NARSTCO

Steel Ties
and Turnout Sets

Assembly Instructions

More Versatile.
More Durable.
More Economical.

Page 1

INDEX
1 Drawings and Guidelines..........................................

Page 2

2 Track Construction...................................................

Page 5

3 Turnout Assembly.................................................... Page 8

4 Field Drilling Holes at the Frog.................................. Page 17

5 Steel Ties Encase in Concrete..................................... Page 20

6 Surfacing and Lining New Construction.................. Page 21

7 Installation and Maintenance Existing Tracks........ Page 25

8 Contact Information................................................. Page 26

Revised
2012
Issued:December
February 2012

Section 1 - Drawings and Guidelines

Page 2

Page 3

Page 4

Note This page to be printed as a folded 11 by 17 page.

Page 5
Section 2 - Track Construction
1 Steel ties are normally shipped in bundles of 20 ties. H12 ties and deep spade H10 ties are shipped
in bundles of 15 ties. For tangent track and curves up to 4 degrees, steel ties are spaced at 24 inch
centers. It is recommended that ties be spaced at 22 inch centers for curves from 4 degrees to 12
degrees. For curves over 12 degrees, ties are spaced at 20 inch centers.
For tangent track and curves up to 4 degrees, bundles with 20 ties should be distributed every 40 feet
along the subgrade and bundles with 15 ties should be distributed every 30 feet along the subgrade. For
curves between 4 degrees and 12 degrees, bundles with 20 ties should be distributed every 36 feet
along the subgrade and bundles with 15 ties should be distributed every 27 feet along the subgrade. For
curves over 12 degrees, bundles with 20 ties should be distributed every 33 feet along the subgrade and
bundles with 15 ties should be distributed every 25 feet along the subgrade.
2 For tangent track, use a string line or paint line to align the Steel Ties. Place the Steel Ties at right
angles to the string line, at 24 inch centers. It is recommended that the Steel Tie center measurements
be marked with paint every 24 inches along the string line in order to ensure proper spacing. Adjust the
Steel Tie spacing on curves over 4 degrees as required.

Track Construction Photo #1

3 Install hook in shoulders on all the Steel Ties. Refer to Table 1 below to determine the proper hook
in shoulder to be used. CAUTION: Different hook in shoulders are used with different types of Steel
Ties. Care must be taken to ensure that material is managed on the job site so that the proper
shoulders are installed as required See Table #1.

Page 6

Hook In Shoulders
Steel Tie Type

Shoulder
Part No.

M8 Non Insulated
M10 Non Insulated
M10 Insulated
H10 Non Insulated
H10 Insulated
H12 Non Insulated
H12 Insulated

4040
4020
4010
4020
4010
4080
4030

Table #1 Hook in Shoulder Part Numbers

4 Install the rail onto the rail seats of Steel Ties. (Note: If relay or second hand rail with curve wear is
used, the curve wear must be placed on the field side of the Steel Tie). Rail should be laid so that
joints fall between Steel Ties and not on top of Steel Ties. Once the rail is in position, install the e-clips
(See Track Construction Photo # 2), installing the gauge side clips first. Clips should be installed with an
8 lb. sledge hammer. Spike mauls should not be used to apply e-clips. If required, the end of the Steel
Tie should be nipped to ensure that the base of the rail sits flat on the rail seat. If one end of the Steel
Tie must be raised more than 2 inches to install an e-clip, both ends of the Steel Tie should be raised
using track jacks so that the Steel Tie is level.

Track Construction Photo #2

Page 7
5 When jointed rail is installed, appropriate expansion gaps should be used at the joints as required, in
accordance with the railroads Standard Practice Policy. Rail joints on opposite rails should be staggered
by at least 12 feet, or in accordance with the railroads Standard Practice Policy. Joint clips (j-clips)
should be installed at rail joints, installing the gauge side clips first. (See Track Construction Photo # 3).
Rail should be laid so that joints fall between Steel Ties and not on top of Steel Ties.

Track Construction Photo # 3

6 For CWR the rail must be de-stressed after surfacing and lining, prior to placing the track in service.
7 For insulated Steel Ties the insulating pads need to be installed on the rail seats after the hook in
shoulders are installed and before the rail is put in place. Once the rail is in position, place the insulator
against the base of the rail and apply the e-clip (See Track Construction Photo # 4).

