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MILLCREEKCENTRALRAILROAD
TrackBuilding&TrackLayingStandards
FromnotespublishedbyBrianKeiminAugust,2003
Initiallypublishedonwebsite1/07/2006,lastupdated01/12/2006

Introduction
TrackWorkPhilosophy
DefinitionsofTrackBuildingComponents
StandardsForTrackBuildingComponents
RightOfWayPreparation
TrackAssemblyStandards
Appendix

Introduction
ThegoldenageofprototyperailroadingwasaresultofengineeringcollaborationthroughtheAmerican
AssociationofRailroads.Theireffortshelpedstandardizerailroadconstructiontoeliminateproblemsat
connectingrailroadinterchanges.Standardsweredevelopedforrailroadconstructionandmaterialsselectionto
reducemaintenancecostsandtoimprovesafety.OurmodelLiveSteamhobbystrivestoaccomplishthesesame
goals:toeliminateproblemswithinterchangingequipmentduringopenmeets,toreduceamountofseasonal
maintenance,andtoimprovesafety.
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SinceourmodelLiveSteamhobbyisnotgovernedbyanoverseeingbodysuchastheA.A.R.,itisuptoclubs
andprivatetrackownerstodevelopandimplementtheirownsetofstandards.Fortunately,theInternational
BrotherhoodofLiveSteamershasadoptednumerouswheelandtrackgaugestandardsthatareaccepted
worldwide.Theactualrightofwaydesign,materialsselection,andconstructionarestillleftuptothe
individualcluborprivatetrackowner.Manyarticles,speeches,anddebateshaveoccurredoverthepast30+
yearsconcerningthesetopics.Thisisagoodthingforitpromotescriticalthoughtbynumerouspersonsabouta
singleproblemorsetofproblems.Muchinformationissharedthroughmagazineandnewsletterpublications
andtheInternet.Handsonexperienceisalsosharedatopenmeets,hostedbynearbyclubsandowners,where
informationaboutwhat'hasworkedforthem'isprovided.Eachcluborprivatelayoutfindssuccesswith
varyingconstructiontechniquesandmaterialsduetotheirownuniqueenvironmentalandtrafficconditions.For
example,arightofwaythatislaidentirelywithinwoodedareasandthatonlyseesserviceforafewweekends
peryearwilllikelyrequireverylittleseasonalmaintenancefortheconstructionmethodemployed.However,
thesameconstructionmethodappliedtoanactiveclublayoutthathasopenfieldtrackage,willlikelysuffer
fromconstantmaintenancerequirementsthroughouttheyear.Withdevelopmentsinnewmaterialsandactual
testingofthesematerials,thestandardsagreedupontodaycanberevisedinthefuture.Afterall,adopted
standardsarealwaystheevolutionandcontinuousimprovementofideasandpractices.

Thefollowingstandardsforbuildingcomponentsandassemblytechnique,areasaresultofexperience
obtainedfrom30yearsoftrackrightofwaybuildingandmaintenanceattheNorthEasternOhioLiveSteamers
layout,formerlylocatedinCopley,Ohio.Asubstantialamountofinformationandpracticeshavebeen
introducedtotheN.E.O.L.S..frommemberexperiencewhothemselvesarealsotrackownersand
operators.Thiscollectionofstandardsistheresultofthemostcurrentandsuccessfulmaterialsselectionand
assemblytechniquesforheavilyoperatedrightofwaysanddiverseenvironmentalconditions.

Thefollowinglistofprivatetrackownershavebeeninstrumentalinsupplyingexperienceandinsighttoward
thedevelopmentofthesestandardscontainedwithin.

ClintEnsworth
BillHayes
KenStemen
LarryVolzer
CharlesFair
RichardMcCloy

PA&WRailroad
MichiganCentralRailroad
PennsylvaniaRailroad
GreatNorthernOhio&MassillonEasternRailroad
Walden&LakeshoreRailroad
MillCreekCentralRailroad

SharonCenter,Ohio
Metamora,Michigan
Metamora,Michigan
Massillon,Ohio
Jeromesville,Ohio
Coshocton,Ohio

