INSPECTION REPORT

[Inspection Name, such as No. 8 DOUBLE CROSSOVER IN-PLANT INSPECTION]

[Project Name]

[CONTRACT NUMBER]

By

[Lead Inspectors Name]

Inspection Date: [Inspection Date]

Report Date: [Date the report is submitted]

INSPECTION REPORT

[Inspection Name]

[Project Name]

[Contract Name]

1. Introduction This report presents the results of an [Inspection Date] inspection of [Inspection Name] for [Project Name].

The report is in the following order:

Basis of inspection (references, tolerances, etc.). Inspection conditions. Inspection procedures. Inspection results. Contractor Follow-up actions from the inspection. Recommendations for field installation preparations. Appendices.

2. Basis of Inspection The inspection was commissioned by [Project Manager Name and Affiliation] for [Client Name]. [One sentence description of nature of the inspection and where conducted]. See Appendix A, Contacts, for the list of participants.

The inspection was conducted by [Name and affiliation of the inspector(s)].

The inspection was conducted in accordance with the Project specification and accepted industry practice. See Appendix B, Technical References, for the list of technical documents applicable to this inspection, Appendix C, Drawing List, and Appendix I, Drawings.

The tolerances applied in this inspection are either directly from or derived from the cited Technical References. See Appendix D, Track Tolerances and Compliance Requirements, for the list of tolerances.

3. Inspection Conditions The [name the components inspected] was presented for inspection at [location name and address of the inspection].

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[Briefly describe the inspection conditions. As example for an in-plant double crossover inspection, the following was described.

The crossover was fully assembled except for the following items:

Most joints were loosely assembled (not all bolts were installed, installed bolts were not torqued)

Glued and Hucked joints intended for field installation were joined with standard bars and bolts.

Rail ends intended for field welding were loose (not joined) Switch machines, throw rods and throw rod adaptor were not available for the inspection.

Prior to inspection, the Contractor provided material certifications from third party vendors whose products are included in the crossover assembly. The Contractor also provided updated shop drawings (included in Appendix I).]

4. Inspection Procedures [Briefly describe the inspection procedures. Include the inspection tasks in order, tasks that could not be performed and reason, and any qualifying information on the nature of the inspection.]

5. Inspection Results Summary [Generally characterize the inspection results, particularly whether the components and assemblies will meet specification upon shipment. Refer to the detailed inspection data that should be in the Appendix. Example for a No. 8 Double Crossover:

Based on the inspection measurements and observations, the No. 8 Double Crossover complies with the Specification, except for those elements of the crossover that could not be inspected. (please refer to Section 3, above, for incomplete assembly elements).

Inspection results are in Appendix E, Turnout Inspection Reports, Appendix F, Crossing Diamond Inspection Report, Appendix G, Rail Joint Inspection, and Appendix H, Turnout A Tie Inspection.

The inspection results did not comply with all tolerances that are shown as assumed in the list of tolerances (Appendix D). The assumed tolerances are more restrictive than the specification for critical portions of the assembly. However, the assembly did largely meet these tighter tolerances. The basis of acceptance must, contractually, be the specification tolerances, not the tighter assumed tolerances.

All components inspected were located properly, and were free from flaws after identified repairs or corrections were made. ]

6. Follow-up Actions [Identify any contractual or construction actions that should be done prior to installation or final acceptance, as applicable.]

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7. Recommendations for Field Installation Preparation [If applicable, identify any requirements or precautions that field personnel should be aware of in their planning the installation.]

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Appendix A Contacts

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CONTACTS

Sheet 1 of 2 [Inspection Name]

[Project Name] [Contract Number]

FIRST NAME

LAST NAME TITLE AFFILIATION STREET CITY

STATE/ PROV ZIP WORKPHONE

Project Management

Design

Construction Contractor

Vendor

Fabricator

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CONTACTS

Sheet 2 of 2 [Inspection Name]

[Project Name] [Contract Number]

FIRST NAME

LAST NAME TITLE FAX Other Phone E-mail Note UPDATED

Project Management

Design

Construction Contractor

Vendor

Fabricator

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Appendix B Technical References

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TECHNICAL REFERENCES

[Inspection Name] [Project Name] [Contract No.]

Inspection Date: [Date] Inspection Location: [Facility Name, address and phones] Contract Specifications1 Quality Control Plan (Section XXXXX) 2 Track (Section XXX-XX) Contract Plans3 Track Plans, Sheet Nos. XX through XX. Contractor Submittals4 Quality Control Plan 5 Working Drawings for XXXXX (see Drawing List) Other Reference Drawings (Hanning & Kahl)6 7 Industry References8 American Railway Engineering and Maintenance Association Portfolio of Trackwork Plans, with specific attention to Plan XXXX-XX Plan XXXX-XX Plan XXXX-XX Plan XXXX-XX 9 American Railway Engineering and Maintenance Association Manual for Railway Engineering

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Appendix C Shop Drawing List

