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Rail Projects

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

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 transloading facilities in the world.  As a round-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 hydroinsensitive, 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

Crossing Use:

Heavy haul freight (silica mine), urban street by short line

The Job:

100 track feet of crossing panels settled. This caused the adjacent asphalt pavement to fail, and caused tripping hazards at the adjacent pedestrian sidewalk. The crossing ran diagonally across the roadway. The crossing had been replaced twice in the past. The last replacement used flowable fill as the base material. Due to the urban, primarily passenger automobile traffic, there was little deflection of the crossing panels from highway traffic. However, there were up to four inches of deflection from rail traffic loading.

The deflection from rail traffic loading caused the top edges of adjacent panels to be in compression with each other. This caused extensive spalling of the surface, which affected approximately 8 panels. While not a functional problem for panel integrity, the spalled areas were within the sidewalk portion of the crossings, and therefore posed tripping hazards.

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 a sand mine, so repair was designed around high service loads for heavy haul rail traffic.

Due to scheduling constraints of the railroad, the repair method had to tolerate the potential for rail traffic during the repair.

CJGeo’s Solution:

CJGeo modular grade crossing repair crew filled the voids and corrected settlement in less than a day using polyurethane grouting. 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. Traffic control was done to accommodate pedestrians and roadway traffic.

Two trains passed through the crossing over the panels being repaired during the repair. This did not affect the integrity of the repair.

Industrial Short Line Tub Crossing Repair

The Job:

12 tub-style grade crossing panels developed a 2.5″ belly on a heavy haul industrial scrap short line. The railway’s FRA inspector directed the railway to address the settlement of the crossing panels to bring the crossing geometry back into compliance. Along with being non-compliant from a track geometry perspective, accumulation of water below the panels was causing deterioration of the adjacent asphalt pavement.

The Challenge::

The belly only affected one travel lane of the roadway, but repairs had to not affect the other lane, so that traffic could be maintained to the adjacent industrial properties. Due to rail traffic schedules, the repair had to allow for rail traffic during the repair.

CJGeo’s Solution:

CJGeo crews performed the crossing repair in a single day, using polyurethane grouting. During the repair, two trains utilized the crossing.

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 which did not disturb the adjacent asphalt pavement.

CJGeo’s 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 less 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 settlement of the adjacent track.

Industrial Driveway Crossing Repair

The Job:

Settlement and deflection were affecting an eight panel modular grade crossing in an industrial driveway. The crossing was used by both commuter rail and freight. Settlement of modular grade crossing was causing spalling of the panel edges due to more than 2 inches of deflection from rail traffic.

The Challenge:

The repair had to quickly and thoroughly address the voids and settlement of the panels to avoid disruption to commuter revenue traffic. A daily window of four hours between last morning and first afternoon commuter traffic was available for the repair.

Due to scheduling constraints within the busy Washington, DC metro area freight market, the repair area had to be openable to freight traffic on 15 minute notice any time during the repair.

CJGeo’s:

High density polyurethane polyurethane grouting to stabilize and lift the affected precast grade crossing panels. Polyurethane grouting is an effective repair for both void filling to address deflection, and also lifting panels to correct settlement.

The crossing was repaired and returned to service without disruption to commuter or freight rail service.

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.

CJGeo’s 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 installation of a 42″ jack & bore casing below a three track Class 1 railroad in Martinsburg, WV, ballast started showing in the spoils. Soon afterwards 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.

CJGeo’s 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

Challenge:

CSX crews were surfacing 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 water line, 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 Solution:

The project designer, OBG, identified cellular concrete as a potential solution to the problem, and reached out to CJGeo to determine 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 the 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 finished product, could be grouting in a single shot.

Result:

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.

Vineland, NJ Grade Crossing

Railway Grade Crossing Repair–Vineland, New Jersey

Crossing Use:

Heavy haul freight (silica mine), rural highway by short line

Problem:

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.

Constraints:

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 a sand mine, so repair was designed around high service loads for heavy haul rail traffic.

Solution:

High density polyurethane 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.

Result:

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.

Urban Grade Crossing, Cumberland, NJ

Urban modular grade crossing repair–Cumberland, New Jersey

Crossing Use:

Heavy haul freight (silica mine), urban main road by short line

Problem:

32 track feet of crossing panels settled. This caused the adjacent asphalt pavement to fail, and caused tripping hazards at the adjacent pedestrian sidewalk. The grading in the area was relatively good, however the adjacent ballast was fouled, which caused water to accumulate under the crossing panels and wash out the sandy subbase material. The crossing had been replaced recently. Due to the urban, primarily passenger automobile traffic, there was little deflection of the crossing panels from highway traffic. However, there were up to four inches of deflection from rail traffic loading.

The deflection from rail traffic loading caused the top edges of adjacent panels to be in compression with each other. This caused extensive spalling of the surface, which affected two of the panels. While not a functional problem for panel integrity, the spalled areas were within the sidewalk portion of the crossings, and therefore posed tripping hazards.

Constraints:

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

Due to scheduling constraints of the railroad, the repair method had to tolerate the potential for rail traffic during the repair.

2015-12-27-14.28.57-300x225
Polyurethane grouting, asphalt patching and panel patching.

Solution:

High density polyurethane 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.

Epoxy-augmented patching of the spalled areas to restore a smooth walkway for pedestrians.

Result:

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 two hours. The roadway and rail opened up immediately after the repair.  Traffic control was done to accommodate pedestrians and roadway traffic.

Two trains passed through the crossing over the panels being repaired during the repair. This did not affect the integrity of the repair.

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