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2004 Specifications CSJ 0337-2-042

SPECIAL SPECIFICATION

2259

Grade Crossing Signal System Installation with Warranty

1. Description. This Item shall govern for the railroad grade crossing signal system

rehabilitation work, including work on constructed trackbed. Grade crossing signal system

rehabilitation includes, but is not limited to, installing bonded insulated joint assemblies;

installing non-bonded insulated joint assemblies; installing narrow band multi-shunts;

installing rail head bonds; installing track wire extensions; installing emergency notification

signs; installing DC shunt enhancer circuits; installing railroad instrument case; flasher

assembly; and other incidentals as specified herein.

2. Materials.

A. Narrow Band Multi-Shunts.

Use Safetran Multi Frequency Narrow Band Shuts or GETS FSS-1 Frequency

Selectable Shunts supplied by the Contractor and conforming to the requirements of

American Railway Engineering and Maintenance of Way Association Communications

& Signal Manual of Recommended Practices (AREMA C&S) for replacing hard wire

shunts or installing as necessary in plans. GETS NBS-1 and Safetran Narrow Band

Termination Shunts of the correct frequency may be used if included in the plans or

approved by the Engineer. The Contractor will furnish transportation of the shunts and

all other necessary materials for the installation of same.

B. Track Wire Extensions.

Use track and signal cable supplied by the Contractor and conforming to the

requirements of the Association of American Railroad’s Manual for Railroad Signaling

(AAR) (latest revision) and AREMA C&S approved Direct Burial Type Okonite or

other material approved by the Engineer. Standardized cables shall be sized as follows:

Table 1

Cable Types and Size

Cable Size

Flashing Light Signal Cable 5 Conductor, #6 minimum

Gate Control Cable 7 Conductor, #14 minimum – Combo

Interconnection Cable 7 Conductor, #14 minimum

Pushbutton Cable 7 Conductor, #14 minimum

Track Wire Cable 2 Conductor, #6 twisted (1 foot)

Power Cable 3 Conductor, #6 with ground minimum

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C. Rail Head and Rail Web Bonds.

Use 3/16” rail head bonds supplied by the Contractor and conforming to Association of

American Railroad’s Manual for Railroad Signaling (latest revision) AREMA C&S and

approved by the Engineer.

Welded Web Bonds shall also be installed (with the rail head bonds) behind gauge side

joint bars. The use of bond strand with track connectors may be used for this purpose.

D. Non-Bonded Insulated Joints.

Use new non-bonded 6-hole insulated joint components consisting of core bars, end

posts, washer plates, bushings, bolts, and lock washers conforming to the requirements

of AREMA. Use insulated tie plates conforming to AREMA requirements where

necessary. The insulated joint assembly and insulated tie plate shall be of proper design

for the rail sections being connected. Track cut spikes shall have the heads reversed

away from the joint to remove the possibility of the spikes damaging the joint

insulation.

E. Signage

Use new materials and construct signage in accordance with the Texas Manual of

Uniform Traffic Control Devices Part 8 in the locations as shown on the plans.

3. Equipment.

All on-track equipment used in connection with the project shall comply with Federal

Railroad Administration regulations contained in 49 CFR 214 Subpart D, Roadway

Maintenance Machine Safety.

4. Construction or Work Methods.

A. General Requirements.

1. The Contractor shall fully inform the Engineer of the construction methods he

proposes to use, the adequacy of which shall be subject to the approval of the

Engineer.

2. Upon Final Inspection and no later than thirty (30) days there from the

contractor shall furnish seven (7) corrected (As Built) 280 mm x 432 mm (11”

x 17”) and one computer disc complete sets of circuit schematics for the

crossing to the Engineer. One (1) copy of corrected (As Built) circuit schematics

of the crossing shall be placed in a storage container provided by the contractor in

the crossing signal enclosure. The remaining corrected circuit schematics (As Built)

of the crossing shall be provided to the Engineer by the contractor.

3. Concurrence on the part of the Engineer of any proposed construction methods or

approval of equipment does not relieve the Contractor of the responsibility for the

safety or correctness of the methods, the adequacy of his equipment or from

carrying out the work in full accordance with the contract.