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DRAWING LIST No. 8 DOUBLE CROSSOVER PLANT INSPECTION

SAN YSIDRO INTERMODAL TRANSPORTATION CENTER PROJECT, PHASE 2 CONTRACT LRT-453

Inspection Date: 4/24/03 SHOP DRAWINGS RAIL PRODUCTS AND FABRICATIONS Drawing No. MTD87601

Sheet Revision Revision

Date Drawing Title

Listed drawings are included in this report as Appendix I

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Appendix D Track Tolerances and Compliance Requirements

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TRACK TOLERANCES AND COMPLIANCE REQUIREMENTS [Project Name]

[Contract Number] Inspection Date: [date]

[The following are examples. Enter the proper items, the correct tolerances, and the specification reference for the tolerance.] Parameter Tolerance Spec Reference Metric English

Tie Length 152.40 mm 0 6'' AssumedTie Spacing (Tie to Tie Spacing and Cumulative Distance) Concrete Ties 25.40 mm 0 1'' 10-12-2.07.G Switch Ties (Tie Nos. -1 to 16) 6.35 mm 0 1/4'' Assumed Turnout Ties (Tie Nos. 17 to 29) 25.40 mm 0 1'' 10-12-2.07.G Frog & Crossing (Tie Nos. 30 to 46) 6.35 mm 0 1/4'' Assumed Tie Condition Tie length and width 25.40 mm 0 1'' AREMA Ch 3, 2.1.3.1 Wane within rail bearing area ## 25.40 mm Max 1'' Max AREMA Ch 3, 2.1.3.1 Conditions: Splits, holes, knots, shake, checks ## 0 AREMA Ch 3, 2.1.4 Straightness, deviation from chord bet. Ends ## 50.80 mm Max 2'' Max AREMA Ch 3, 2.1.4 Track Gauge Within Switch and Frog (incl. Crossing diamonds) Limits 1.59 mm 0 1/16'' Assumed All other track 3.18 mm 0 1/8'' 10-12-2.07.AStock rail gauge 1.59 mm 0 1/16'' Assumed Curve closure rail offsets 1.59 mm 0 1/16'' Assumed Guard rail location 25.40 mm 0 1'' AssumedTurnout lead 25.40 mm 0 1'' Assumed

Switch Throw, 4 3/4" (121 mm) 1.59 mm 0 1/16'' Assumed (refer to 10-12-4.02.B) Switch Point Stagger 6.35 mm 0 1/4'' Assumed

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Parameter Tolerance Spec Reference Metric English Alignment Horizontal misalignment from design, all track 12.70 mm 0 1/2'' 10-12-2.07.C.3 Horizontal misalignment from design, within stations 6.35 mm 1/4'' 10-12-2.07.C.2 Horizontal rate of change in 31' (9450 mm) 3.18 mm 0 1/8'' 10-12-2.07.C.1 Horizontal misalignment in curves 6.35 mm 0 1/4'' 10-12-2.07.D.2

Horizontal curve & spiral rate of change in 62' (18.90 m) chord 3.18 mm 0 1/8'' 10-12-2.07.D.1 & 10-12-2.07.E Profile deviation from design 12.70 mm 0 1/2'' 10-12-2.07.F.2 Profile rate of change in 31' (9450 mm) 3.18 mm 0 1/8'' 10-12-2.07.F.1Crosslevel 3.18 mm 0 1/8'' 10-12-2.07.B Rail Welds ##

Vertical Crown in 18" (457 mm) with 36" straight edge ## 1.59 mm Max 1/16'' Max AREMA Ch 4, Part2.2.2.c.1,10-12-3.04.4

Vertical Dip in 18" (457 mm) with 36" straight edge ## 0.00 mm Max 0'' Max AREMA Ch 4, Part2.2.2.c.1,10-12-3.04.4

Horizontal misalignment + rail end offset in 18" (457 mm) with 36" straight edge 1.59 mm 1/16'' AREMA Ch 4, Part2.2.2.d,10-12-3.04.4

Top of rail finish to parent rail section 0.25 mm 0.010'' Max 10-12-3.04.4

Rail side head finish to parent rail section 0.25 mm 0.010'' Max AREMA Ch 4, Part2.2.2.f,10-12-3.04.4 Rail end cut squareness 0.79 mm 1/32'' 10-12-3.04.4 Rail End Hardening Hardness 341 BHN Min 10-12-3.04.B 401 BHN Max 10-12-3.04.B Flangeway Width ## 47.63 mm Min 1 7/8'' Min 10-12-4.02.F Flangeway Depth ## 47.63 mm Min 1 7/8'' Min 10-12-4.02.F Guard rail guages (guard face guage, guard check gage 1.59 mm 1/16'' Assumed

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Appendix E Turnout Inspection Reports

Appendix F Crossing Diamond Inspection Report

Appendix G Rail Joint Inspection

Appendix H Tie Inspection

Appendix I Drawings

IntroductionBasis of InspectionInspection ConditionsInspection ProceduresInspection Results SummaryFollow-up ActionsRecommendations for Field Installation PreparationAppendix ACONTACTSCONTACTS

Appendix BInspection Date: [Date]

Appendix CSheet

Appendix D