.
TrackWorkPhilosophy
:
Itisthegoalofeveryoneinvolvedinourminiaturerailroadhobbytobuildarightofwayonwhichtooperate
ourmodellocomotivecreations.Asuccessfullydesignedandbuiltrightofwaymustbe:
1.Simpletoconstruct.
2.Requireverylittlemaintenance.
3.Simpletomaintain.
4.Resilienttoseasonal.climatechanges.
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5.Abletoaccommodateabroadrangeoflocomotivewheelbases,startingwith040upthrough484types.
6.Affordable.
7.Manufacturedfromreadilyavailableandprovenmaterials.
Beforeanyrailroadcanbebuilt,adeterminationofthetypeorservicetherailroadwillberequiredtoprovide
mustbeconsidered.Decisionsaboutthegradesandcurvaturesmusttakeintoaccountthetypesofmotive
powerandtrainlengthsthatwilloperateoverit.Ashortwheelbaselocomotivecaneasilynegotiateverytight
curvesandsomewhatuneventrack..Howevershortwheelbaselocomotivestendtolackpowerandtractive
effort,thereforelimitingthelengthoftrainandmaximumgradethattheycantraverse.Alargewheelbase
locomotive,suchasa484type,isconsiderablymoresensitivetosharpcurvesandpoorlyleveledtrack.The
largersizeandweightofa484classlocomotivemakeitsuitableforhaulinglongertrainsaswellas
negotiatinggrades.Thelogicalactiontotakeindesigningarightofwayistothereforelimitthecurvatureand
meangradientssuchthatalltypesoflocomotiveswillbeabletooperatesafely.

Oncetheplanoftherightofwayisestablished,anunderstandingofhoweachcomponentinteractsandreacts,
asacompletesectionoftrackisnecessary.Atypicaltracksectioniscomposedofballast,crossties,crosstie
screws,rail,railjoiners,andrailjoinerbolts.Improperselectionandassemblyofanyoneorcombinationof
componentswillhaveadefiniteandmeasurableeffectuponthestabilityofanentiretracksection.Itisessential
thatonedoesnotmisinterprettrackbuildingpracticesutilizedbyour1:1cousins.Thephysicsofmass,thermal
.expansion,static,anddynamicloadingaswellasenvironmentaleffectsuponfullsizerailroadsarefardifferent
fromthoseexperienceduponourminiaturerailroads.Rememberthatthereareno48'tallgiantbeingswalking
alloverprototypetrackage.A39'longprototypetracksectionweightsabout7700lbsyeta1/8scalesectionof
ourmodeltrackageweightslessthan15lbs.Alsoconsiderthattherateofthermalexpansionofaluminumrail
isnearlytwicethatexperiencedbysteelrail.Aproperlyconstructedandinstalledtracksectionisknowntobe
abletocarryamaximumaxleloadingof500lbs.
Understandingtheconsiderationsoutlinedabove,wecannowidentifythefunctionsofeachcomponent
utilizedinourmodeltrackbuilding.

DefinitionsofTrackBuildingComponents

Rail
.Makesdirectcontactwithlocomotiveandrollingstockwheels.
.Distributesloadacrossthesupportingcrossties.
Railjoiners
.Formsaslidingjointthatalignstwoendsofrailtogether.
.Permitsagapbetweenrailendsforthermalexpansionandcontraction.
Railjoinerboltsandnuts
Clampsrailjoinersandrailstogether,yetallowforslidingfitofjoint.
Crossties
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Distributesloadappliedbyrailtotheballast.
Crosstiescrews
Holdsrailtocrosstiesurface,whilepermittingmovementofrailalongitsaxis.
Keepsrailsingaugeoncrosstie.
RailGauge
Establishescorrectdistancebetweenadjacentrailheads.
Mustbeabletoprovidereliableandrepeatablemeasurements.
RailDrillingJig
Establishescorrectholelocationandspacingfordrillingholesinrailendthathasnotbeenpunched.
Ballast
Supportsanddistributesloadofcrossties.
Lockspositionofcrosstie,preventingmovement.
TampingBar
Designedtoproperlyworkballastunderacrosstie.

StandardsForTrackBuildingComponents

1)Rail
a)Tobemadefrom6063T6extrudedaluminumorsteel.
b)Dimensionsof'T'headprofileareasfollows,1"high,7/8"widefoot,~"widehead,5/32"thick
web,suppliedin10'or12'lengths,referencedrawing#2000.SeeFigure1.
c)Eachendofaluminumrailistobepunchedwithoblongholestosatisfythermalexpansion
requirement.

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2)RailJoiners
Foraluminumrail
a)Tobemadefrom6061T6extrudedaluminum.
b)Dimensionstobe1/8"thick,1/2"wide,and4"long,referencedrawing#2001.SeeFigure2.
c)Mustbepunchedwith4oblongholestoaccepttworailends.
Forsteelrail
a)Apreformedslipjoinercanbe.used

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3)Railjoinerscrews
a)Stainlesssteelhexhead#1032x3/4"long..