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4. The following codes, regulations, reference standards, and specifications apply to

work included in this section:

a. AREMA, “Communications & Signal Manual of Recommended Practices”

b. Association of American Railroads “Manual for Railroad Signaling”

c. U.S. DOT Manual of Uniform Traffic Control Devices

d. Track Safety Standards of the Federal Railroad Administration (FRA)

e. Standard Drawings supplied by TxDOT

f. Special Specifications contained herein

5. Any Items not covered specifically herein shall be in accordance with AREMA

Standards and recommended practices subject to the approval of the Engineer.

Construction must adhere to all TxDOT Standard Plans and FRA requirements.

6. The following review/approval milestones will be monitored during the project:

Grade Crossing Signal System Rehabilitation. Review, approve and coordinate

the grade crossing signal system rehabilitation and construction to assure

compliance with TxDOT requirements.

7. No installation shall be considered complete until it has been inspected and

approved by the Engineer with all deficiencies corrected and with the contractor’s

certification that all tests were conducted in accordance with the applicable Federal,

State, Local, and Railroad standards.

8. All workers employed in the project or supervising the project shall have been

certified according to Federal Railroad Administration regulations contained in 49

CFR 214, Subpart C, Roadway Worker Protection.

9. The contractor shall obtain all licenses and/or permits that may be necessary. The

contractor shall arrange for any local inspections that may be required.

10. When the Contractor desires to occupy any space above the top of rail within the

horizontal distance of 10 ft. of either side of the centerline of any track, measured at

right angles to the track centerline, it will be necessary that he obtain authority from

Texas Pacifico Transportation (TXPF) with at least 24 hr. advance notice. The

authority will be requested and granted according to TXPF operating rules, and the

Contractor will fully comply with all instructions issued by TXPF in regards to

occupancy of the track. If, in the judgment of TXPF, flagmen are required, they

will be furnished at TXPF’s expense.

11. The Contractor shall require his employees, agents, or subcontractors to comply

with any and all instructions or warnings of TXPF’s flagmen as to clearance for the

passage of trains.

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12. All scaffolding, materials, and equipment used in the Contractor’s operations shall,

at all times, be maintained at a clearance from the tracks as approved by the

Engineer, except when working within the limits of authority granted to occupy the

tracks.

13. TxDOT’s acceptance of signal systems, trackage, and its appurtenances which have

been built shall be based on the Engineer’s written statement that construction and

construction materials have met TxDOT standards.

14. Unless otherwise specified in the plans or as directed by the Engineer, all removed

materials shall become the property of the contractor. All removed materials and

debris must be removed from TxDOT property and disposed of in a manner in

accordance with Federal, State, and Local Regulations.

15. The contractor shall be responsible for all damages to existing equipment, cables,

connections, etc. in the performance of his work and shall, at his own expense,

replace or repair any existing equipment, cables, connections, etc. that are broken

or otherwise damaged by the Contractor.

B. Trackwork

1. Where the installation of joint bars is required, the joint bars must be installed with

the full number of bolts and the nuts tightened to the proper tension. Joint bars

shall be either 4-hole, 24 in. or 6-hole, 36 in. joint bars fully bolted with lock

washers; elliptically punched for oval necked bolts. Bolts shall be inserted into the

joint bars from alternating sides of the rail, seated in the elliptical bolt holes, so that

bolt heads are located next to the nut of the bolt in the adjoining bolt hole. Rail

joints shall be applied so that bars are not cocked between base and head of rail.

Bars are to be properly seated in rail.

2. Joint bars shall be removed or applied with a wrench or socket of the appropriate

size for bolt and nut being used.

3. Track bolts, with nuts, which have wrench turn fittings, shall be used where

required. Spring washers shall be the correct size to fit the bolt. All bolts on non-

insulated joints will be tightened with an approved bolt machine or torque wrench

to a torque of 650 ft.-lbs. Bolting shall be started with the center bolts working

toward the ends and all nuts shall be turned up tight with bolt heads staggered

inside and outside of the rail alternately.

4. Joints in opposite rails on tangent track shall be staggered no less than 12 feet apart.

Joints in opposite rails on curved track shall not be staggered less than 8 feet apart

except as closer joints may be required at insulated joints or turnouts.

