"SPECIFICATIONS FOR STEEL RAILS.[E]
[Sidenote: Process of manufacture.]
"1. The entire process of manufacture shall be in accordance with
the best current state of the art.
"(_a_) Ingots shall be kept in a vertical position until ready to be
rolled, or until the metal in the interior has had time to solidify.
"(_b_) Bled ingots shall not be used.
[Sidenote: Chemical composition.]
"2. The chemical composition of the steel from which the rails are
rolled shall be within the following limits:
=================+============================+============================
| BESSEMER. | OPEN-HEARTH.
+-------------+--------------+-------------+--------------
|70 lbs. and | |70 lbs. and |
| over, but |85 to 100 lbs.| over, but |85 to 100 lbs.
|under 85 lbs.| inclusive. |under 85 lbs.| inclusive.
-----------------+-------------+--------------+-------------+--------------
Carbon |0.40 to 0.50 |0.45 to 0.55 |0.53 to 0.66 |0.63 to 0.76
Manganese |0.80 to 1.10 |0.80 to 1.10 |0.70 to 1.00 |0.70 to 1.00
Silicon |0.07 to 0.20 |0.07 to 0.20 |0.07 to 0.20 |0.07 to 0.20
Phosphorus, | | | |
not to exceed | 0.10 | 0.10 | 0.04 | 0.04
Sulphur, | | | |
not to exceed | 0.075| 0.075 | 0.06 | 0.06
=================+=============+==============+=============+==============
"3. When the average phosphorus content of the ingot metal used in
the Bessemer Process at any mill is below 0.08 and in the
Open-Hearth Process is below 0.03, the carbon shall be increased at
the rate of 0.035 for each 0.01 that the phosphorus content of the
ingot metal used averages below 0.08 for Bessemer steel, or 0.03 for
Open-Hearth steel.
"The percentage of carbon in an entire order of rails shall average
as high as the mean percentage between the upper and lower limits.
[Sidenote: Shearing.]
"4. The end of the bloom formed from the top of the ingot shall be
sheared until the entire face shows sound metal.
"All metal from the top of the ingot, whether made from the bloom or
the rail, is the top discard.
[Sidenote: Shrink]
"5. The number of passes and speed of train shall be so regulated
that, on leaving the rolls at the final pass, the temperature of the
rails will not exceed that which requires a shrinkage allowance at
the hot saws, for a 33-ft. rail of 100 lb. section, of 6-1/2 in. for
thick base sections and 6-3/4 in. for A. S. CC. E. sections, and 1/8
in. less for each ten pounds decrease of section, these allowances
to be decreased at the rate of 1-100 in. for each second of time
elapsed between the rail leaving the finishing rolls and being
sawed.
"The bars shall not be held for the purpose of reducing their
temperature, nor shall any artificial means of cooling them be used
between the leading and finishing passes, nor after they leave the
finishing pass.
[Sidenote: Section]
"6. The section of rail shall conform as accurately as possible to
the templet furnished by the Railroad Company. A variation in height
of 1-64 in. less or 1-32 in. greater than the specified height, and
1-16 in. in width of flange, will be permitted; but no variations
shall be allowed in the dimensions affecting the fit of splice bars.
[Sidenote: Weight]
"7. The weight of the rail shall be maintained as nearly as
possible, after complying with the preceding paragraph, to that
specified in the contract.
"A variation of one-half of one per cent. from the calculated weight
of section, as applied to an entire order, will be allowed.
"Rails will be accepted and paid for according to actual weight.
[Sidenote: Length]
"8. The standard length of rail shall be 33 ft.
"Ten per cent. of the entire order will be accepted in shorter
lengths varying by 1 ft. from 32 ft. to 25 ft.
"A variation of 1/4 in. from the specified lengths will be allowed.
"All No. 1 rails less than 33 ft. shall be painted green on both
ends.
[Sidenote: Finishing]
"9. Care shall be taken in hot-straightening rails, and it shall
result in their being left in such condition that they will not vary
throughout their entire length more than four (4) in. from a
straight line in any direction for thick base sections, and 5 in.
for A. S. C. E. sections when delivered to the cold-straightening
presses. Those which vary beyond that amount, or have short kinks,
shall be classed as second quality rails and be so marked.
"The distance between supports of rails in the straightening press
shall not be less than forty-two (42) in.; supports to have flat
surfaces and out of wind. Rails shall be straight in line and
surface and smooth on head when finished, final straightening being
done while cold.
"They shall be sawed square at ends, variations to be not more than
1-32 in., and prior to shipment shall have the burr caused by the
saw cutting removed and the ends made clean.
[Sidenote: Drilling]
"10. Circular holes for joint bolts shall be drilled in accordance
with specifications of the purchaser. They shall in every respect
conform accurately to drawing and dimensions furnished and shall be
free from burrs.