Track Construction Photo # 4

Page 8
Section 3 Steel Tie Turnout Assembly
The components for each Steel Tie turnout are usually shipped in one large component sack (See
Turnout Assembly Photo #1), with the NARSTCO job number (Example: B840) and the individual Steel
Tie turnout designation (Example: 1 of 3) painted on the outside of the component sack. Copies of this
installation manual and the appropriate Steel Tie turnout drawing are included in the component sack.
The drawing shows a list of all NARSTCO components and indicates the quantity of each component
supplied. Normally, rails, switch points, frogs, heel blocks, switch rods, connecting rods and switch
stands are provided by a supplier other than NARSTCO.

Turnout Assembly Photo #1 - NARSTCO Turnout Component Sack

Each Steel Tie turnout tie has at least one stainless steel tag welded on at one end of the tie (straight
line side). This tag shows the tie number and the distance, in feet and inches, from the point of switch
to the center of the tie. (NOTE: if there is a negative number on the tag (Example: -1-6) this indicates
that the tie is to be placed ahead of the point of switch or ahead of Tie No. 1). (The tags on BNSF/UPR
Common Standard Steel Tie turnouts show the distance, in feet and inches, from the center of Steel
Tie No. 1 to the center of the Steel tie. The center of Steel Tie No. 1 is normally located 4 inches from
the point of switch for BNSF/UPR Common Standard turnouts.)
For shipping purposes, Steel Tie turnout ties are banded together in several bundles. Each bundle is
marked with a letter (A, B, C, D, etc.). The top Steel Tie in each bundle has three additional stainless
steel tags, one showing the turnout number and rail weight, one showing the NARSTCO job number
(Example: B840) and the sequential number of the turnout in that job (Example: 1of 3), and the third
showing the month and year of manufacture. Several transition Steel Ties (marked TT on the stainless
steel tags) are included with each Steel Tie turnout. Steel Transition Ties are to be installed ahead of the
switch points and past the last long Steel Switch Tie, as shown on the turnout drawing.

Page 9
A typical Label Format is shown in the following drawing:

Label Format Drawing

Page 10
Turnout Layout and Assembly
1 Lay out a base line for the entire length of the turnout, using a tape or a string line. For Non
Insulated turnouts, this line should be located 4-3 from the centerline of the track along the straight
side of the turnout. Mark this line on the ground using spray paint. Mark the point of switch (or center
of Tie No. 1 for BNSF/UPR turnouts) and mark the position of the center of each tie on the ground, using
spray paint.
2 Lay out each Steel Tie along the base line, with Steel Ties centered on the paint marks and the ends
of the Steel Ties positioned on the base line (See Assembly Photo #2). All stainless steel tags must be
on the end of the Steel Tie closest to the base line (straight side of the turnout). Steel Transition Ties
should be placed ahead of the switch points and beyond the last long Steel Switch Tie, as shown on the
drawing.

Assembly Photo # 2 Laying out the turnout ties

3 Install ALL hook-in shoulders in position on the Steel Ties. See Assembly Photo #3. The larger hook
in shoulders used with rail braces and frog clamps should be installed on the appropriate Steel Ties in
switch point, guard rail and frog areas. The locations where these larger hook-in shoulders are to be
installed are shown on the detailed turnout drawing. (NOTE: In most cases, holes for the frog clamps
are drilled in the field during turnout assembly. These holes are drilled after the frog has been placed
and in position, after all adjacent rails are bolted and clipped in place).

Page 11

Assembly Photo #3 Hook in Shoulders

4 Place the straight stock rail in position on the Steel Ties. Mark the point of switch and the center of
each Steel Tie on the top of the rail, measuring from the point of switch (or from the center of Tie No. 1
for BNSF/UP turnouts). Take care to ensure that the Steel Ties are at right angles to the straight stock
rail.
5 - Clamp the straight stock rail in position with e-clips, using an 8 lb. sledge hammer, ensuring that the
Steel Ties are centered on the marks on top of the rail. Spike mauls should not be used to apply e-clips.
In order to ensure that the rail is properly seated on the Steel Tie, a bar should be used to nip the Steel
Tie against the base of rail.
6 To install rail braces, the Steel Tie should be level and the base of the rail should be flat on the rail
seat. If necessary, track jacks should be used at both ends of the Steel Tie. Care must be taken to
ensure that the base of the stock rail is tight against the riser slide plate (which is welded to the top of
the Steel Tie). The wedge shaped rail braces should be driven into place with a sledge hammer and
secured in place with a serrated washer and an e-clip. After installation of the rail brace, serrated
washer and e-clip, check to ensure that the base of the stock rail is properly seated on the top of the
Steel Tie against the riser slide plate and that the base of the rail has not moved up onto the riser slide
plate. See Turnout Assembly Photo # 4.

