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Rail

By applying unique solutions to increase the safety and longevity of our environment.

MSE Wall Backfill

The Job

The geotechnical investigation for a double bridge replacement in Amelia County, Virginia found a layer of compressible soils below four proposed abutments.

Anticipated settlement exceeded allowable settlement, so the abutments were designed to be backfilled with expanded shale lightweight aggregate.

The two parallel bridges have an AAWDT of 14,000 and carry a rural divided highway (US-360) over Norfolk Southern Railway & Business 360 in Amelia Courthouse, Virginia.

The Challenge

Lightweight fill placement had to be unaffected by frequent rail traffic, have a limited footprint, and be economical.

The Solution

CJGeo provided a value engineering proposal to utilize 30lb/cuft cellular concrete in place of the expanded shale lightweight aggregate. This significantly reduced the unit weight of the lightweight fill, given the 70lb/cuft density used in the design, further reducing the anticipated settlement.

CJGeo mobilized a 200CY/hour cellular grout plant to the site and placed lifts ranging in size from 35 to 300CY. Wall erection crews were able to walk on the in-place cellular concrete without leaving footprints as quickly as 4 hours after each placement.

The total project volume was approximately 7200CY.

Coal Pier Sinkhole Grouting

The Job

With an annual throughput capacity of 48 million tons, Norfolk Southern’s Pier 6 at Lamberts Point in Norfolk, Virginia is one of the largest coal trans-loading facilities in the world. As an around-the-clock facility built around precision logistics, there’s little tolerance for disruption or downtime.

The Challenge

When two sinkholes opened up at the end of Pier 6 adjacent to the bulkhead, railroad personnel reached out to an onsite maintenance contractor. Steel plates were installed to provide temporary protection while a long-term solution could be implemented.

The Solution

CJGeo performed DCP testing at the site in order to quantify the depth of voids below the pavement adjacent to the sinkholes. The DCP testing showed that in addition to large voids visible from the sinkholes immediately below the pavement, there were large pockets of voids down to 15’ below the surface. 

CJGeo crews then used CJGrout 35NHV61, a hydro insensitive, NSF-certified geotechnical polyurethane to fill all voids and restore stability to the area. The grouting work took five hours onsite to install 3400 pounds of material, with zero disruption to operations.

Tub Crossing Repair

The Job

The sandy soils of South Jersey are great for growing produce and mining pure silica sand. While most of the produce is shipped by truck, a lot of the silica is shipped by rail. The rails inevitably cross the roads, and many of the crossings are at grade.

The Challenge

A short-line railroad was experiencing significant settlement and pumping of multiple precast modular crossings in the Vineland & Millville areas. Each crossing saw significant truck traffic, primarily from aggregate mining, and also significant heavy haul rail traffic from transporting sand.

The Solution

Working with a rail maintenance contractor, CJGeo performed polyurethane grouting on a total of four precast tub crossings in the area. Each was done in a single day, with the immediate resumption of automobile traffic, and rail traffic. Supplemental bolting was performed to address the deterioration of the panels that had resulted from the extensive movement of the panels.

Industrial Short Line Tub Crossing Repair

The Job

Sparrows Point, in Baltimore, Maryland is a brownfield site being redeveloped from steel manufacturing to industrial and logistics use. From it says as a heavy manufacturing facility, there is an extensive freight rail network throughout the site, with many grade crossings subject to significant heavy truck traffic & heavy haul rail traffic.

The Challenge

A precast tub-style grade crossing on a road feeding a metals recycling plant developed a 2.5″ belly. The local FRA inspector instructed the railroad to correct the settlement.

The Solution

CJGeo performed structural polyurethane grout injection to fill voids below the panels, and then lift them back into their correct alignment. The work was completed in a few hours, without disruption to the rail or auto traffic.

NC Tub Crossing Repair

THE JOB

The 8′ long panels of tub-style grade crossing settled. As a result, a speed restriction was placed on the crossing, which affected passenger schedules. Three panels were affected, and the belly in the slabs was approximately 2 inches. Slight deflection with heavy truck traffic was noted, and significant deflection with rail traffic was present.

THE CHALLENGE

The repair had to be completed in just a few hours, to avoid disruption to rail traffic. The repair had to allow for immediate resumption of rail traffic, and tolerate tamping of the adjacent truck during the repair. Additionally, the tub crossing repair had to be done in a manner that did not disturb the adjacent asphalt pavement.

THE SOLUTION

High-density geotechnical polyurethane grouting to stabilize and lift the affected modular grade crossing panels. Geotechnical polyurethane grouting is far superior to mudjacking, in that the process is faster, and can more easily ensure a complete filling of voids under the crossing panels. Lifting precision of fewer than 0.1 inches is standard.

A CJGeo modular grade crossing repair crew filled the voids and corrected settlement in a few hours. During the tub crossing repair, tamping was done by the rail system to address the settlement of the adjacent track.

Industrial Driveway Crossing Repair

The Job

MARC’s Brunswick Line’s Frederick extension passes through multiple industrial sites & driveways. This particular crossing served as the driveway of a ready mix concrete operation, so saw extensive high dynamic loading in a wet environment.

The Challenge

The repair had to be performed without disrupting either rail or industrial traffic. There was a four-hour window between the last morning train and the first evening train for performing the repair to the eight modular tub crossing panels. The settlement was up to two inches, with extensive spalling.

The Solution

CJGeo’s crew installed supplemental bolts due to replace the OEM center panel anchors, and then grouted the crossing in the mid-day window, without disruption to any stakeholder.