5. Joint bars that are found broken during construction shall be replaced by the

Contractor. The cracked or broken joint bars shall be held for inspection by the

Engineer.

6. An insulated tie plate shall be used when necessary when insulated joints are

located on a tie. Suspended joints are preferred.

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7. Rail saws shall be used when necessary to cut rail. The use of a torch or track chisel

will not be permitted. All necessary new bolt holes shall be marked, using an

approved rail drilling template and the drilling operation shall be carefully

performed. Both cutting and drilling shall use proper lubrication. Cut rails shall be

drilled and fully bolted. There shall be no extra holes in the rail.

The burred edges on bolt holes drilled in the field shall be carefully removed by

grinding. When necessary to cut secondhand rail, the cut end shall be beveled.

When necessary to cut new standard carbon rail, the cut end shall be end hardened

and beveled in accordance with Railroad Specifications.

8. Rail not in CWR locations shall be staggered according to the direction of the

Engineer, except when balancing the joints for switch leads, road crossings, bridge

ends and signal circuits. To reduce the resonant reaction, rail joints shall be

staggered at 12 feet from the nearest joint on the opposite rail. To avoid

unnecessary rail cutting in providing staggered joints, a two-foot tolerance will be

permitted in either direction. When laying rail, joints must not be located in road

crossings, bridge decks, or on ends of bridges.

9. Joint surfaces shall be ground smooth to the proper profile where existing rails

exhibit end batter or head flow that could damage the insulating coating.

10. Where the end post protrudes beyond the contour of a worn rail head, the end post

shall be modified by means approved by the Engineer to prevent rolling stock from

damaging the end post.

11. Rail expansion shims must be used to establish the proper opening between rails.

Expansion shims must not be used at the ends of strings when laying CWR.

12. At joints, the opening between rail ends must be as shown in the following table:

For 39 ft Rail:

Rail Temperature Opening

Below 25° F ½”

51° F to 75° F 1/8”

Above 75° F 1/8” every other joint

For 78 ft Rail:

Rail Temperature Opening

Below 25° F ½”

25° F to 50° F 3/8”

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51° F to 75° F 1/4”

75° F to 100° F 1/8”

Above 100° F 1/8” every other joint

13. Rail thermometers of the approved type must be used to determine the rail

temperature.

14. Joint bars and rail ends must be cleaned and lubricated with an approved joint

lubricant when installing joint bars. To maintain free rail movement in existing

joint rail territory, joint area must be thoroughly lubricated along all marring

surfaces and into the interior of the bars, using a Hudson sprayer or equivalent.

15. At permanent connections of different rail sections, compromise joints shall be

used, and where practicable they shall not be located in crossings, main track

curves, on open deck bridges, or in turnouts.

16. Spiking of joints will maintain the existing spiking pattern or as shown on the

plans.

17. All track spikes are to be the proper size. Care shall be taken to make sure that the

base of rail is not riding on the shoulder of the tie plate when spikes are driven.

Spikes shall be started, driven vertically, and square when driven into the spike

holes of the tie plate. Crooked or bent spikes shall be removed and replaced.

Straightening with maul of spikes started crooked will not be permitted. When

spikes are pulled, the hole shall be plugged with a standard treated tie plug. In

driving the spikes, the last few blows of the hammers shall be such that the spike

head will not be bent or broken, and the hammer shall not be permitted to strike

directly upon the rail.

C. Signal System Work.

1. Wire runs shall be parallel with no sharp bends where practical. Wire runs shall be

supported and protected from sharp edges.

2. AMP solderless pre-insulated terminals or other materials as approved by the

Engineer shall be used where necessary and applied carefully over stripped wire

ends, using proper tools and complying with the manufacturer’s specifications.

3. Wire and cable terminations shall follow AREMA C&S standards. Double nuts

shall be used at terminations where nuts are required. Insulated nuts shall be used

on all high voltage (110 VAC or greater) terminations.

4. Cables shall be placed in a trench no less than 36” below the surface of the ground.

Trenches shall not be left open at the close of a workday.

5. When excavating within the track structure, the ballast shall be covered to prevent

contamination.

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6. Cables shall be handled with care to avoid damage to the cable jacket and

insulation.