Page 12

Turnout Assembly Photo #4

7 Place the remaining rail past the stock rail along the straight side on the Steel Ties to the end of the
turnout. (NOTE: In order to avoid variance in rail gauge due to rail head eccentricity, all rails throughout
the Steel Turnout should be placed so that all branding is facing in the same direction.) Install joint bars
and bolts at the joints. Once the straight rail is installed, mark the position of all Steel Ties past the stock
rail on top of the rail. Clamp the remaining straight side rail in position with e-clips, using a sledge
hammer, ensuring that the Steel Ties are centered on the marks on top of the rail.
8 Place the bent stock rail and switch point in place, such that the switch points are squarely opposite
each other, using a large square or by the triangulation method. Mark the point of switch and the
center of each tie on the top of the switch point, measuring from the point of switch (or from the center
of Steel Tie No. 1 for BNSF/UP turnouts). Clamp the bent stock rail in position with e-clips, using a
sledge hammer, ensuring that the Steel Ties are centered on the marks on top of the rail.
9 Place the straight closure rail on the Steel Ties. Install the heel block or floating heel joint. Once the
straight closure rail is installed, mark the position of all Steel Ties past the heel block on top of the rail.
Clamp the straight closure rail in position with e-clips, using a sledge hammer, ensuring that the Steel
Ties are centered on the marks on top of the rail.

Page 13
10 Install the switch point and heel block on the straight side. Place the curve closure rail in position
and complete assembly of the heel block or joint bars. At this point, before e-clips are installed to
secure the curve closure rail in place, check to ensure that the end of the straight closure rail and the
curved closure rail are properly positioned to place the frog. When pre cut straight and curve closure
rails are supplied, if the rail ends are not even after installation, it may be necessary to use a front end
loader or other piece of equipment, to push against the end of the straight or bent stock rail in order to
shift the turnout slightly to even up the rail ends at the frog. When the turnout is completely square,
the curve closure rail can be clamped in position with e-clips.
11 When horizontal switch rods are used, single hole non-adjustable side jaw clips (AREMA Drawing
222-03) are required. See Illustration #1. Adjustable four hole side jaw clips or transit clips cannot be
used with steel tie turnouts.

Illustration #1 One Hole Side Jaw Switch Rod Clip

12 For BNSP/UPR turnouts, the huck bolts on vertical switch rods must be installed such that huck
bolts face away from the point of frog.
13 For most Steel Turnouts, wedge plate pins and wedge plates are used on two to four Steel Ties past
the heel of the point. See Assembly Photo # 5. The wedge plate pins are welded to the Steel Ties during
manufacture at the NARSTCO plant. The wedge plates are stamped with the Steel Tie number and an
S for the straight side of the turnout and a T for the turnout side, for easy identification. The wedge
plates cannot be installed until after the rails are in place. The wedge plates are secured in place using
standard e-clips. Many Steel Tie Turnouts also have box plate pins and box plates in the frog area.
These box plates are stamped with the Steel Tie number for easy identification.

Page 14

Assembly Photo # 5 Installed Wedge Plate

Assembly Photo # 6 Installed Box Plate

14 Place the frog in position. Install the remaining rails and clamp into position. For RBM frogs, the
guard rails should be installed after the frog is in position. Guard rails should be positioned in
accordance with the dimension from the end of the guard rail to the point of frog as shown on the
appropriate drawing. Guard rails are often secured in place on the gauge side of the running rail using a
combination of frog clamps and rail braces. There is a detail on the drawing which shows the Steel Ties
on which rail braces are used and the Steel Ties on which frog clamps are used. Note: Only AREMA Trail type guard rails can be used on steel ties.

*************************************************************************************************

Installation Manual Updates

Page 15

Page 1 - At the bottom of the page, change "Issued: April 2012" to "Revised December 2012"

15 In most cases, the holes for the frog clamp assemblies are field drilled. After the turnout assembly

Page 2is-complete,
Replace the
existing
drawing
oninpage
2 with
appended
with
the frog
securely
place,
checkthe
gauge
on bothdrawing
sides ofNo.
the 1068
frog. The Steel Ties in the

frog area can then be field drilled, using an electric powered magnetic base drill and a 1-7/16 annular
cutter bit (Hougen Rotabroach cutters are recommended). For some special orders, the holes for the
clamps
punched.
1frog
- Steel
tiesare
arepre
normally
shipped in bundles of 20 ties. H12 ties and deep spade H10 ties are shipped in bundles of 1

