STRAIL - installation instructions. Subject to technical changes / December STRAIL level crossing systems & STRAILastic track damping systems

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Brittany McKinney
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Gummiwerk KRAIBURG Elastik Gmbh / D-85429 Tittmoning Goellstrasse 8 Phone +

1 STRAIL - installation instructions Subject to technical changes / December 2009 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

STRAIL installation instructions page 2/7 last update: 01.12.2009 STRAIL-rubber level crossings are successfully performing in many countries throughout the world for 30 years.

2 STRAIL installation instructions page 2/7 last update: STRAIL-rubber level crossings are successfully performing in many countries throughout the world for 30 years. Our know-how in rubber processing and railway track technologies have made us a leading manufacturer in this field. STRAIL is a technologically mature and field-proven system providing exceptional safety and durability. Non-compliance with these assembly instructions, will void the warranty by the manufacturer. The STRAIL - System Material STRAIL contains recycled rubber compounds obtained from automobile tyre retreading processes and other high-quality sources. Weight (50 kg rail) Inner panel mm: approx. 135 kg Inner panel - 1,200 mm: approx. 270 kg Outer panel: approx. 107 kg filler block: approx. 12 kg (Weight vary for different gauges and track designs) 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. # 1 / Site preparation Requirements and preparation work which must be fulfilled/done prior to installation of STRAIL concrete sleepers, steel sleeper or smooth, plain timber sleepers. Requirement: the sleepers must not have sleeper plate recesses. Timber sleepers with baseplate recess require different panel thickness. Fill in track ballast flush with sleepers surface and compact. Measure the length of the crossing and mark off both ends and the centre point. 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!

STRAIL installation instructions page 3/7 last update: 01.12.

3 STRAIL installation instructions page 3/7 last update: Ribbed plate should not have recesses, in case of recessed ribbed plates the possibility exists to have the sleepers made level by KRAIBURG/STRAIL. Tamp track as required to adjust it to proper horizontal and vertical alignment. Always consult your STRAIL representative before installing special configurations such as turnout-sections, small-radius curves, superelevations, intervia, etc. # 2 / Tools and Storage STRAIL installation tools A 1,200 mm lever for 1,200 mm and 600 mm panels, 600 mm lever only for 600 mm panels. We recommend using the mounting lever to install the individual panels, thereby ensuring careful installation and avoiding any damage to the panels. hand truck STRAIL lubricant - with brush. 90 angle gauge Allan key with 27 mm span 2 plastic sledge hammers 2 crowbars small vibrating compactor for use between sleepers roller compactor for use on connection to road pavement (roller width: at least 60cm) hammer, head weight approx. 250 g track or switch broom Manual installation > 600 mm inner panels (IP): approx. 4-6 people / 1,200 mm inner panels (IP): approx. 7-9 people ensure smooth installation. Installation using an excavator > approx. 4-6 people ensure smooth installation. please note: Protective bucket tips required (so panels are not damaged) Store wooden pallets upright and do not place on top of one another. It is essential that the panels are stacked flatly, in a horizontal position. Avoid any deformation of the panels and do not store them in direct sunlight! # 3 / Removal of old pavement surface Remove pavement surface up to approx. 1.8 m from the outer rail of each track. When using kerbstones, excavate soil for poured subbase to a depth of approx. 60 cm from the top of the rails. When using prefabricated concrete subbases instead of poured subbase, excavate to a depth of approx. 70 cm. Clear all pavement debris and other foreign material off of track bed. Visually inspect fastenings; retighten if they are loose and replace any damaged or missing fastening hardware.

STRAIL installation instructions page 4/7 last update: 01.12.2009 # 4 / Connection to street pavement with kerbstones A) Poured Concrete Subbase (Requires Long Road Closure Time) Excavate approx. 1.

Before pouring concrete, place a formwork board next to the ends of the sleepers to separate the subbase from the sleeper ballast.