4)Railjoinernuts
a)Stainlesssteelhex#1032Nylocnut..

5)Crossties
a)Minimum11/2x11/2x16"long.(Actualmeasurementofcrosstieassawedfromastandard2
x4wouldbe11/2"x15/8").
b)Tobecutfrompressuretreatedlumber,ratedforgroundcontact.(Note:theCCAarsenicbased
treatedlumberispreferabletotheACQtreatedlumbersinceitdoesn'treactwithplatedsteel
screwsoraluminumorsteelrail.)

6)CrossTieScrews
a)#10xl"washerheadplatedselfdrillingsheetmetalscrewforCCAtreatedwoodorstainless
steelscrewsforACQtreatedwood..

7)RailGauge
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a)Tobemadeoutofsolidsteelorstainlesssteelbarstock.
b)Minimumgaugebetweenrailheadstobesetat75/8",referencedrawing#2002.SeeFigure3.

8)Ballast.
a)Limestone617'sorequivalent(57'swithfines,etc.).Thisisamixtureof3/4"sizerockwith
fines.

9)TampingBar
a)Shouldbea1"to11/2"widex1/16"to1/8"thickpieceofsteelattachedtoahandle.
b)Airtamperwith4"widebladefromHarborFreightlongreachscraper.

RightOfWayPreparation
Thepreparationofarightofwayroadbedisessentialtomaintainingtheintegrityofthefinishedtrackage.
Trees,treeroots,rocks,ditches,andcreeksaresomeofthecommonobstaclesthatareofteninthewayofa
desiredroadbed.Eachobstaclewillrequireitsownsolutionforbeingdealtwith.Attimes,specificobstacles
cannotbeeasilyalteredthereforerequiringrevisionstorightofwayplans.Thefollowingrulesaretobe
appliedwhenplanning,constructing,andmaintainingarightofway.
1.Aminimumof48"shallbeclearedandgradedforasingletrackrightofway.SeeFigure4.
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2.Arightofwaywhichwillcontainparallelrunningtracksshallhaveawidthof24"measuredfromboth
outsidetrackcentersplustheseparationspacingofeachadjacenttracksection.SeeFigure5.
3.Opendrainageditchesshallnotrunparallelalongtrackageatadistancelessthan24"fromtrackcenter.See
Figure5.

TrackAssemblyStandards
1)Straighttrack
a)Tracksectionsaretobeconstructedinatrackjig.Thismaintainsevenspacingbetweentiesas
well.asprovidesaflatfoundationonwhichtowork.
b)Crosstiesaretobespacedatnolessthan3tiesper12"oftrack(4"spacing).
c)Crosstiesshouldbeorientatedwiththesmoothmillcutsidetobeagainstbottomfootofrail.
d)Railsaretobegaugedusingrailgauges.Threeormoregaugesshouldbeusedtoensure
parallelismbetweenadjacentrailheads.SeeFigure6.
e)Railgaugesshouldnotbepositionedsuchthattheyaremorethan2crosstiesapart.SeeFigure
6.
f)Railsaretobesecuredtoacrosstie,usingtwocrosstiescrewsperrail,oratotalof4crosstie
screwspertie.SeeFigure6.
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g)Crosstiescrewsaretobelocatedinlinetoeachotheronoppositesidesoftherailfoot.See
Figure6.

h)Crosstiescrewsaretobedrivenintothecrosstieataslightangle,matchingtheangleoftherail
foot.SeeFigure7.