Page 5 - Revise Item 1 as follows:

spaced at 24 inch centers. It is recommended that ties be spaced at 22 inch centers for curves from 4 degrees to 12 d
16 The switch stand should be installed and adjusted in accordance with the switch stand
centers.

manufacturers installation instructions. For most turnouts, the holes required to secure the switch

For
tangent
and curves
up are
to 4drilled
degrees,
bundles
withsame
20 ties
should base
be distributed
every
stand
to the track
headblock
Steel Tie
in the
field. The
magnetic
drill used to
drill40
thefeet along the subgr
along the subgrade. For curves between 4 degrees and 12 degrees, bundles with 20 ties should be distributed every 3
holes for the frog clamp assemblies should be used for the switch stand holes. The size of the drill bit
distributed every 27 feet along the subgrade. For curves over 12 degrees, bundles with 20 ties should be distributed e
required forevery
the switch
stand
holes
be chosen to accommodate the switch stand hold down bolts
distributed
25 feet
along
the should
subgrade.

supplied in the turnout component sack. Refer to Table No. 2 below which indicates the number and

Page 15
#2 - Switch
Stand
Fastenings
replace
the table
in the manual with the following table:
size- Table
of fastenings
supplied
with
common -types
of switch
stands.

Type of Switch Stand

Type of Switch Stand

36H36H
36E36E
22E
(United
States)
22E (United States)
22E (Canada)
22E (Canada)
Any ARS
Any ARS
51A (for switch stand)
51A (for
switch
stand)
51A
(for latches)
51A (for latches)

Bolt Diameter and

Quanty of Bolts
Bolt Hole Diameter
Bolt Diameter and Length
Length
Supplied Quantity of Bolts Supplied
7/8 x 3 7/8 x 3
7/8 x 3 7/8 x 3
7/8 x 3 7/8 x 3
x 3
x 3
7/8 x 3
7/8 x 3
5/8 x 3
5/8 x 3 5/8 x 2-1/2
5/8 x 2-1/2

10
10
10
10
6
6
8

10 1
10 1
10 1
10
7/8
6
1
6
8

Table #2 Switch Stand Fastenings

Page 21 - add the following table under the list of ballast gradations:

Percent Passing
Nominal
17 Switch point Opening
guards should
be installed
to
2-1/2"
2 in accordance
1-1/2" with
1" the turnout
3/4" drawing,
1/2" prior
3/8"
Size No.

distributing ballast. Note: For uninsulated Steel Tie Turnouts, two # 4010 hook in shoulders are supplied
for
use on channel
headblock
tie
with the
point guard.
#4010 hook in shoulders
Gradaon
3
2"-1"
100
95-100
35-70 The 0-15
0-5 should be inserted
inGradaon
the holes in the headblock tie before the point guard is installed. See Assembly Photo #7. Note: Steel
2"-3/4"
100 90-100 60-90 10-35 0-10
0-3
4A
Tie Turnouts
with switch point guards where the switch stand is on the straight (through) side of the
Gradaon
4 1-1/2"-3/4"
100extended
90-100
0-15
0-5 are
turnout
require
No. 1 switch rods that are
by 1120-55
inches and
connecting rods that
Gradaon by
5 11 inches,
1"-3/8"so that the switch rod/connecting
100 90-100
15-35
0-15guard base
shortened
rod bolt 40-75
is not under
the point
plate.

Table #3 - Ballast Gradations

Page 21 - Revise the final paragraph to read:

"Ten inches (10") of ballast is recommended under steel ties (see Ballast Drawing #1). Ballast depth may be specified
distributed and compacted prior to steel tie distribution, final ballast depth under the ties will be 10 inches or more.
Replace the existing drawing at the bottom of page 21 with the appended drawing.