7. Cables are to be laid in the trench parallel to each other and surrounded by 6” of

suitable fine material, free of stones and other sharp objects.

Cable shall be tested before and after installation to insure that the conductors are

free from open circuits, short circuits, and grounds. All cable runs shall be

terminated on test lengths, including mast bases.

8. Trenching will not be permitted across any roadway surface. Any work that

requires wire or cable to pass underneath any paved roadways shall be encased in a

conduit that is directionally bored under the paved surface at a minimum depth of 3

ft. When more than one wire must go beneath the pavement surface, two conduits

shall be bored under the road with a minimum of 6 in. spacing between conduits.

Boring shall be in accordance with TxDOT Standard Specification Item 476.

Conduits shall be schedule 80 PVS UL approved electrical conduit in accordance

with Item 618 Conduit.

9. Track connections shall be welded ERICO SBTBBU4A 3/16” x 1” x 4” long

Bootleg or equivalent, welded to the web of the rails. Slack in track connections

shall be kept to a minimum. Rubber hose shall be used for encasing riser wire. All

underground connections shall be made using splice kits with the proper size

nicropress sleeves fully encased with epoxy.

10. When plug bonds are used they shall be installed the same day that the holes are

drilled. The plug bond shall be installed 1/2” above the centerline on the gauge

inside web of the rail and 3” from the end of the joint (insulated). Use

Safetran Track Connection Assemblies Model RCP-10 Rail Plug or No.

021127-4X with vertical drop under center of rail or other materials approved

by the Engineer.

11. All joints in extended track circuits shall be double bonded in accordance with this

specification including a rail head bond, and a welded web bond behind the joint

bars. Additional joint bonds in the crossing approaches that are found to be

defective or missing shall be replaced as directed by the Engineer.

12. All joints within the highway circuit limits shall have two separate bonds per

joint unless otherwise specified. Web bonds shall be welded on the web

behind joint bars on gauge side of rails. Rail head bonds shall be welded on

the field side of rails. Use 3/16” bonds manufactured by Dwight and Wilson

Co., ERICO or other materials approved by the Engineer. Bonding shall be in

compliance with the AREMA C&S and Association of AAR’s Manual for

Railroad Signaling (latest revision) (AAR) Rules and Regulations. Bond strand

with track connectors shall be used in addition to a rail head bond welded to

the web of the rail, and fed through the joint bars as a double bond for all

joints requiring bonding.

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13. The railroad instrument case (house) shall be 4’X6’ aluminum case including

equipment rack, load center, surge protector, fan with thermostat, light

fixtures, shelving, batter racks, and other appurtenances as shown in the plans.

This case shall be RSI (Railroad Signal Internationa, Inc.) Part No. RSIH-609

or approved equivalent. The following table identifies major components

included in the railroad instrument case.

The list of major components with part numbers is provided for contracro’s

information only. The contractor will be allowed to provide approved

equvivalent parts.

Item Vendor Part No. Railroad Instrument Case

1 RSI RSIH-609 4X6 House with basic wiring setup. House Assembly 4'X6' Alum W / Equipment Rack, Load Center, Surge Protector, Fan W/Thermostat, Light Fixtures, Shelving, Battery Racks and Appurtenances As shown in plans