Light Rail Tub Crossing Repair

THE JOB

A suburban grade double-crossing was rebuilt to address poor drainage infrastructure in the area. This included installing two different culverts adjacent to the crossing panels, and then resetting all of the panels which had to be removed for the culvert installation. During routine track inspections, the panels showed signs of deflection up to one inch with rail traffic. The system’s track division was concerned that pumping of the crossing panels would lead to destabilization of the base, and settlement. At the lower elevation end of the crossing, there was extensive evidence of sub-base material being pumped out from under the crossing within two weeks of the crossing reconstruction. 368 track feet were affected.

THE CHALLENGE

Work had to be completed during non-revenue hours, between 0200 & 0430 over two nights. There was also a high probability of the voids below the panels being waterlogged.

THE SOLUTION

High-density polyurethane grouting to stabilize the grade crossing panels. Specially-formulated hydro-insensitive void filling (high-mobility) grout was proposed in order to ensure complete filling of voids below the panels, whether waterlogged or dry.

CJGeo successfully stabilized the crossing during the two-night work period.

Railroad Sinkhole Stabilization

THE JOB

During the installation of a 42″ jack & bore casing below a three-track Class 1 railroad in Martinsburg, WV, ballast started showing in the spoils. Soon afterward a sinkhole appeared between tracks 2 & 3, 15 feet above the casing. The jack & bore installation was stopped, and the contractor reached out CJGeo requesting an emergency mobilization.

THE CHALLENGE

CJGeo had to mobilize with very little notice, and work had to be performed adjacent to an operational track.

THE SOLUTION

CJGeo mobilized two polyurethane grouting crews, who were on the road in less than an hour. Within four hours of the sinkhole formation, CJGeo was onsite with more than 250CY of material placement capacity.

CJGeo successfully grouted the sinkhole. Rail traffic continued on adjacent tracks, and the face of the bore was restored, allowing the jack & bore operation to safely restart. CJGeo performed this repair using a polyurethane grout with an elastic modulus similar to the existing soil in order to prevent creating a hard spot in the rail.

1 Mile 36″ Waterline Abandonment

THE JOB

CSX crews were surfacing the mainline track in Baltimore when the tamping equipment struck an object immediately below the ties. Investigation revealed that it was a manhole associated with nearly 6000LF of 36″ water main primarily running immediately below the tracks. The municipality relocated the waterline but was faced with the challenge of abandoning the pipe from just two intermediate points. There were three sections of pipe; 1200LF, 1600LF & 2900LF. Various solutions were floated, including threading sacrificial tubing and grouting on the way out, but none were economical or could guarantee a pipe abandonment below the railroad.

THE CHALLENGE

The project designer, OBG, identified cellular concrete as a potential solution to the problem and reached out to CJGeo to determine its feasibility. CJGeo confirmed the appropriateness of cellular concrete and set out to create a grouting plan. Coordination between the utility contractor and slurry provider (the site was too small to set up a batch plant) was crucial to ensure that the runs of pipe were all successfully filled in a single shot each. With train frequencies of 3-4 per hour, if the operation didn’t work and the pipes were only partially filled, there was no opportunity to create intermediate access points to finish grouting a section of pipe.

0-2

Based on the required bearing capacity and production requirements, CJGeo proposed 22lb/cuft cellular concrete for abandonment. With a 25psi break strength at 28 days, the mix provided the required strength, met the CSX utility occupancy standard for abandonment, and maximized expansion in order to ensure the longest run, which required nearly 1000CY of the finished product, could be grouting in a single shot.

THE SOLUTION

CJGeo mobilized a 150CY/hour cellular concrete crew to the site and performed the two shorter runs the first week. The project was broken into two different weeks due to the criticality of ensuring the longest run was filled completely without issue. The first two runs allowed CJGeo, the GC, railway flaggers, railway operations, and the slurry provider the opportunity to work out any kinks in operations during the lower risk placements.  

The following Tuesday, starting at 0600, Chaney Enterprises delivered the first of 24 loads of slurry. Completeness of fill was confirmed by uniform cellular concrete venting out the far end of each placement. Overall, the work was completed in three days. CJGeo generated & pumped a total of 1710 cubic yards of cellular concrete to successfully complete the abandonment.

Railway Grade Crossing Repair

THE JOB

112 track feet of crossing panels settled. This caused the adjacent asphalt pavement to fail. The crossing ran diagonally across the highway. The road was graded so that the crossing was the primary flow path for surface water. The crossing had been replaced twice in the past. The last replacement used flowable fill as the base material. The crossing panels experienced approximately 1 inch of deflection with highway traffic. There were also 4-inch voids below the panels.

amtrac-nj-grade-crossing-featured
Lifting modular grade crossing using polyurethane grouting.

With highway traffic from heavily-loaded vehicles, the crossing deflected enough to squirt water three to four feet in the air. This water pumping action actively pumped the subbase material from under the crossing.

THE CHALLENGE

The repair had to allow immediate vehicular traffic to facilitate a single-lane closure that was flipped halfway through the repair. The repair also had to allow for immediate resumption of rail traffic. The crossing served as a sand mine, so the repair was designed around high service loads for heavy haul rail traffic.

THE SOLUTION

High-density polyurethane grouting to stabilize and lift the affected modular grade crossing panels.  

Supplemental anchor bolting was also used to ensure longterm integrity of the repair.

CJGeo modular grade crossing repair crew filled the voids and corrected settlement in less than a day.  Asphalt patching was done concurrently with polyurethane injection. The entire repair was completed in less than one day. The roadway and rail opened up immediately after the repair.

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