Page 24 - Item 5 - Revise sentence 6 of this item as follows:

Page 16

Page 16

Assembly Photo # 7 Switch

Point
Guard
Assembly
Photo
# 7 Switch Point Guard

eel tie turnouts can

18 either
Steel tie
be assembled
turnouts can
in either
place (new
be assembled
construction),
in place
or they
(newcan
construction),
be assembled
or they
at can be assembled at
enient location adjacent
a convenient
to anlocation
existing adjacent
turnout to
tobe
anreplaced,
existing turnout
and moved
to beinto
replaced,
place using
and moved into place using
tors or other equipment.
excavatorsSee
or Assembly
other equipment.
Photo # 8.
SeeWhen
Assembly
moving
Photo
assembled
# 8. When
turnouts,
moving
the
assembled
point
turnouts, the point
hould be blockedarea
withshould
wood to
beprevent
blockedthe
with
base
wood
of the
to prevent
stock rail
theshifting
base ofout
theofstock
position
rail shifting
against out of position against
er slide plates. Rail
thebraces
riser slide
should
plates.
be checked
Rail braces
andshould
adjusted
beifchecked
necessary,
andonce
adjusted
the Steel
if necessary,
Tie
once the Steel Tie
ut is in its final position.
Turnout is in its final position.

Assembly Photo # 8

Assembly Photo # 8

Page 17
19 When Steel Tie Turnouts are located within 200 feet of each other, additional Steel Transition Ties
are often supplied for installation between the Steel Tie Turnouts. Steel Turnout Ties and Steel
Transition ties have a flat rail seats. Steel Track ties are supplied with a canted rail seat.

Section 4 Field Drilling Holes at the Frog

An electric powered magnetic base drill and a 1-7/16 Hougen Rotabroach annular cutter (slug cutter)
should be used to drill the holes for installation of the frog clamp assemblies.
NOTE: Hougen Manufacturing Trak-Star Model MD50 magnetic base drills and Hougen Manufacturing
annular cutter bits (1-7/16" for frogs and 1", 7/8" or 3/4" for switch stands) are available for purchase
from NARSTCO. Additional information on Trak-Star drills and Hougen annular cutter bits is available
at www.trak-star.com.
1 - Place a frog clamp on the Steel Tie to be drilled (Photo 1). The clamp should be tight against the base
of the frog. The left edge of the clamp should line up with the top edge of the Steel Tie as shown.

Photo 1 Frog Clamp Drilling

Page 18
2 Place the magnetic base drill in position on the Steel Tie with the annular cutter in the center of the
Steel Tie, against the frog clamp (Photo 2).

Photo 2 Frog Clamp Drilling

3 - Activate the magnetic base. Check to ensure the magnet is activated by trying to move the drill.
Once the drill is secured in place, remove the frog clamp, turn on the drill and drill the hole (Photo 3).
Use an appropriate drilling lubricant while drilling the hole. Start drilling slowly to avoid damaging the
cutter bit. When the hole is completed, retract the cutter and ensure that the steel plug from the Steel
Tie is removed or has fallen out.

Photo 3 Frog Clamp Drilling

4 Clean the top of the Steel Tie by cautiously removing the sharp metal shavings,
shoulder, drive the frog clamp into place using a sledge hammer,
and
Page
19 apply a serrat
(Photo 4).
Page 19
4 Clean the top of the Steel Tie by cautiously removing the sharp metal shavings, install the hook in
shoulder, drive the frog clamp into place using a sledge hammer, and apply a serrated washer and e-clip
(Photo 4).

he Steel Tie by cautiously removing the sharp metal shavings, install the hook in
og clamp into place using a sledge hammer, and apply a serrated washer and e-clip