2 Fill Dirt

3 Dress Stone

4 RSI RSI-546 T4 Highway Crossing Unit

5 RSI RSI-531A Panel, Track Arrestor and Surge-TP-02

6 RSI RSI-566 Panel, Lamp Resistor, LRP-60

7 Safetran 91165-1101 Controller Unit, Crossing SSCCIIIA-20AMP

8 RSI RSI-548 Panel, Cut Out

9 RSI RSI-508 Panel, Lightning Arrestor, LAP-17

10 RAILWAY

EQPT 520620 Charger, Battery, 20Amp, Cragg

11 RAILWAY

EQPT 520740F Charger, Battery, 40Amp, Cragg

12 NRS 403764 Battery, Flooded Lead Acid, ELM 240

13 NRS 403762 Battery, Flooded Lead Acid, ELM 160

14 RSI RSI-557 Panel, DC Surge Protector, DCSP-10

15 RSI RSI-560 TP-01

16 GRAINGER REL-234 Relay, Potter and Brumfield POR

17 GRAINGER REL-288 Base, Potter and Brumfield, POR

18 Graybar 94065349 Box, Electrical, Hoffman Style 16"x16"x6"

19 RSI RSI-534 Panel, AC Surge Protector, ACSP-20

20 Allied 809-0270 Block, Terminal, WAGO

21 Misc. Mounting Hrdw and Surge Protection

22 ALSTOM A62-262 500 Ohm Relay(xfer-1,xfer-2,GCR,GCPR,GDR)

23 ALSTOM A62-162 Biased Nuetral Relay

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14. The flasher assembly shall be RSI Part No. RSI-546 or approved equivalent. The

following list of components is provided for contractor’s information only. The

contractor will be allowed to provide approved equivalent parts.

Item Vendor Part No. Flasher Assembly

1 RSI RSI-514 Mast, Signal 2 RSI RSI-337 ENS (FRA) mast mounted sign

3 RSI RSI-337A Decals for ENS sign

4 RSI RSI-511A Junction Box, Split base 5"

5 RSI RSI-082 Rodent Plate

6 RSI RSI-500 Junction Box Lightarm assy 2-Way for gate signal

7 RSI RSI-096 12" LED Flashing light unit w/alum 20" background and hood, Stainless Steel hardware

8 REBEL

R/W 220-0008 Gold Nut

9 WCH 38-0045-

89-R Insulated Test Link

10 RSI RSI-308A Cross buck, RR Crossing Extruded Sign High intensity

11 RSI RSI-572 Mount, Bracket, Cross buck Sign

12 GSI EB-3-360-

5 Bell, Electronic, Highway Crossing

13 RSI BNRR-02 Foundations, Precast, Concrete

14 Timber pole and electrical services with meter

D. Testing Procedures (Cut-In, TXDOT Final Certification Testing)

1. Final Testing – The Contractor shall perform every practical test to insure that the

system is functioning properly and that faulty components are replaced before

attempting to place the system in service.

All tests shall conform to the requirements of the FRA Part 234, and the

Owner or standard typical railroad highway crossing tests. These shall include

tests of all battery systems, relays, grounds on battery busses, cable insulation

resistance, proper lamp voltage, gate timing up and down, and lamp unit alignment.

Proper forms for each shall be made available to the Owner or the Engineer for

review, in accordance with FRA Part 234.273.

These forms shall include the following, made available by the contractor to the

Engineer prior to PE Certification and acceptance of the crossing:

Record Signal Housing

Copy FRA

Requirement

Cable Resistance to Ground X 234.267

Relay Test Records X 234.263

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Timing Relay Test Records X 234.265

Battery Bus Grounds X 234.249

Battery Cell Voltages (Individual) X 234.251

Crossing Test Record X 234.257

Detailed Circuit Plans X 234.201

2. If having been placed in service and a failure takes place prior to PE Certification

and acceptance by the Engineer of the crossing project, the Contractor shall

maintain adequate inventory of parts to ensure prompt correction.

3. No installation shall be considered complete until it has been approved and

accepted in writing by the Engineer and the appropriate State and or Federal

Highway representative and all other Railroad and Government agencies involved.

4. Contractor's Work Responsibility: In addition to the Contractor's responsibilities

defined elsewhere in the contract documents, the Contractor shall also be

responsible for all damages due to his negligence to existing equipment, cables,

connections, etc. in the performance of his work defined under the various work

requirements of this contract. The Contractor shall, at his own expense, replace or

repair any existing cables that are broken or otherwise damaged by his forces, and

shall be held responsible for the proper operation of the repaired circuits. The

Contractor shall satisfy himself as to the operating conditions and integrity of the

facilities that shall be affected by his work. This shall be accomplished prior to

making any new electrical connections to existing facilities or the relocation of

existing equipment. The Contractor shall notify the Engineer in the event that the

operating condition or integrity of any affected facilities is not within performance

standards.

5. Warranty. The Contractor will warrant the grade crossing signal system rehabilitation for a

period of 12 months. The warranty period begins with the Engineer’s acceptance of the

work.

(1) Contractor Inspections. Conduct initial and semiannual inspections of the Grade

Crossing Signal System Rehabilitation.