Accelerators may be added to the concrete to shorten the setting process.

4 STRAIL installation instructions page 4/7 last update: # 4 / Connection to street pavement with kerbstones A) Poured Concrete Subbase (Requires Long Road Closure Time) Excavate approx. 1.8 m of the road approach from each side of the track to the required depth as shown in the STRAIL Installation Drawing over the entire length of the crossing. Before pouring concrete, place a formwork board next to the ends of the sleepers to separate the subbase from the sleeper ballast. Using C20/25) or better grade concrete, pour the subbase strip (approx. 30 cm high, approx. 40 cm wide). The subbase serves as a support for the kerbstones. Allow at least 28 hours setting time. Accelerators may be added to the concrete to shorten the setting process. B) Prefabricated Concrete Subbase (Allows Short Road Closure Time) When using prefabricated concrete subbase blocks, place them such that their upper surface is approx cm below the top of the rails. (see STRAIL installation drawing) The support layer for the subbase blocks should be a firmly compacted crushed rock/clay mixture cm thick or dry lean concrete. # 5 / Installation of kerbstones Installation Moisten the subbase and the kerbstones. Apply a approx. 1-3 cm thick levelling layer of mortar over the subbase. With the help of the two installation gauges the T-kerbstones are placed at the proper distance, at the right angle and at the correct height (upper edge of the rail) Important > The gauges have to be exactly flush with the rail, kerbstone and sleeper! In addition, always use a crossbar to check for the correct height, since the sleepers are also subject to dimensional tolerances. Important > only mix 1 bag of mortar at a time, since working time amounts to only approx. 20 min (depending on ambient temperature) Usage: 1 bag is enough for approx. 1.5 m. Observe instructions for use! Fill joints and back support with mortar. For especially short closing periods we recommend using our special fast-setting mortar. Adjusting the installation gauge Make sure crossbar is resting on both sides. Fit installation gauge tightly to crossbar and the outer side of the rail (see picture). Loosen screws on installation gauge. Put sheet of installation gauge against a level spot of the sleeper. Tighten screws > the installation gauge is now set. Use the adjusted installation gauge to install the T-kerbstones.

STRAIL installation instructions page 5/7 last update: 01.12.2009 # 6 / Installation of panels Please sketch a layout plan before starting the job.

Lubricate rail base, kerbstones, filler blocks and STRAIL panels with STRAIL lubricant to simplify installation.

Be sure to position the edges of the protector sheets even with the edges of the sleepers. Between the rails (i.e. support surfaces for inner panels), use at least 6 of the wide-head nails supplied per sheet.

As the protector sheets can expand under strong sunlight exposure, only install them just before installing the STRAIL panel they will support.

5 STRAIL installation instructions page 5/7 last update: # 6 / Installation of panels Please sketch a layout plan before starting the job. Clear all foreign material off of sleepers and rails and use a tape measure to check for correct sleeper separation. Lubricate rail base, kerbstones, filler blocks and STRAIL panels with STRAIL lubricant to simplify installation. For timber sleepers: Nail on sleeper protector sheets on all sleeper surfaces which will support STRAIL panels. Be sure to position the edges of the protector sheets even with the edges of the sleepers. Between the rails (i.e. support surfaces for inner panels), use at least 6 of the wide-head nails supplied per sheet. Outside the rails (i.e. support surfaces for outer panels), use at least 4 of the wide-head nails supplied per sheet. As the protector sheets can expand under strong sunlight exposure, only install them just before installing the STRAIL panel they will support. You should start in the middle when installing the panels. Insert filler blocks. Please note that inner filler blocks are marked I and outer filler blocks are marked A. Most outer panel types come without filler blocks! Install movement stoppers over the sleepers. The ridge located in the centre of the movement stopper fixes the two adjoining STRAIL panels in place, preventing lateral displacement. The movement stopper should not be located directly below wheel paths, i.e. where vehicle wheels will normally move over. Place the first two panels directly around the movement stopper The surfaces of the panels should be tapped continuously with a plastic sledge hammer during installation in order to release any existing tension. Use either the installation lever or excavator shovel (protective bucket tips) to push the lips of the inner panels under the railheads Use the centre tie rods (marked red) to connect the first 2 inner panels. Tighten all tie rods with uniform tightness.