Photo 4 Frog Clamp Drilling

Photo 4 Frog Clamp Drilling

Photo 4 Frog Clamp Drilling

Page 20
Page 20
Section 5 Steel Ties Encased in Concrete

Page 20

Steel ties that are to be encased in concrete are supplied without end spades to allow the concrete to
Section 5 Steel Ties Encased in Concrete
flow under the Steel Ties during construction. Normally a base concrete slab is poured to an elevation
just
bottom
ofencased
the Steel
Ties.
The are
Steel
Ties arewithout
laid outend
in position
and
the track
is
Section
the
Steel
Ties
Encased
inin
Concrete
Steelbelow
ties5 that
are
to be
concrete
supplied
spades to
allow
the concrete
to
Page 20
constructed
in
the
normal
manner,
as
described
in
Section
2
of
this
installation
manual.
Small
shims
can
flow under the Steel Ties during construction. Normally a base concrete slab is poured to an elevation
Steel
tiesunder
that are
be encased
in concrete
are supplied
without
end
spades to
allow
the
concrete
to
be
theto
Steel
set
the final
the
track.
Preformed
rail
seal
can
be
justused
below
the bottom
ofTies
theto
Steel
Ties.
Theelevation
Steel Tiesofare
laid
out in
position
track
is installed
Sectionand
5 Steelthe
Ties Encased
in Concrete
flow
underthe
therequired
Steel Tiesflange
duringway.
construction.
Normally
a base concrete
slab
is #1.
poured
to an
elevation
Steel ties that
are toOnce
be encased inthe
concrete
are supplied
to
provide
Steel Ties
Photo
track
iswithout
setend spades to allow the concrete to
constructed
in the normal
manner, asSee
described
in Encased
Section 2inofConcrete
this installation
manual.
Small
shims
can
flow under the Steel Ties during construction. Normally a base concrete slab is poured to an elevation
just
below
the
bottom
of
the
Steel
Ties.
The
Steel
Ties
are
laid
out
in
position
and
the
is
just below
the bottom
of track
the Steel Ties.
The Steel Ties are laid out in position and the track is
at
final
elevation,
the Ties
finalto
concrete
pour elevation
is done. of the track. Preformed
beits
used
under
the Steel
set the final
railin theseal
installed
constructed
normal can
manner, be
as described
in Section 2 of this installation manual. Small shims can
be used under
the Steel Ties toSmall
set the final elevation
of the
track. Preformed rail seal can be installed
constructed in the normal manner, as described in Section 2 of this installation
manual.
shims
can
to provide #1.
the required
flange way.
See Steel
Ties Encased
Concrete Photo #1. Once the track is set
to provide the required flange way. See Steel Ties Encased in Concrete Photo
Once
the
track
is inset
at its final elevation, the final concrete pour is done.
be used under the Steel Ties to set the final elevation of the track. Preformed
rail seal can be installed
at its final elevation, the final concrete pour is done.
to provide the required flange way. See Steel Ties Encased in Concrete Photo #1. Once the track is set
at its final elevation, the final concrete pour is done.

Steel Ties Encased in Concrete Photo # 1

Steel Ties Encased in Concrete Photo # 1

Steel Ties Encased in Concrete Photo # 1
Steel Ties Encased in Concrete Photo # 1

Steel Ties In Asphalt

Please give me a call if you have any questions.

Jim

NARSTCO

Jim Presley
Track Engineer
905-580-6627
jim.presley@narstco.com

Page 21

****************************************************************************************************************************************************

Section 6 Surfacing and Lining New Construction

Installation Manual Updates

Page 1 - At the bottom of the page, change "Issued: April 2012" to "Revised December 2012"
Page 2 - Replace the existing drawing on page 2 with the appended drawing No. 1068

Ballast
Page 5 - Revise Item 1 as follows:

1 - Steel ties are normally shipped in bundles of 20 ties. H12 ties and deep spade H10 ties are shipped in bundles of 15 ties. For tangent track and curves up to 4 degrees, steel ties a

Physical spaced
and chemical
properties
of ballast
supplied
for
with
steel
should
meet For
thecurves
requirements
at 24 inch centers.
It is recommended
that ties be
spaced at 22
inchuse
centers
for curves
fromties
4 degrees
to 12 degrees.
over 12 degrees, ties are spaced at 20 inch
centers.
Page
21
of the American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for
Railway
For tangent track and curves up to 4 degrees, bundles with 20 ties should be distributed every 40 feet along the subgrade and bundles with 15 ties should be distributed every 30 feet
Engineering
Part
2 Ballast.
The following
listed
Table 1-2-2
along the
subgrade.
For curves between
4 degrees and ballast
12 degrees,gradations,
bundles with 20 ties
should in
be distributed
every 36of
feetthe
alongAREMA
the subgradeballast
and bundles with 15 ties should be
Section 6 distributed
Surfacing
and
Lining
NewForConstruction
every 27
feet along
the subgrade.
curves over 12 degrees, bundles with 20 ties should be distributed every 33 feet along the subgrade and bundles with 15 ties should
specification
are
recommended
for
steel
ties:
distributed every 25 feet along the subgrade.
Page 15 - Table #2 - Switch Stand Fastenings - replace the table in the manual with the following table:

Yard Tracks AREMA Gradation No. 4 or No. 5

Ballast

Type of Switch Stand

Bolt Diameter and

Quanty of Bolts

Length
Yard Leads AREMA Gradation
No. 4ASupplied
or No. 4

Bolt Hole Diameter

36H
3
10
1
Physical and chemical
properties7/8
of xballast
supplied
for use with steel
ties should meet the requirements
36Ein Yards AREMA
7/8 x 3 Gradation No.
10 4A or No. 4 1
Turnouts
of the American
Railway
Association
(AREMA) Manual for Railway
22E (United
States)Engineering
7/8 x 3and Maintenance-of-Way
10
1
22E (Canada)
x 3
10
7/8
Engineering
Part
The7/8
following
ballast
listed
in Table 1-2-2 of the AREMA ballast
Turnouts
inBallast.
Yard Leads
AREMA
Gradation
No. 4A or
No.
Any 2
ARS
x 3
6gradations,
1 4
51A (for switch stand)
5/8 x 3
6