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i)Crosstiescrewsaretobedrivenintothetieonlyuntilthescrewmakescontactwiththerailfoot.
Thescrewshouldneverdeformorcutintotherailfoot,otherwisemovementduetothermal
expansionofrailwillbeimpeded.
j)Whenpossible,itisgoodpracticetolocateatiedirectlyunderajoint.Thishelpstosupportboth
joiningrailendsandpreventsags.
k)Tracksectionsor'panels',tobetransportedtoaremotelocationforfinalassemblytorightof
way,shouldbeassembledwithallcrosstiescrewsalongonerailproperlysecured.Theadjacent
railistobesecuredinfourplaces,(attheendsandtwoplacesinthemiddle).Oncethepanelis
transportedtotheneededarea,theadjacentrailisthenloosenedandslidintoproperpositionto
matchtheexistingrailjointoffset.Oncethepanelisconnectedtotheexistinglinewithrailjoiners,
theadjacentrailcanthenbesecuredtothecrossties.
l)Railjoints,betweenadjacentrailheads,shouldbeaminimumof16"apart.Thisistohelp
preventkinksandsagsatthejoints.
m)Railjointsaretobelooseenoughtoallowforrailmovementduetotemperaturechanges.A
commonruleofthumbistotightenboltandnutbyhand,thenbackoffby1/2turn.
n)Agapbetweenjoiningrailendsmustbemaintained.Agapof1/8"fora65Fto85Frail
temperatureisrecommended.Thiswillallowforsufficientexpansionorcontractionofthejointfor
thetypicaltemperatureextremestypicalofourclimate.SeeTable1.
o)Whenrequired,asectionofrailmayhaveboltholesdrilledthroughwebratherthanpunched.
Whenthisisrequired,holesmustbedrilledusingtheraildrillingjig.
p)Ballastshouldbeappliedonlytosectionsofjoinedandsecuredtrack.Ifbothrailsarenot
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attachedtocrossties,thenthatsectionshouldnotbeballasted.
q)Ballastshouldbetampedunderthetiesateachrail.Ballastshouldnotbeexcessivelytampedat
thecenterofthetieasthiswillreducestabilityofthetie.
r)Trackshouldbecheckedwithalevel,ensuringthatonerailheadisnothigherthantheother.
Straighttrackshouldalwaysbelevel.
s)Trackshouldbecheckedforsuddenrisesandfallswithineach10'section.Anylowspotsmust
bebroughtuptocreateasmoothandlevelprofile.
t)Ifthesectionispartofagradient,thenanylowspotswithina10'sectionshouldbebroughtupto
createauniformtransitionbetweentheendsofthesection.
u)Ballastshouldbesweptlevelwithtopofties.
v)Sectionsoftrackthatareproperlyballastedandleveledwilltendtohavebecomeseveralinches
abovethegradelevel.Theseareasoftrackneedtohavetheedgeoftheballastreinforcedwith
earthfilltopreventerosionfromweatherandfoottraffic.SeeFigure8.

2)CurvedTrack
Thetreatmentofcurvedtracksections,asfarastheassemblyisconcerned,followsthesamesetofrulesas
outlinedinrule1,a)throughv).However,therearespecificconditionsandconsiderationsuniquetocurved
trackage.Theserulesareoutlinedasfollows:
a)Theminimumradiusformainlinerightofwayandpassingsidingsshallnotbelessthan60feet
(minimumradiusfora484).
b)Whenacurvedsectionofrightofwaymustbelessthan60feet,thentrackgaugemustbe
increased.
c)Railmustberolledtofollowtheplannedcurvatureoftherightofway.Asectionofcurvedtrack
shouldneverbe'sprung'intopositionsincethesectionwilltendtoworkitselfbacktoitsoriginal
stateofcurvature.
d)Assemblyofacurvedtrackpanelshouldbedoneonatrackjigspecificallydesignedand
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adjustedtosuittheintendedrateofcurvaturealongrightofway.
e)Transitionsbetweenstraightandcurvedsectionsalongmainlinerightofwayshouldbeplanned
forandimplemented.(Atransitionisagradualincreaseincurvatureradiusattheintersectionof
straightandcurvedsections).
f)Directlyconnectedreversecurvesshouldbeavoided.Apairofreversecurvesshouldbe
separatedbyastraightsectionoftracknolessthan10feet.Theadditionofthestraightsection
allowsforlongwheelbaselocomotivesortruckassembliestonegotiatethechangeincurvature
withoutbinding.Theadditionofthestraightsectionalsopreventscouplerswingbetweentwo
connectedcarsfrombeingusedup,binding,andcausingaderailment.
g)Maximumvalueforsuperelevationshallbe1/8".Theoutsiderailalongacurveshouldneverbe
belowtheheightoftheinsiderail.(Superelevationisdefinedastheconditionwheretheoutside
railofacurveishigherthantheinsiderail).

3)Grades
a)Themaximummeangradeshallbenomorethan3%onmainlineand5%onbranchline.

4)Bridges,Trestles,andSteamingBays
a)Theprimaryloadbearingbeamsorstringersshallalwaysbemadefromsteel(Channel,tubing,
or'I'beams,etc.).Thesizeofselectedsteelshapeshouldbedeterminedbaseduponadistributed
loadof4000lbs+additionalweightofdeckingandgirderspera10'sectionoftrackage.
b)Verticalsupportsortrestlebentscanbemadefromsteel,concrete,ortreatedwood.
c)Spacingofverticalsupportsmustbeinaccordancetothesizeofbeamselected.Smallerbeam
sectionswillrequirecloserspacingofsupports.Conversely,largerorthickerbeamsectionswill
permitgreaterseparationbetweensupports.
d)Verticalsupportsshallbesetinplacebelowfrostline(forOhio,minimumof36"deep).

