rail fasteners
in a manner that will produce uniform loading to each fastener. An uplift load
of 2,000 pounds plus the weight of the rail used in the test assembly shall be
applied to the rail p
erpendicular to the rail seat. The displacement of the rail
relative to the
resilient tie

unit shall be measured continuously from initiation of
loading through maximum loading to the full release of loading. Without
resetting (i.e. without re
-
zeroing) the

deflection measurement, the uplift load
and release shall be repeated five times.

b.

The position of all components after release of load shall be within the
tolerances stated on the
Shop Drawing
s. The rail fastener components shall not
permanently deform.
The difference in uplift displacement at 2,000 pounds
between any one of the five repetitions of loading and the average total
displacement of all repetitions shall not be greater than + 5% of the average
total displacement. At no time during the test shal
l any
resilient tie

component
exhibit evidence of failure such as slippage, yielding or fracture.

B.

Tie Pad Test
s
:

1.

Tie Pad Material Tests: The tie pad material properties shall be determined by
performing the tests specified in Article 2.03G.1.

2.

Tie Pad
Vertical Elasticity Test
:

a.

One rail seat or the rail seat of the tie block shall be assembled using a short
section of
119RE

rail, clips, rail insulators, and the tie pad to be tested.

b.

The rail shall be loaded downward in the vertical direction of its axis
using a
loading machine capable of applying a load over the range of 0 to 20,000
pounds.

c.

Displacement devices shall be attached to the rail capable of measuring vertical
displacements of 0.0001 inch. Devices shall be located at the four corners of the
pad.

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d.

Load shall be increased, at a rate between 3,000 and 6,000 pounds per minute,
from 0 to 20,000 pounds in 1,000
-
pound increments. Deflection at each
increment shall be read on the four measuring devices, averaged and recorded.
Sufficient time shall be allo
wed at each increment of loading for the deflection
to stabilize.

e.

Measure and record the time in seconds during both the loading and unloading
cycle.

f.

At the completion of the loading cycle, the load shall be decreased, at a rate
between 3,000 and 6,000 pou
nds per minute, in 1,000
-
pound increments,
recording and averaging deflection as before.

g.

Plot load versus deflection for the loading and unloading cycles.

h.

Draw a line between zero and the 16,000
-
pound point for the loading and
unloading load
-
deflection cur
ves.

i.

Calculate the slope of each line.

j.

The requirements of this test shall have been met if when:

1)

The slope of each line is between 1 by 10
6

and 2 by 10
6

pounds per inch,
and

2)

The pad returns to within
0.01

inch of its original position within 10
seconds after removal of the final increment of load.

1.09

CONCRETE BLOCK QUALITY ASSURANCE AND QUALITY CONTROL
REQUIREMENTS

A.

Concrete Block Inspections and Tests:

1.

Positive Bending Moment Test

a.

This test shall not be perf
ormed before 28 days or a 7000 psi concrete
compressive strength is achieved, whichever is sooner.

b.

The configuration for the positive bending moment test shall be as shown in
Figure 3.

c.

The objective of this test shall be to record the load required to pro
duce the first
crack in the concrete block, and to evaluate the reinforcements' effectiveness in
closing the cracks after the removal of the load.

d.

Levels P1 and P2
:

The concrete block shall be positioned under the press
actuator and subjected to an initial

load of 20,000 pounds.

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e.

The loading of the concrete block shall be progressively increased by 4000
pounds increments. After each increment, the load shall be maintained for a
minimum of one minute while both side surfaces of the concrete block are
examined

for the presence of cracks.

f.

P1 shall be defined as the load required to generate the first crack.

g.

After P1 has been reached, the concrete block shall be subjected to successive
zero
-
to
-
peak loading cycles. The peak load of each cycle shall be increased b
y a
4000 pounds increment.

h.

In each cycle, the load shall be gradually increased from zero up to the peak
load. The peak load shall be held for a minimum of one minute before being
fully released.

i.

Once the load has been released, the width of the cracks on

the side surfaces of
the unloaded concrete block shall be measured and recorded.

j.

The crack widths shall be measured at the level corresponding to the theoretical
position of the lower reinforcement's centroid. If it is not possible to measure a
crack at t
his level due to chipping of the concrete or surface imperfections,
measurements shall be taken equidistant and as close as possible above and
below this level; the two values shall be averaged to obtain the width of the
crack.

k.