specification are
recommended5/8
forx 2-1/2
steel ties:
51A (for latches)
8

Main Tracks (Including Turnouts) AREMA Gradation No. 3 or No. 4A

Yard Tracks AREMA Gradation No. 4 or No. 5
Page 21 - add the following table under the list of ballast gradations:
Steel ties can be distributed directly on the finished subgrade. In order to reduce the number of
Percent Passing
Size No.
Yardpasses
Leadsrequired,
Nominal
AREMAaGradation
4A of
or No.
4 1/2"be 3/8"
surfacing
4 to 62inchNo.
layer
distributed and compacted prior to steel
Opening 2-1/2"
1-1/2"
1" ballast
3/4" can
tie distribution
and track
assembly.
Gradaon 3
2"-1"
100 95-100 35-70
0-5
Turnouts
in
Yards

AREMA
Gradation 0-15
No. 4A or No.
4
Gradaon
2"-3/4"
100 90-100 60-90 10-35 0-10
0-3
"Ten inches 4A
(10") of ballast is recommended under steel ties (see Ballast Drawing #1). Ballast depth may
Gradaon
4
1-1/2"-3/4"
100
90-100
20-55
0-15
0-5
Turnouts in Yard Leads AREMA Gradation No. 4A or No. 4
be specified
by the
railroad,
consultant100
or engineer.
layer0-15
of ballast is distributed and compacted
Gradaon
5
1"-3/8"
90-100 40-75If a15-35
prior to
steelTracks
tieTable
distribution,
final ballast
depth under
the ties
beNo.
10 4A
inches or more.
#3 - Ballast Gradations
Main
(Including
Turnouts)
AREMA
Gradation
No.will
3 or
Page 21 - Revise the final paragraph to read:

Steel ties can

be distributed
onunder
thesteel
finished
subgrade.
order
tomay
reduce
the
number
of
"Ten inches
(10") of ballast isdirectly
recommended
ties (see Ballast
Drawing #1).InBallast
depth
be specified
by the
railroad, consultant
or engineer.
distributed and compacted prior to steel tie distribution, final ballast depth under the ties will be 10 inches or more.
surfacing passes required, a 4 to 6 inch layer of ballast can be distributed and compacted prior to steel
Replace the existing drawing at the bottom of page 21 with the appended drawing.
tie distribution and track assembly.

If a layer of ballast is

Page 24 - Item 5 - Revise sentence 6 of this item as follows:

"Ten inches (10") of ballast is recommended under steel ties (see Ballast Drawing #1). Ballast depth may
be specified by the railroad, consultant or engineer. If a layer of ballast is distributed and compacted
prior
1 of
2 to steel tie distribution, final ballast depth under the ties will be 10 inches or more.

Ballast Drawing #1

Ballast Drawing #1

1/23/2

Page22
Surfacing and Lining
1 - For new construction, ballast should be unloaded and regulated such that the ballast is level with the
top of the rail and should extend twelve inches past the ends of the Steel Ties.
2 A tamping machine equipped with traversing vibratory work heads and sixteen tamping tools must
be used for surfacing steel tie track.
3 The tamping tool paddles (or blades) must be in good condition. Paddles worn beyond normal wear
limits must be replaced before surfacing steel tie track. Worn blades will not move sufficient ballast to
fill the pods on the underside of the steel ties, nor will they provide sufficient compaction to consolidate
the ballast under the steel ties.
4 For surfacing steel ties, the maximum depth of insertion of the tamping tools must be adjusted such
that the top of the tamping tool blade is to below the bottom of the steel tie. Depth of tool
insertion should be carefully checked before surfacing steel ties (See Surfacing & Lining Photos # 1 and
# 2).

Surfacing & Lining Photo # 1

Page 23

Surfacing & Lining Photo # 2

There is approximately a 2-1/2 difference between the depth of a wood tie and a steel tie (Ballast
Drawing #2 Tamping Tool Depth). The limit switches on the tamper should be adjusted so that the
depth of insertion for steel ties is 2-1/2 less than the depth of insertion for wood tie surfacing. This is
critical for proper steel tie surfacing and lining. If tamping tool insertion is set too deep (not adjusted
from the setting for wood tie construction), proper compaction of the ballast under the steel ties will
not be achieved.

