STRAIL level crossing systems & STRAILastic track damping systems

Transcription

1 pontistrail - installation instructions Subject to technical changes / February 2010 STRAIL level crossing systems & STRAILastic track damping systems Gummiwerk KRAIBURG Elastik GmbH / D Tittmoning Goellstrasse 8 Phone + 49 (0)8683/701-0 Fax +49 (0)8683/ info@strail.de

2 pontistrail installation instructions page 2/6 last update: STRAIL railway crossings have been in use throughout the world since the 1970s and have proven themselves in the best possible way. As a specialist dealing in the particular requirements of rail operators, we have developed into the leading provider of railway crossing systems. By choosing pontistrail you have decided upon a technically sophisticated, outer panel system made from a combination of rubber and aluminium that is suitable for everyday use and that will ensure safe traversal of crossings for many years into the future, if installed correctly. The manufacturer s warranty shall lapse if the installation instructions are not followed. It takes 6 people to install the pontistrail system without problem. Mechanical aids are required to install the foundations and kerbs THE pontistrail OUTER PANEL SYSTEM NEW - for highest loads > pontistrail outer panel system combined with 1,200 mm STRAIL inner panels. Material pontistrail is a combination of aluminium bearings with integrated rubber supports and the tried-and-tested rubber panels. Weight Rubber panel: Aluminium bearing: approx. 110 kg approx. 30 kg NOTE Please complete the checklist provided and return it to STRAIL well in advance before installation. Consult your local STRAIL representative if you have questions concerning the checklist or need further information of any kind.

3 pontistrail installation instructions page 3/6 last update: # 1 / Site preparation Requirements, measures and checks to be carried out before installing pontistrail Completely remove the old track covering in the outer area. Clean the rails, rail mounting and sleepers (the rail base and web of the rail must be cleaned particularly thoroughly > contact surface for the rubbers). Welded seams in the fishing surface are to be ground flat. Tighten the mountings and replace missing ironmongery. Timber sleepers must be sanded flat. Measure the length of the railway crossing and mark the beginning, middle and end. The distance between the track ballast and the upper edge of the sleeper must be at least 220 mm. Check entire area of level crossing using a sufficiently long tape measure to ensure exact distribution of sleepers and correct where necessary (600mm +10/-10mm); Under no circumstances shall sleeper distances be measured and corrected individually! Tamp track as required to bring it into proper horizontal and vertical alignment. Correct the position of the sleeper if you find deviations! In the case of track radii, the track axis is the basis for the matrix dimension. Always consult your STRAIL representative before installing special configurations such as turnout-sections, small-radius curves, superelevations, intervia, etc. Difference between the STRAIL and pontistrail system The pontistrail system only makes contact with the rail base and the abutment with the road and may not touch the ballast and sleeper. Please proceed with care when transporting and storing the pontistrail system! # 2 / REQUIRED TOOLS AND AIDS Installation tools for the pontistrail system Installation lubricant* Paintbrush hand truck 2 sledge hammers (synthetic) 2 rods Allen key SW 27 *, or torque key with hexagonal socket key SW 27 1 vibrating roller for producing the connection with the road (minimum working width 60cm) Installation gauge * crossbar (>/= 2.50 m) Pull-off gauge transport- and installation tool * included in delivery

4 pontistrail installation instructions page 4/6 last update: # 3 / Road connection with Kerbstones Cut back the old road surface >/= 2 m from the outer edge of the rail. Excavate the soil for the foundation >/= 70 cm from the upper edge of the rail. Concrete foundation with concrete mixed on site (requires a long closure period) Creation of shuttering to separate the track ballast from the foundation Produce foundation strips from concrete with minimum compression strength class C25/30. Observe the setting time as specified by the manufacturer. Concrete foundation as laying foundation (fast installation method) The installation dimensions (see structural overview) must be observed when installing the laying foundation! A very thick mineral mix or lean concrete layer (>/= cm) should be used as the bedding for the laying foundation! Laying the kerbs Moisten the subbase and kerbstones (using a paint brush). Apply the quick-setting kerb laying mortar specially designed for the system (follow the enclosed instructions for use). Apply a approx. 1-3 cm thick levelling layer of mortar over the subbase. Usage: 1 bag is enough for approx. 1.5 m. Observe instructions for use! Use the installation gauges and crossbar to place the kerbs on the foundations with the kerb laying mortar at the height and alignment on a compensating layer of mortar. In addition, always use a crossbar to check for the correct height, since the sleepers are also subject to dimensional tolerances. Fill joints and back support with mortar. Ballast must be filled in the space between the outer edge of the sleeper and the kerb (support for the aluminium bearing) (ballast to the front!) The gauges must be exactly flush with the rail strut, the kerbstone and the rail. The kerbs may only be installed after the filling work is complete! The pontistrail aluminium bearings are to be installed immediately after each kerb has been laid (prevents the kerbs from shifting laterally).

5 pontistrail installation instructions page 5/6 last update: # 4 / Installation of pontistrail system When installing eg. STRAIL inner- and pontistrail outer panels please start in die middle of the level crossing and continue then each on the left and right side of the central panel. Aluminium bearings are installed as follows Position the central bearing at the previously marked center (see the installation plan provided). Place the bearing on the rail strut and carefully positioning net to the kerb. Make sure the aluminium bearing is positioned correctly! If the bearing sticks, lift it at the rail once again. Do not use force to position it correctly! The adjusting wedge may not be adjusted at initial installation. (Bearings are supplied with the adjusting wedge in central position! It may be necessary to move these after you have completed your work!) Rubber panels are installed as follows Apply installation compound to the rail head, the groove on the kerb and the tongue/groove joint of the panels. Start by installing the marked central panel (with the groove on the underside) above the central aluminium bearing. Use an installation- and transport tool to remove the rubber panel from the pallet. First insert the panel with the tongue in the groove of the kerb and then press it down under the head of the rail. Knock the panels together with a plastic hammer and use tensioning rods to screw them together. The plastic sledge hammer can be used on the panel to knock the gaps between the panels closed when tightening up the tensioning elements! OPTIONAL End restraint as anti-creep device in case of higher longitudinal forces, as well as diagonal traffic (crossing angle < 75 and > 105 ).

6 pontistrail installation instructions page 6/6 last update: # 5 / RAIlway crossing with superelevation The pontistrail bearings can be raised or lowered in order to adapt to the slope of the road. The maximum/ minimum values depend on the superstructure form. The values can be found in the drawing supplied. In the case of timber sleepers, it may be necessary to sand down the sleeper heads! # 6 / area between the tracks (intervia) The pontistrail outer panel system is also installed between the tracks. The resulting gaps between the kerbs of the two tracks should be filled with cast asphalt. # 7 / removal for track maintenance Mark the panels so as to be able to re-install them at the same position (: Observe the track system marking!). Open the lock tight systems. Remove the panels using variant 1 (installation and transport hook and excavator required) or variant 2 (insert crowbars in the holes for the lock tight system and lever out the panels). Store panels, bearings and accessories on their sides, clean them and prepare them for reinstallation. All wear and tear parts (rubber supports, adjusting wedges with rubber fittings, locking components) should be inspected to ensure they are in good condition and fully functional! Use the adjusting wedge on the aluminium bearing to compensate for lateral movement of the track due to filling work up to 6 mm! Adjusting the adjusting wedge on the aluminium bearing Use a locking element to loosen the adjusting wedge from the bearing (press the snap connector)! Thoroughly clean the adjusting wedge and the teeth on the bearing! Fix the adjusting wedges in place in accordance with the new track position! Spare locking elements are included in each delivery and can be find together with a support (marked with stickers).