P2 shall be defined as the p
eak load of the last cycle in which the widest crack
on the concrete block is closed after the removal of the load. A crack whose
width does not exceed 0.002 inch shall be defined as closed.

l.

Levels P3 and P4
:

After reaching level P2, the incremental loadin
g cycles shall
be resumed.

m.

P3 shall be defined as the peak load of the last cycle in which the opening of the
widest crack on the unloaded concrete block is not greater than 0.02 inch.

n.

After reaching level P3, the load shall be gradually increased until th
e ultimate
failure of the rail concrete block.

o.

P4 shall be defined as the maximum load carried by the concrete block.

p.

Specified values for P2 and P3 are: P2
=
40,000 pounds, P3
=
60,000 pounds.

1.10

MISCELLANEOUS EMBEDMENTS QUALITY ASSURANCE AND QUALITY
CONTROL

REQUIREMENTS

A.

Contact Rail Insert Test: The following test shall be performed on each contact rail insert
in a manner similar to Figure 4 to determine the ability of inserts to resist tension when the
surrounding concrete is unrestrained. An axial load P
of
1,000

pounds shall be applied to
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each insert separately and shall be held for not less than three minutes. The embedded insert
shall not move and the concrete shall not crack, as observed by visual inspection.
Separation of laitance surrounding the inse
rt will not be cause for rejection.

1.11

R
ESILIENT
T
IE

QUALIFICATION TESTING

A.

General:

1.

Approval of the
resilient ties

designs is dependent upon the successful completion of
the specified qualification testing program. Retesting and redesign, if required, shall
be at the
Contractor
's expense.

2.

Following review and approval of the Shop Drawings, test program plan and Quality

Assurance/Quality Control Plan by VTA, a minimum of sixteen
resilient tie

units
shall be manufactured for qualification testing

of the resilient tie units and the rail
fastener assembly
. These
resilient tie

units shall be manufactured in the same manner
a
s the
Contractor

plans to use for production runs.

3.

From
a
lot of
not less than
sixteen
resilient tie

units produced
in accordance with
these Specifications,
five
resilient tie

units
will be selected
at random
by VTA
for
qualification testing.

4.

The remainin
g 11
resilient ties

shall be utilized as follows:

a.

Three
resilient ties

shall be retained by the
Contractor

for control reference of
dimensional tolerances and surface appearance of
resilient ties

subsequently
manufactured.

b.

Three
resilient ties

shall be delivered to VTA for control reference of
dimensional tolerances and surface appearance of
resilient ties

subsequently
manufactured.

c.

The
Contractor

for further test usage shall retain five
resilient ties
.

5.

All qualification testing shall be perform
ed in accordance with the approved Test
Program Plan.

B.

Test Preparations:

1.

The
resilient tie

units selected for testing shall be carefully measured and examined to
determine their compliance with the approved
Shop Drawing
s and
the
specified
dimensions and to
lerances
.

2.

Upon satisfactory completion of the measurement and examination, the
resilient tie

units shall be assembled and permanently marked with identifying numbers in
accordance with the following sequence: A1, B1, C1, D1 and E1 for first iteration of
te
sts and A2, B2, C2, D2 and E2 for second iteration of tests.

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3.

A
resilient tie

unit, fully assembled but not embedded in concrete, shall be aged in an
air oven for a period of 70 hours at a temperature of 212 degrees
F
ahrenheit

(or for a
period of 336 hours
at 160 degrees
F
ahrenheit

if it comprises one or more natural
rubber components) in accordance with ASTM D573, Accelerated Aging of
Vulcanized Rubber by the Oven Method. EVA rail pads shall be exempt from this
test.

4.

Before assembly, the metal parts and el
astomers shall be hand cleaned and wiped dry.
The test units shall be assembled as shown on the approved
Shop Drawing
s and as
outlined in the approved test procedures. The test configuration shall simulate fully
installed embedded
resilient tie

unit condit
ions, except where specifically stated, and
shall consist of two
resilient tie

units on 30 inch centers with a piece of the same rail
as specified for the project that is at least 42 inches long assembled to the
resilient tie

units. The minimum encasement
concrete depth below the embedded
resilient tie

units shall be 2 inches. The perimeter of the encasement concrete shall be located at
least 20 inches horizontally from the nearest point of an embedded
resilient tie

unit.
Any forms shall be removed prior to

testing. The embedment concrete shall attain its
full compressive strength prior to initiation of testing. The embedment concrete shall
have a compressive strength of no less than 4,000 psi in accordance with ASTM
C39/C39M.

