BODAN. Highway-Rail Level Grade Crossing System. Design Book. Engineered. Innovative. Products & Services. For Transportation

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1 Engineered Innovative Products & Services For Transportation BODAN Highway-Rail Level Grade Crossing System Design Book 20 Jones Street, New Rochelle, NY Phone: Fax: Web: transpo.com

2 BODAN Polymer Concrete Grade Crossing Systems Improve Safety and Reduce Maintenance The BODAN highway-rail grade crossing system consists of precast polymer concrete panels that are reinforced with internal rebar cages. These modular panels transfer heavy traffic loads directly to the rails. Panels are held in place using rubber sleeves, with no permanent attachment to the crossties. This unique bridge concept eliminates direct loading on the ties, while maintaining a constant level with the rail throughout the life of the crossing. The BODAN system has low cost maintenence. Removing the panels takes moments, rather than hours, so it may not be necessary to shut down an entire crossing to perform routine track maintenance. High-strength polymer concrete material enables BODAN panels to resist the effects of wear, weather, salt and diesel fuel. The exposed aggregate surface provides a highly skid-resistant surface even under wet conditions. BODAN is the only grade crossing system offering optional built-in flashing warning lights. This is an important safety feature considering the many vehicles involved in dangerous crossing incidents every year. BODAN is available in various sizes to accomodate installation on any rail crossing. Existing designs include: single or double track, curved track, as well as turnouts and switches that require a heavy-duty crossing surface to handle excessive traffic loads. This system has been tested with axle loads in excess of 44,000 lbs, making it one of the most durable crossings in the world today.

3 BODAN Polymer Concrete Grade Crossing Systems A unique feature for the BODAN grade crossing surface system is the LED flashing warning light option. These lights are not intended to be a replacement for gates or signals at active grade crossings, but rather, are a supplemental warning system activated by the same alert system as gates and signals. The LED fixture is placed in the edge beam of the crossing system, the part that serves as the paving stop for the highway. Physical Properties* Property Unit of Measure Test Mechanical Compressive Strength 14,000 psi (96 MPa) ASTM C-109 Flexural Strength 3,200 psi (22 MPa) ASTM C-384 Impact Strength 100 ft. lbs.min. ASTM D-2444 Physical Freeze/Thaw Resistance No Change ASTM C666 * To be used as general guidelines only Features and Advantages Durable, High-Strength Polymer Concrete No Attachment to Crossties Easy to Install Modular Components High Impact and Compressive Strength Chemical and Corrosion Resistant High Load-Bearing Capacity Skid Resistant Surface Low Maintenance Class A Fire Rated 20 Jones Street, New Rochelle, NY Tel: Fax: info@transpo.com 6/08 2K 9 0 0l/20 00

4 The Only Grade Crossing System With Built-in Flashing Warning Lights U.S. Patent Nos. 5,799,868 and 5,806,764 BODAN TRANSPO S, Bodan Level-Crossing Safety System utilizes high-strength precast polymer concrete panels that bridge between the rails and requires no fastening to the cross ties. The modular panels are maintenance free. They re designed for high load-carrying capacity, impervious to salt spray, moisture or diesel fuel and come with a skid and wear resistant surface.the Red warning lights alert approaching vehicles and are continuous on both sides of the crossing. This could eliminate the need for quad gates at crossings. TRANSPO INDUSTRIES, Inc. The Smart Solutions Company Tel Fax For Further Information On The Bodan Level Crossing System Call or visit us on our web site at

5 BODAN Polymer Concrete Panels The Polymer concrete material used for precasting the Bodan modular panel consists of acrylic resin composite and specially formulated aggregate fillers. This highly formulated polymer concrete exhibits unique physical property performance characteristics vastly superior to those of Portland cement. Polymer Concrete is highly resistant to water and salt penetration thus preventing corrosion of the reinforcing bar and deterioration of the concrete. Transpo has been manufacturing Polymer concrete material systems and precasts at its Castek facility in Berwick, PA for over 20 years. We have supplied polymer concrete materials for the repair of bridges, airport tarmacs, parking structures and commercial buildings. Precast Polymer concrete products include tunnel wall liners, retro reflective Jersey barriers, curbing, utility box covers, corrosion resistant drains, high voltage insulators, roof pavers, acid cells, architectural fascia panels and BODAN modular panels. The BODAN modular precast polymer concrete panels are maintenance free. They are impervious to salt spray, moisture or diesel fuel and have a lifetime skid resistant granular surface. The panels are designed for high load-carrying capacity with compressive strengths in excess of 14,000 psi. As an added safety feature, red LED warning lights to alert approaching vehicles are molded into the edge beam of the BODAN system which runs parallel to the track on both sides of the crossing. 20 Jones Street, New Rochelle, NY Tel Fax: Web: AN EQUAL OPPORTUNITY EMPLOYER

