Module 12: Track Inspection & Maintenance

1. Module 12:Track Inspection & Maintenance

2. Objectives Track Inspection • Importance of Track Inspection • Methods and Types of Inspection • Application of the Track Safety Standards • Specialized Inspection Vehicles Maintenance Practices • Preventative Maintenance • Typical Activities • Production Activities • Integration of Maintenance in Design

3. Importance of Track Inspections • FRA / Transport Canada Required • First and Last “Line of Defense” against track related derailments • Initial phase of planning for maintenance activities and future track upgrade programs • Public and employee safety

4. Inspection Methods • Hi-Rail Inspection • Walking Inspection • Train Inspection

5. Inspection By Hi-rail • Hi-Rail • The hi-rail is a versatile vehicle that allows the inspector to traverse the track in one direction and return by road • Provides flexibility/versatility • Most common method utilized for scheduled and special inspections • Most often one, and sometimes two Inspectors observing the track • Scheduled per regulatory requirement and/or company policy • Visual detection of defects • “Feel” and sound of the track that may indicate the presence of a substandard condition

6. Walking Inspections • Allows for a more detailed look at the track. • Quantify defects with physical measurements • Planned at various times of year, or; • Company policy may dictate an annual walking inspection. • Regulatory requirement for inspecting turnouts, track crossings and lift rail assemblies or other transition devices on moveable bridges to be performed “on foot”

7. Train Inspection • Provides a “feel” of the track under loaded conditions • Frequency depends on amount and type of train traffic, anywhere from twice annually to monthly • No regulatory requirement – Company Policy

8. Types of Track Inspection • Normal or Scheduled (Routine) • Regulatory Compliance • Company Standard • Special Inspection • Specific Planned (i.e. Culverts, Rail Wear etc) • Emergency (Weather related, Incidents/Accidents) • Specialized Inspection Vehicles • Rail Flaw Detection Vehicles • Track Geometry Vehicle

9. Scheduled Inspections • Regulated, Mandatory inspection of Main track and sidings (Hi-rail or Walking) • Monthly Inspection of “Other than Main” track, Turnouts & Special Track Work (Walking) • FRA/Transport Canada outlines minimum inspection frequencies • Report of tracks inspected, conditions found and actions taken are completed during the inspection.

10. Track Safety Standards 46 CFR 213 SUBPARTS A-F • GENERAL • ROADBED • TRACK GEOMETRY • TRACK STRUCTURE • TRACK APPLIANCES & DEVICES • INSPECTIONS

11. Defects • Defect Classification • Class of Track (Speed) Specific • Quantitative • Non-Class of Track Specific • Quantitative • Qualitative • Defect Identification • Visual • Hidden Repair Restrict Remove

12. General Max. Speed Max. Speed Track Freight Passenger Excepted 10 N/A Class 1 10 15 Class 2 25 30 Class 3 40 60 Class 4 60 80 Class 5 80 90 CLASS OF TRACK 1-5 • 213.1 Scope of Part • 213.3 Application • 213.4 Excepted Track • 213.5 Responsibility for Compliance • 213.9 Class of Track • 213.11 Restoration or Renewal Under Traffic • 213.7 Designation of Qualified Persons to Supervise Renewal & Inspect Track • 213.13 Measuring Track Not Under Load • 213.15 Penalties • 213.17 Waivers

13. Roadbed • 213.33 Drainage • 213.37 Vegetation REPAIR RESTRICT REMOVE

14. Track Geometry • 213.53 Gage • 213.55 Alignment • 213.57 Curves -Elevation & Speed Limitations • 213.59 Elevation of Curved Track • 213.63 Surface

15. Gage The gage must But not more Class of Track be at least - than - ¢ ² Excepted Track n/a 4 10-1/4 ¢ ² ¢ ² Class 1 Track 4 8 4 10 ¢ ² ¢ ² Class 2 and 3 Track 4 8 4 9-3/4 ¢ ² ¢ ² Class 4 and 5 Track 4 8 4 9-1/2

16. Alignment

17. Surface • Run-off • Profile • Deviation In Crosslevel - Tangent • Reverse Elevation - Curves • Difference in Crosslevel • Harmonics