[Sidenote: Branding]
"11. The name of the manufacturer, the weight of the rail, and the
month and year of manufacture shall be rolled in raised letters and
figures on the side of the web. The number of the heat and a letter
indicating the portion of the ingot from which the rail was made
shall be plainly stamped on the web of each rail, where it will not
be covered by the splice bars. Rails to be lettered consecutively A,
B, C, etc., the rail from the top of the ingot being A. In case of a
top discard of twenty or more per cent. the letter A will be
omitted. Open-Hearth rails to be branded or stamped O. H. All
marking of rails shall be done so effectively that the marks may be
read as long as the rails are in service.
[Sidenote: Drop testing.]
"12. (_a_) Drop tests shall be made on pieces of rail rolled from
the top of the ingot, not less than four (4) ft. and not more than
six (6) ft. long, from each heat of steel. These test pieces shall
be cut from the rail bar next to either end of the top rail, as
selected by the Inspector.
"The temperature of the test pieces shall be between forty (40) and
one hundred (100) degrees Fahrenheit.
"The test pieces shall be placed head upward on solid supports, five
(5) in. top radius, three (3) ft. between centers, and subjected to
impact tests, the tup falling free from the following heights:
70 lb. rail 16 ft.
80, 85 and 90 lb. rail 18 ft.
100 lb. rail 20 ft.
"The test pieces which do not break under the first drop shall be
nicked and tested to destruction.
"(_b_) (It is proposed to prescribe, under this paragraph, the
requirements in regard to deflection, fixing maximum and minimum
limits, as soon as proper deflection limits have been decided upon.)
[Sidenote: Tests.]
"13. (A) Two pieces shall be tested from each heat of steel. If
either of these test pieces breaks, a third piece shall be tested.
If two of the test pieces break without showing physical defect, all
rails of the heat will be rejected absolutely. If two of the test
pieces do not break, all rails of the heat will be accepted as No. 1
or No. 2 classification (according as the deflection is less or
more, respectively, than the prescribed limit[A]).
"(B) If, however, any test piece broken under test A shows physical
defect, the top rail from each ingot of that heat shall be rejected.
"(C) Additional tests shall then be made of test pieces selected by
the Inspector from the top end of any second rails of the same heat.
If two out of three of these second test pieces break, the remainder
of the rails of the heat will also be rejected. If two out of three
of these second test pieces do not break, the remainder of the rails
of the heat will be accepted, provided they conform to the other
requirements of these specifications, as No. 1 or No. 2
classification (according as the deflection is less or more,
respectively, than the prescribed limit[F]).
"(D) If any test piece, test A, does not break, but when nicked and
tested to destruction shows interior defect, the top rails from each
ingot of that heat shall be rejected.
[Sidenote: Drop testing machine.]
"14. The drop-testing machine shall be the standard of the American
Railway Engineering and Maintenance of Way Association, and have a
tup of 2,000 lbs. weight, the striking face of which shall have a
radius of five (5) in.
"The anvil block shall be adequately supported and shall weigh
20,000 lbs.
"The supports shall be a part of or firmly secured to the anvil.
[Sidenote: No. 1 Rails.]
"15. No. 1 rails shall be free from injurious defects and flaws of
all kinds.
[Sidenote: No. 2 Rails.]
"16. Rails which, by reason of surface imperfections, are not
accepted as No. 1 rails, will be classed as No. 2 rails, but rails
containing physical defects which impair their strength, shall be
rejected.
"No. 2 rails to the extent of five (5) per cent. of the whole order
will be received. All rails accepted as No. 2 rails shall have the
ends painted white, and shall have two prick punch marks on the side
of the web near the heat number near the end of the rail, so placed
as not to be covered by the splice bars.
"Rails improperly drilled, straightened, or from which the burrs
have not been properly removed, shall be rejected, but may be
accepted after being properly finished.
"Different classes of rails shall be kept separate in shipment.
"All rails shall be loaded in the presence of the inspector.
[Sidenote: Inspection.]
"17. (_a_) Inspectors representing the purchaser shall have free
entry to the works of the Manufacturer at all times while the
contract is being executed, and shall have all reasonable facilities
afforded them by the Manufacturer to satisfy them that the rails
have been made in accordance with the terms of the specifications.
"(_b_) For Bessemer Steel the Manufacturer shall, before the rails
are shipped, furnish the Inspector daily with carbon determinations
for each heat, and two complete chemical analyses every twenty-four
hours representing the average of the other elements specified in
section 2 hereof contained in the steel, for each day and night turn
respectively. These analyses shall be made on drillings taken from
the ladle test ingot not less than 1/4 in. beneath the surface.
"For Open-Hearth Steel, the makers shall furnish the Inspectors with
a complete chemical analysis of the elements specified in section 2
hereof for each melt.
"(_c_) On request of the Inspector, the Manufacturer shall furnish
drillings from the test ingot for check analysis.
"(_d_) All tests and inspections shall be made at the place of
manufacture, prior to shipment, and shall be so conducted as not to
unnecessarily interfere with the operation of the mill."