5)Switches
a)Pointsshallbemilledfrom1"highx1/2"widesteel'c'channel.
b)Stockrailsshallhavethefootandaportionoftheheadmilledouttoaccommodatethepoint.
c)Theminimumfrogsizeforallmainlineswitchesshallbea#8.
d)Switchesshallbeofaspringthrowtype.
e)Crosstiescrewsmaybedrilledthroughthefootoftherail.Thisisoftennecessarydueto
physicallimitations(oppositefootmilledawayforrailpoint,tworailsconvergingatafrogorend
ofapoint,orwheretheguardrailsinterferewiththeoutsiderail).
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f)Rightofwayshouldbedesigned,whenpossible,suchthatthemainlinetrackistobethestraight
trackthroughtheswitch.
6)Diamonds.

a)Constructionshouldincorporatesteelmaterialsasmuchaspossible,primarilyatthefrogwhere
severeimpactloadingtakesplace.
b)Crosstiescrewsmaybedrilledthroughthefootoftherail.Thisisoftennecessarydueto
physicallimitations(oppositefootmilledawayforassemblyoffrogortworailsconvergingata
frog).

7)ParallelRunningTracks.

a)Mainlines,passingsidings,andyardtracksshallbeseparatedbyadistancegreaterthan40"
betweentrackcenters.
b)Ballastshouldbemaintainedataconstantlevelbetweenadjacenttracks.Thisreducestripping
hazardsaswellasreduceserosionfromfoottrafficandweather.Anotherbenefitisobtainedwhen
rerailingisnecessary.Blockingupofequipmentiseasierandsaferwhenballastlevelis
maintainedbetweenadjacenttracks.Inthecasewhereaderailmentoccurs,especiallywith
passengers,alevelshoulderhelpspreventtippingofequipment.

.8)RoadCrossings.

a)Wherepossibleroadcrossingswillbeofsteelrailsetinreinforcedconcreteofsufficientdepthto
handletraffic.Theareabetweentherailsshouldbelowertoallowforeasycleanout.
b)Crossingsformowersandlightweightvehiclescanbeconstructedoflongertieswithwood
betweenandoutsidetherails.Thewoodbetweentherailsshouldbenohigherthantherailheight.

9)Tunnels.

a)Tunnelswillbeconstructedpreferablyoutofsteelwithaminimumheightof6'.
b)Longtunnelsshouldprovideforadequateventilation.

10)Signals.

a)Signalswillbeprovidedforoperationofbidirectionalsingletrack.
b)SignalswillbeofacolorpositiondesignsimilartothatusedontheB&O.Thisallowsfor
colorblindoperatorstoseetheaspectofthesignal.
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c)Signalswillbeactivatedbyalimitswitch,button,ortrackcircuit.

11)Passingsidings.

a)Passingsidingsforbidirectionaloperationswillbelocatedapproximatelyevery500'.
b)Sidingsshouldbeofsufficientlengthtohandlethelongestnormaltrain.

Appendix

DeterminationofRailJointGap.
Anassembledrailjointsectionutilizingpunchedrailendsandpunchedrailjoinerswillallowforaconsiderable
gapopening.Wewould.liketoassemblerailjointswithagapwideenoughtoaccommodateanincreaseinrail
lengthduetoatemperatureincrease.However,wedonotwanttohaveagapopeningtoowideforthis
promotesdamageora'beatingdown'ofrailends.Instead,wewanttofindthesmallestgapopeningfora
typicalrailtemperaturethatonewouldencounterduringtrackassembly.TheaverageairtemperatureinOhio
canvaryfrom20Fto100F.Howeverwewanttoknowwhat.therailtemperaturerangethatcanoccurSince
railisheatedbyconductionfromtheearth,convectionfromtheair,andradiationfromthesun,rail
temperaturescanvaryfrom20Fto140F.Thisgivesusameanrailtemperatureof80F.(Extreme
temperaturesof180Fhavebeenencounteredonparticularlyhotandsunnyafternoons).Withthisaveragerail
temperatureestablished,nowweneedtolookathowouraluminumrailexpandsandcontractswithtemperature
todetermineaminimumjointgapopening.Ametalbarwillchangeinlengthduetoachangeintemperature.
Thischangeinlength,orthermalexpansion,isdeterminedbythefollowingequation:

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