5.

Figure 2 illustrates a typical

test assembly.

C.

Sequence of Design Qualification Tests: The
resilient tie

qualification tests shall be
performed in the sequence shown in
Figure 1
.

D.

Qualification Testing Failure:

1.

Should any
resilient tie

unit fail a test, the entire sequence of tests, as specified, in
which the failed test is included, shall be performed on a new unit selected from the
lot by VTA.

2.

A second
resilient tie

unit failure shall require the production of a new lot of sixteen
res
ilient tie

units and the performance of another complete series of qualification
tests.

3.

If the
resilient tie

unit must be modified to pass any test, Shop Drawings of the new
design shall be submitted and approved by VTA before qualification testing is
cont
inued.

4.

A new lot of 16
resilient ties

of the new VTA
-
approved design shall be produced and
all tests performed on the new units.

5.

The cost of all such additional designing, manufacturing, and testing caused by failure
of any component
to

comply with these

Specifications, including expenses for VTA
to witness the tests, shall be at no additional expense to
VTA
.

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1.12

BLOCK PADS QUALIFICATION TESTING

A.

General:

1.

Approval of the block pads designs is dependent upon the successful completion of
the specified qualification testing program. Retesting and redesign, if required, shall
be at the
Contractor
's expense.

2.

Following review and approval of the Shop Drawings, te
st program plan and Quality
Assurance/Quality Control Plan by VTA,
a minimum of
nine block pads of each type
shall be manufactured for qualification testing. These block pads shall be
manufactured in the same manner as the
Contractor

plans to use for produ
ction runs.

3.

All qualification testing shall be performed in accordance with the approved Test
Program Plan.

B.

Test Preparations: All nine block pads shall be subjected to the aspect, flatness and
dimensional controls inspections prior to performing the qual
ification tests.

C.

Sequence of Design Qualification Tests:

The
block pads

shall be subjected to the following
tests:


1.

Static Spring Rate
and Static Versus Dynamic Spring Rate
Test
s
: Five block pads
shall be subjected to the static spring rate test foll
owed by the static versus dynamic
spring rate qualification test for two of them, the high and low temperature spring rate
qualification test for one of them, the before versus after heat aging spring rate
qualification test for another one and the before
versus after fatigue spring rate
qualification test for the last one.

2.

Porosity Test: The porosity test shall be performed on two of the remaining four
block pads as well as on the block pad subjected to the fatigue spring rate
qualification test, both bef
ore and after the completion of the fatigue test.

3.

Acoustic Stiffness Ratio Test: One of the last two block pads shall be subjected to the
acoustic stiffness ratio test.

4.

Ozone Test: The last remaining block pad shall be subjected to the ozone test.

D.

Quali
fication Testing Failure:

1.

In addition to the qualification tests specified above, t
he test block pads shall be
visually inspected and found flawless and clean edged. Small surface defects, such as
chips or blisters, shall, however, not constitute cause
for rejection.

2.

Should any
block pad

fail
the visual inspection or
a
qualification
test

specified herein
,

the q
ualification
t
esting
f
ailure

procedures for
resilient

ties specified in Article 1.11E
shall apply, as applicable.

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3.

The cost of all such additional designing, manufacturing, and testing caused by failure
of any component
to

comply with these Specifications, including expenses for VTA
to witness the tests, shall be at no additional expense to VTA.

1.13

RUBBER BOOTS QUALIFICAT
ION TESTING

A.

General:

1.

Approval of the rubber boots designs is dependent upon the successful completion of
the specified qualification testing program. Retesting and redesign, if required, shall
be at the
fabricat
or
's expense.

2.

Following review and approval o
f the Shop Drawings, test program plan and Quality
Assurance/Quality Control Plan by VTA,
a minimum of
three rubber boots of each
type shall be manufactured for qualification testing. These boots shall be
manufactured in the same manner as the
Contractor

p
lans to use for production runs.

3.

All qualification testing shall be performed in accordance with the approved Test
Program Plan.

B.

Test Preparations: The boots selected for testing shall be carefully measured and examined
to determine their compliance with
the approved
Shop Drawing
s and these Specifications
prior to performing the qualification tests.