Ballast Drawing #2 Tamping Tool Depth

Page 24
5 A complete tamping sequence consists of tool insertion, squeeze and withdrawal. To fill the pods on
the underside of the steel ties with properly compacted ballast during an initial surfacing lift, four
complete tamping sequences (tool insertion, squeeze and withdrawal) are required under the rails.
Then the traversing work head must be moved to the center of the Steel Tie, and three complete
tamping sequences are needed in the center of the Steel Tie. This must be repeated for each large
ballast lift. For larger projects, where a Jackson 6700 tamper is used, it is recommended that additional
tamping tools be mounted on the tamper in the center of the track. For larger projects, it is
recommended that additional tamping tools be mounted on the tamper in the center of the track. This
will achieve center tamping at the same time as rail seat tamping is done. Check with your equipment
manager to determine if the equipment in use on your job site can be modified in this manner. See
Surfacing & Lining Photo # 3.

Surfacing & Lining Photo # 3

6 Tamper blade spacers (available from the tamper manufacturer) should be installed to space the
tamper blades further apart, so that the blades do not contact the ties during the squeeze cycle.
7 During surfacing, the ballast inspection holes, which are located on either side of the rail seats, must
be regularly checked to confirm that the Steel Tie pods are full of ballast.
8 Lining track should be done while lifting and tamping and should be completed prior to the final
surfacing lift. For the final surfacing lift, which is normally less than one inch, three insertions under the
rail seats and one insertion in the center of the tie is recommended. Lining Steel Ties after tamping will
cause a gap to form adjacent to the end spades. If this gap is not filled immediately by tamping, the
steel ties will develop a memory effect and are likely to return to their previous alignment.

Page 25
9 After completion of tamping and prior to regulating, it is suggested that steel tie track be compacted
with an on track ballast compactor or track stabilizer.
10 After final surfacing, ballast should be regulated and additional ballast distributed if necessary, to
ensure that the cribs between the ties are full of ballast to a level one inch above the top of the steel
ties, and to ensure proper ballast shoulder width. The ballast regulator broom and blades should be
adjusted so that the broom elements do not contact the e-clips during regulating, in order to avoid
knocking off e-clips.
11 When tamping Steel Tie Turnouts, after the Steel Tie Turnout is brought to final line and surface, it
is recommended that the tamper be used to squeeze all ties under the rail seat area without jacking or
raising the track.
12 An appropriate speed restriction, in accordance with the railroad standard practice
instructions, should be in place for the first few trains to pass over newly tamped steel tie track. Steel
ties require a longer settling in period than timber or concrete ties. Therefore, some spot resurfacing
may be required during the first three to six months in order to achieve complete track stability.
Section 7 Steel Tie Installation and Maintenance Existing Tracks
1 Any standard equipment used for handling and installing wood ties can be used for steel ties as well.
2 Steel ties can be installed out of face or interspersed with wood ties in existing tracks. Surfacing and
lining should be carried out in accordance with the instructions in the previous section of this manual
(Surfacing and Lining New Construction).
3 When steel ties are interspersed with wood ties, two full surfacing passes should be made. With the
first pass, surface the entire track in accordance with normal procedures. For the second pass, only
tamp the steel ties, without lifting the track. It is important that the tamping tools are set at the proper
insertion depth for steel ties. Two insertions at the rail seats are required. Center tamping of the steel
ties is not required for this final pass. This procedure will result in uniform compaction under all ties.
Steel ties should always be tamped last.
4 At transition points from steel to wood tie sections, when entering the wood tie section, tamp the
first 15 wood ties. Then back up and tamp the last 12 steel again, without lifting. Next move forward,
skipping the 15 wood ties previously surfaced and carry on surfacing again from the 16th wood tie.
5 Once track has been disturbed during tie installation, ballast should be unloaded and regulated to
restore the ballast section.
6 Ballast should be compacted or stabilized or an appropriate slow order should be put in place, in
accordance with the Railroads Standard Practice Policy, prior to restoring the track to service.

Page 26

7 Steel ties require a longer settling in period than wood or concrete ties. As a result, some spot resurfacing may be required during the first 3 to 6 months in order to achieve complete track stability.

Section 8 - Contact Information

NARSTCO Corporate Office

300 Ward Road
Midlothian, Texas
76065
Tel: 972-775-5560
Fax: 972-775-5514
Additional contact information is available on the NARSTCO website - www.narstco.com