STRAIL installation instructions page 6/7 last update: 01.12.2009 Use an angle gauge to check the positions of the first two panels connected. Both must be at exactly 90 to the rails.

For road connections including kerbstones: First place outer panels tight against rail. Other panel edge over the edge of the kerbstone knock down.

20 m section to be screwed together with the standard 1.2 m tie rods. After installing the last inner panel, install the deflection plate before screwing in the last tie rods.

If the crossing contains an odd number of panels, use special 1.8 m long tie rods (coloured blue) to screw the last three panels on that side together.

6 STRAIL installation instructions page 6/7 last update: Use an angle gauge to check the positions of the first two panels connected. Both must be at exactly 90 to the rails. Correct with a plastic sledge hammer as necessary. For asphalt road connection without use of kerbstones: Pull the outer panels tight against the railhead. For road connections including kerbstones: First place outer panels tight against rail. Other panel edge over the edge of the kerbstone knock down. Install the next two inner panels and the next two outer panels and lubricate tongue and groove joint. Use a plastic sledge hammer to tap these panels together. Each 1.20 m section to be screwed together with the standard 1.2 m tie rods. After installing the last inner panel, install the deflection plate before screwing in the last tie rods. Please note that one type of deflection plate is used to connect to tongue, and another type of deflection plate is used to connect to groove profiles. If the crossing contains an odd number of panels, use special 1.8 m long tie rods (coloured blue) to screw the last three panels on that side together. Tap all panels several times with plastic sledge hammer immediately after installation to ensure stress-free fit. OPTIONAL End restraint as anti-creep device in case of higher longitudinal forces, as well as diagonal traffic (crossing angle < 75 and > 105 ). # 7 / road connection with asphalt Before installing the outer panels, apply and thoroughly compact the bearing subbase flush with the sleeper surface. (1) After installing outer panels, apply and compact the bitumenous bearing layers. (2) Then install an approx. 4 cm thick wearing course to complete the connection to the street. (3) Based on experience, pourable hot asphalt is recommended as the material for the bitumenous bearing layers and the wearing course. (3) (2) (1) (1) For any procedures, dimensions or materials not specified here, follow your national specifications for road surface renovation (e.g. in Germany: RstO-E - Guidelines for Road Surface Renovation / Draft 2001)

STRAIL installation instructions page 7/7 last update: 01.12.

7 STRAIL installation instructions page 7/7 last update: # 8 / crossing with Superelevation On timber sleepers On lower side of crossing, adjust outer edge of STRAIL panels to road gradient by means of plastic wedges which are screwed onto the sleepers. Level on opposite side by milling the sleeper shoulder as required. On concrete sleepers Special design on demand. # 9 / Removal for track maintenance Proceed in reverse order of installation for regular tamping of the tracks. To disassemble the panels, first remove the tie rods and then tip the panels upwards using crowbars. Make sure to mark the exact position of removal, since the center panels need to be reinstalled at exactly the same spot. Likewise, in case of installed radius and/or compensation panels be sure to mark all parts which belong together accordingly and to make them all available for re-installation. When using an excavator for disassembly > use removal aid. Clean all parts after removal and prepare them for re-installation.

innostrail - installation instructions Subject to technical changes / January 2010 STRAIL level crossing systems & STRAILastic track damping systems

innostrail - installation instructions Subject to technical changes / January 2010 STRAIL level crossing systems & STRAILastic track damping systems gummiwerk kraiburg elastik gmbh / D-84529 Tittmoning