C.

Sequence of Design Qualification Tests: The rubber boots shall be subjected to the
following tests:

1.

Measurement of the Shore A Hardness.

2.

Measurement of the U
ltimate Strength and Elongation at Break.

D.

Qualification Testing Failure:

1.

In addition to the qualification tests specified above, t
he rubber boots shall be visually
inspected and found flawless and clean edged. Small surface defects, such as chips or
blisters, shall, however, not constitute cause for rejection.

2.

Should any
rubber boot

fail
the visual inspection or
a
qualification
test

specified
herein
,

the q
ualification
t
esting
f
ailure

procedures for
resilient

ties specified in Article
1.11E shall apply
, as applicable.

3.

The cost of all such additional designing, manufacturing, and testing caused by failure
of any component
to

comply with these Specifications, including expenses for VTA
to witness the tests, shall be at no additional expense to VTA.

1.14

RAIL
FASTENER
ASSEMBLY

QUALIFICATION TESTING

A.

General:

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1.

Approval of the rail fastener
assembly

design is dependent upon the successful
completion of the specified qualification testing program. Retesting and redesign, if
required, shall be at the
fabricat
or
's exp
ense.

2.

Two concrete blocks manufactured for the concrete block qualification testing shall
be utilized for the rail fastener
assembly

qualification testing.

3.

All qualification testing shall be performed in accordance with the approved Test
Program Plan.

B.

Test

Preparations:

1.

The concrete blocks
and rail fastener assemblies
selected for testing shall be carefully
measured and examined to determine their compliance with the approved
Shop
Drawing
s and these Specifications.

2.

Rail
f
astener
assembly
t
ests shall not
be performed before 28 days or a 7000 psi
concrete compressive strength is achieved, whichever is sooner.

C.

Sequence of Design Qualification Tests:

1.

The rail fastener
assembly

shall be subjected to the following tests:

a.

Rail Fastener Shoulder
Pull
-
O
ut Test.

b.

Rail Fastener Shoulder
Torque Test.

c.

Tie Pad Vertical Elasticity Test.

2.

Two separate fastener assemblies shall be used for each of the qualification tests.

D.

Qualification Testing Failure:

1.

Should any
fastener assembly

fail a
qualification
test

specified herein
,

the
q
ualification
t
esting
f
ailure

procedures for
resilient

ties specified in Article 1.11E
shall apply
, as applicable
.

2.

The cost of all such additional designing, manufacturing, and testing caused by failure
of any component
to

comply

with these Specifications, including expenses for VTA
to witness the tests, shall be at no additional expense to VTA.

1.15

CONCRETE BLOCK QUALIFICATION TESTING

A.

General:

1.

Approval of the concrete blocks design is dependent upon the successful completion
of the s
pecified qualification testing program. Retesting and redesign, if required,
shall be at the
Contractor
's expense.

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2.

Following review and approval of the Shop Drawings, test program plan and Quality
Assurance/Quality Control Plan by VTA, three blocks of each

type shall be
manufactured for qualification testing. These blocks shall be manufactured in the
same manner as the
Contractor

plans to use for production runs.

3.

One concrete block shall be subjected to the qualification testing specified herein.
The two r
emaining concrete blocks shall be utilized for the rail fastener
assembly

qualification testing.

4.

All qualification testing shall be performed in accordance with the approved Test
Program Plan.

B.

Test Preparations:

1.

The concrete blocks selected for testing s
hall be carefully measured and examined to
determine their compliance with the approved
Shop Drawing
s and these
Specifications.

2.

Upon satisfactory completion of the measurement and examination, the concrete
blocks shall be visually inspected for cracks, str
uctural defects and surface finish.

3.

The concrete blocks shall not present cracks, structural defects, or surface finish
defects incompatible with the satisfactory long term performance of the system.

C.

Sequence of Design Qualification Tests:

1.

Concrete Stre
ngth Testing:

a.

P
roduce eight test cylinders from a single pour of concrete used in the
manufacture of the concrete blocks. The vibration of the casting machine or a
vibrating table shall be used to compact the concrete in the moulds. The moulds
shall be moi
st cured from the time of molding until the moment of test. The
curing of the concrete cylinders shall be performed in accordance with ASTM
C192/C192M or other equivalent specification. Four test cylinders shall be
tested at seven days, two for compressive

strength and two for flexural strength.