Conduct initial inspections within 7 days after work is completed. For Grade Crossing

Signal System provide a written report of the existing conditions at the time of the

inspection to the Department. Document each inspection with digital photography, and

provide a copy of the written report and digital photographs to the Department. Provide

sketches, written reports and digital photographs within 30 days after the inspection.

Replace or repair work or materials that do not meet contract specifications. Notify the

Engineer at least 72 hrs. prior to beginning any warranty work.

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If deficiencies are not corrected within 30 days of a semiannual inspection, the warranty

period for the entire project will be extended on a daily basis starting on the 31st day until

the deficiency is corrected.

A Department representative will be present for all semiannual inspections. Provide written

notification to the Engineer no later than 15 days prior to any semiannual inspection.

(2) Department Inspections. The Contractor will be provided a copy of any inspections.

The Contractor will be notified in writing of any needed warranty work between semiannual

inspections. Within 30 days of receipt of the written notification, replace or repair work or

materials that do not meet the contract specifications. If deficiencies are not corrected

within 30 days of receipt of the written notification, the warranty period for the entire

project will be extended on a daily basis starting on the 31st day until the deficiency is

corrected. If it is found that the requirements are met, provide documentation of the

evaluation results to the Engineer for review and his decision per Article 5.2, “Engineer as

Referee.”

The Department will conduct a final warranty inspection prior to the expiration of one year

of the project completion date. The Contractor will be notified in writing of the final

warranty inspection date at least 15 days prior to the inspection to allow the Contractor to be

present. Absence or failure to witness the final inspection will not delay the final inspection.

If the final warranty inspection identifies any work or materials that do not meet the

contract specifications, replace or repair the work or materials to meet the contract

specifications. Failure to repair or replace work or materials that do not meet the contract

specifications, will result in the warranty period for the entire project being extended on a

daily basis until all work or materials meet performance requirements and have passed an

initial inspection.

The Contractor will be considered in default during the warranty period if:

• any warranty work is not completed within 60 days of an initial, semiannual or final

warranty inspection, or receipt of written notice from the Engineer identifying an area of

concern;

• any warranty work from the initial inspection is not conducted within 7 days of when

the work or materials are installed;

• fails to perform the semiannual inspection or provide the report documenting the

inspection; or,

• submits a false or misleading report regarding whether the work or materials meet the

performance requirements.

The warranty bond will insure the proper and prompt completion of required warranty work

following completion of the project, including payments for all labor performed, equipment

and material used in accordance with the specifications.

6. Measurement.

A. Railroad Instrument Case (Railroad House) shall me measured by each railroad case

furnished, installed, and made operational including all equipment inside the case as

well as foundation and other incidental material, as shown in the plan.

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B. Railroad Flasher Assembly shall be measured by each flasher assembly with bells

furnished, installed, and made operational including all items installed on the assembly

as shown in the plans.

C. Track work will be measured as lump sum for all work identified in Exhibit “A” plan

sheets including traffic control and barricades, pavement marking and signing, conduits,

insulated joints, track wires etc.

7. Payment.

The work performed and material furnished by this Item and measured as provided under

"Measurement", will be paid for as follows:

A. Payment for Railroad Instrument Case (Railroad House) will be made at the unit bid

price for “Railroad Instrument Case” for furnishing and installing a 4’ x 6’ aluminum

railroad instrument case assembly. This price shall be full compensation for

transportation, storage, foundation (including fill dirt, dress stone), installation of the

case, including equipment rack, load center, surge protector, fan with thermostat, light

fixtures, shelving, battery racks and all other appurtenances as shown in the plans. This

price shall also include all wiring inside the case and making the flasher assembly

operational.

B. Payment for Flasher Assembly shall be made at the unit bid price for “Flasher

Assembly” for furnishing and installing each flasher assembly with bells. This price

shall be full compensation for transportation, storage, foundation, mast, signals, 12”

LED flashing light with 20” aluminum background and hood, all mast mounted signs,

stainless steel hardware, all mounting brackets and hardware, and any other

appurtenances required to make the flasher assembly operational. This price shall also

include furnishing and installing all flasher wires, junction boxes, grounding, bonding,

etc. as needed.