Module 12:

Track Inspection & Maintenance

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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

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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

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Inspection Methods
Hi-Rail Inspection

Walking Inspection

Train Inspection
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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

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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

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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

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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

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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.
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Track Safety Standards

46 CFR 213 SUBPARTS A-F
GENERAL
ROADBED
TRACK GEOMETRY
TRACK STRUCTURE
TRACK APPLIANCES &
DEVICES
INSPECTIONS

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Defects
Defect Classification
Class of Track (Speed) Specific
Quantitative

Non-Class of Track Specific

Quantitative
Qualitative

Repair

Defect Identification
Visual
Hidden

Restrict
Remove

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General
CLASS OF TRACK 1-5
Track

Max. Speed Max. Speed

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

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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
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Roadbed
213.33 Drainage
213.37 Vegetation

REPAIR
RESTRICT
REMOVE

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

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Gage
Class of Track
Excepted Track
Class 1 Track
Class 2 and 3 Track
Class 4 and 5 Track

The gage must

be at least n/a
48
48
48

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But not more

than 410-1/4
410
49-3/4
49-1/2

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Alignment
Tangent
Track

Curved Track

Class of
Track

The
deviation
of the midoffset from
a 62 foot
line may
not be
more than

The
deviation
of the midordinate
from a 31
foot chord
may not be
more than

The
deviation
of the midordinate
from a 62
foot chord
may not be
more than

Class 1

n/a

Class 2

n/a

Class 3

1-3/4

1-1/4

1-3/4

Class 4

1-1/2

1-1/2

Class 5

3/4

1/2

5/8

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Surface

Run-off
Profile
Deviation In Crosslevel - Tangent
Reverse Elevation - Curves
Difference in Crosslevel
Harmonics
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Run-off

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Profile

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Deviation In Crosslevel - Tangent &

Reverse Elevation - Curves

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Difference In Crosslevel

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Harmonics

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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

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Crossties
NUMBER OF NON-DEFECTIVE TIES REQUIRED
PER 39 RAIL LENGTH
Tangent track and
curves 2 degrees

Turnouts and
curved track over 2
degrees

Class 1 Track

Class 2 Track

Class 3 Track

10

Class 4 and 5 Track

12

14

Definition of Defective Tie

Joint Tie Conditions Fulfilled

Number Non-Defective Ties

Per 39 Rail Length

Non-Defective Ties Effectively

Distributed

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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

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Transverse & Compound Fissures

Transverse
Fissure

Compound
Fissure
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Detail & Engine Burn Fractures,

Defective Weld Defects
Detail
Fractures

Engine
Burn
Fracture

Defective
Weld

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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
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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)
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Emergency Inspections
Unplanned
Weather
Natural Disasters
Incident/Accident

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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

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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 Ultrasonic testing equipment
Specialized Equipment &
Training required

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Track Maintenance
Normal Maintenance
Performed by small sections
Day to day maintenance
Emergency Repairs

Program Maintenance
Capital projects

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Normal Maintenance

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Basic Track Work

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Basic Signal Work

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Weather Challenges

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Maintenance of CWR

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Drainage & Vegetation Control

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Disasters

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Program Maintenance

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

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In-Track Welding

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Road Crossings

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Production Gangs

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Rail Gangs
Largest crews
30 to 60 employees
Relay or Transpose
CWR
Gang Consist

Speed Swing

Unload CWR
Front End of Gang
Middle of Gang
Rear of the Gang

Rail Train
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Rail Gang Make-up

Tie Adzer

Galion Crane Laying Rail

Spiker

Rail Heater
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Production Tie Renewal

Production crew 12
to 30 employees
6 to 20 machines
400 to 2500+ ties
per day

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Tie Gang Make-up

Anchor Spreader

Tie Handler

Spiker

Tie Inserter/Remover
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Mechanized Tie Gang

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Production Surfacing
Highly mechanized
crews
4 to 20 employees
Typical Equipment
Includes:

CAT-09 Tamper

MK IV Operator

Production Tamper
Jr. Tamper
Regulator
Stabilizer

MK IV Tamper
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Surfacing Gang Consist

MK IV Tamper

Dynamic Track Stabilizer

Ballast Regulator

Ballast Unloading
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Undercutting

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Remember
What you Build
Must be
Maintained

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QUESTIONS?
Authors:
Joseph E. Riley, P.E.
Federal Railroad Administration
(202) 493-6357
joseph.e.riley@dot.gov
Larry Romaine
Rail America
(904) 538-6054
larry.romaine@railamerica.com

Gray Chandler
CSX (Retired)
(904) 213-1121
chan840@bellsouth.net

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