18. Run-off

19. Profile

20. Deviation In Crosslevel - Tangent &Reverse Elevation - Curves

21. Difference In Crosslevel

22. Harmonics

23. Track Structure • 213.103 Ballast • 213.109 Crossties • 213.110 Gage Restraint • 213.113 Defective Rails • 213.115 Rail End Mismatch • 213.119 CWR • 213.121 Rail Joints • 213.122 Torch Cut Rail • 213.123 Tie Plates • 213.127 Rail Fastenings • 213.133 Turnouts & Track Crossings • 213.135 Switches • 213.137 Frogs • 213.139 Spring Rail Frogs • 213.141 Self-Guarded Frogs • 213.143 Frog Guard Rails & Guard Face - Gage

24. Crossties Turnouts and Tangent track and curved track over 2 degrees curves 2 degrees £ Class 1 Track 5 6 Class 2 Track 8 9 Class 3 Track 8 10 Class 4 and 5 Track 12 14 NUMBER OF NON-DEFECTIVE TIES REQUIRED PER 39’ RAIL LENGTH • Definition of Defective Tie • Number Non-Defective Ties Per 39’ Rail Length • Joint Tie Conditions Fulfilled • Non-Defective Ties Effectively Distributed

25. Rail Defects • Remedial Action Non-Class Specific • Defects % Cross-Sectional Area – Head • Transverse & Compound Fissures • Detail & Engine Burn Fractures, Defective Weld • Defects Longitudinal • Horizontal Slit Head, Vertical Split Head , Head & Web • Split Web & Piped Rail • Bolt Hole Crack & Broken Base • Ordinary Break, Damaged & Flattened Rail

26. Transverse & Compound Fissures Transverse Fissure Compound Fissure

27. Detail & Engine Burn Fractures, Defective Weld Defects Detail Fractures Engine Burn Fracture Defective Weld

28. Track Appliances & Track Related Devices 213.205 Derails • Clearly Visible • Free of Lost Motion • Maintained to Function as Intended • Properly Installed for Designated Rail Section

29. Special Inspection (Specific) • Planned at specific times for specific items: • Tie defect Counts • Rail Wear Measurements • Rail Grinding Requirements • Culvert Inspections • Gage Measurements • Crossing Audits • Known problem areas • Extreme Heat or Cold (not always planned, but can often be anticipated)

30. Emergency Inspections • Unplanned • Weather • Natural Disasters • Incident/Accident

31. Inspection Records • Filled out while conducting the inspection • List all deviations and the corrective action • Kept on file for 1 year • Type of inspection indicated on report • Signed & dated

32. Special Vehicle Inspections • Rail Flaw Detector Vehicle (RFD) • Scheduled • Regulatory required frequency for Class 3-5 track • More frequent testing dictated by company policy • Internal search for rail defects using NDT “Ultra-sonic testing equipment • Specialized Equipment & Training required

33. Track Maintenance • Normal Maintenance • Performed by small sections • Day to day maintenance • Emergency Repairs • Program Maintenance • Capital projects

34. Normal Maintenance

35. Basic Track Work

36. Basic Signal Work

37. Weather Challenges

38. Maintenance of CWR

39. Drainage & Vegetation Control

40. Disasters

41. Program Maintenance • Rail Grinding • In-Track Rail Welding • Road Crossings • Production & Capital Maintenance • Rail Gangs • Tie Gangs • Surfacing • Undercutting

42. Rail Grinding • Purpose: Remove Surface Imperfections in the Rail & Optimize Rail/Wheel Contact Area • Out-of-Face & Switch Multiple Stone Grinders • Grinds Main Track Based on Railroad Policy • Grinds 6 to 15 MPH

43. In-Track Welding

44. Road Crossings

45. Production Gangs

46. Rail Gangs Speed Swing • Largest crews • 30 to 60 employees • Relay or Transpose CWR • Gang Consist • Unload CWR • Front End of Gang • Middle of Gang • Rear of the Gang Rail Train

47. Rail Gang Make-up Tie Adzer Galion Crane Laying Rail Spiker Rail Heater

48. Production Tie Renewal • Production crew 12 to 30 employees • 6 to 20 machines • 400 to 2500+ ties per day

49. Tie Gang Make-up Anchor Spreader Tie Handler Spiker Tie Inserter/Remover

50. Mechanized Tie Gang