6 BODAN RR Level Crossing Precast Polymer Concrete Panels Physical Properties* Property Value Test Method Average Compressive Strength psi (96 MPa) ASTM C109 Average Flexural Strength 3200 psi (22 MPa) ASTM C384 Average Impact Strength 100 ft lb/min (0.23 m kg/s) ASTM D2444 Fire Resistance Class A ASTM E8487 UV Sensitivity 2.0 max ASTM G53 Resistance to Freeze/Thaw Zero Change ASTM C666 * To be used as general guidelines only. 20 Jones Street, New Rochelle, NY Tel Fax: Web: AN EQUAL OPPORTUNITY EMPLOYER

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8 BODAN Level Railroad Crossing System Standard Drawings System Drawings: Drawing Number Description Latest Rev. Date BD-750-STG Model BD-750, Single Track General Plan Details May 2006 BD-750-S-2 Model BD-750, Single Line Cross-Section Details May 2007 BD-750-D-2 Model BD-750, Double Line Cross Section Details May 2007 BD-1400-STG Model BD-1400, Single Track General Plan Details May 2006 BD STXS Model BD-1400, Single Track Cross Section May 2007 BD-1400-D BD-RPD BD-EB-1 Model BD-1400, Double Track Cross Section Rubber Profile Component Details Model BD-EB-1, Edge Beam Details for use on Single Track Models May 2007 May 2006 May 2007 BD-EB-1 BD-EBWL-1B BD-1400-S-1C Model BD-EB-1, Edge Beam Details for use on Double Track Models Model BD-EBWL-1B, Edge Beam Details With Warning Light Option Model BD-1400-S,-Plan View, Milwaukie Street Crossing, Boise, ID May 2007 May 2007 April 2005 BD-1400-S Model BD-1400-S,Lighting Detail October BD-1400-CWGLTM Model BD-1400, Cross Walk with Lights, ADA Tile & Pavement Markings March 2011 Transpo Industries, Inc., 20 Jones Street, New Rochelle, NY Phone: Fax: Web:

9 Component Drawings: Drawing Number Description Latest Rev. Date BD-EP Sheet 401 BD-EP Sheet 402 External Panel Type EP-750 Model BD-750. External Panel Type EP-1400 Model BD April 2006 April 2006 BD-IP Sheet 403 Internal Panel Type IP-1435 April 2006 BD-EB-501 Sheet 501 BD-EBL-502 Sheet 502 BD-CB-503 Sheet 503 BD-BF-504 Sheet 504 Edge Beam April 2006 Edge Beam with Warning Light April 2006 Center Beam (for Double Track) April 2006 Beam Foundation April 2006 BD-RPD-601 Sheet 601 BD-SR-602 Sheet 602 BD-DP-603 Sheet 603 Rubber Profile Details April 2006 Slab Retainer April 2006 Deflector Plate April 2006 Transpo Industries, Inc., 20 Jones Street, New Rochelle, NY Phone: Fax: Web:

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11 AST/H AST AST/H May 2007 AST

12 May 2007 AST/H AST/H AST/H

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14 AST/H AST/H May 2007 AST/H

15 May 2007 AST/H AST AST/H AST

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17 For Use on Single Track Models May 2007 AST/H

18 For Use on Double Track Models May 2007 AST

19 AST/H BODAN Level Crossing System Edge Beam Details with Warning Light Option Scale: Not to Scale Date: May 2007 Drawing No. BD-EBWL-1B Sheet 1 of 1

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22 BODAN Level Crossing Luminaires Applications: Luminaire: Light Source: Light Pattern: Photometrics: Railroad Crossing, Pedestrian Crosswalk Safety, Traffic Delineation, Tunnel, Platform Edge Flush (zero elevation above ground level) Two LUXEON Star LEDs Bidirectional, Wide From 5 to 80 in vertical plane; ± 65 in horizontal plane in each direction. Peak intensity 15 candelas. Colors: RED AMBER GREEN CYAN BLUE Electrical: Mechanical: LED power consumption 2.5-watts. Power inputs 120/240 volts AC; or low voltage operation AC/DC from 9-volts to 24-volts, polarity independent. Drive over, snow plow proof, weatherproof, completely sealed against road salts & chemicals, shock and vibration resistant, 2.5 inch Ø, 1.46 inches deep, weight 6-ounces 20 Jones Street, New Rochelle, NY Tel Fax

23 BODAN BD-1400-S Shelby, NE BD-1400-S w/led Surface Mounted Lights Boise, ID

24 BODAN BD-1400-S Norfolk, NE BODAN BD-750-S Flemington, NJ

25 BODAN Rail Section Detail BODAN Edge Beam Detail

26 PANEL REINFORCING CAGE CROSS SECTION PANEL CUT