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

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gummiwerk kraiburg elastik gmbh / D-84529 Tittmoning Goellstrasse 8 Phone +49

1 innostrail - installation instructions Subject to technical changes / January 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

innostrail installation instructions page 2/6 last update: 01.12.

2 innostrail installation instructions page 2/6 last update: # 1 / Preparations for installation Requirements, preparation work and checks before installing innostrail 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 the sleepers beds with ballast up to the level of sleeper surface and compact it. Measure the length of the crossing and mark off both ends and the centre point of the crossing. Tamp track as required to adjust to correct horizontal and vertical alignment. An excavator is recommended for installation and removal, its bucket needs to be slightly adapted. A tube or a piece of flat steel must be attached to the teeth to prevent damage to the rubber panels. Always consult your STRAIL representative before installing special configurations such as turnout-sections, small-radius curves, superelevations, intervia, etc. # 2 / Tools and Storage innostrail installation tools Installation lever for inner panels - if an excavator is not available. We recommend using the innostrail installation lever for fitting the individual panels to ensure correct installation and avoid damage to the panels. STRAIL lubricant hand truck large square edge Allen key, 27 mm span, or torque wrench with Allen key socket, width 27 mm 2 sledge hammers (plastic) 2 crowbars 1 small vibrating compactor for use between sleepers 1 roller compactor for making the connection to the road surface (effective) roller width at least 60 cm) Hand-held hammer, 250 g head Yard broom Manual installation > approx. 6-8 people is recommended to ensure that installation runs smoothly. 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! picture > installation lever

innostrail installation instructions page 3/6 last update: 01.12.2009 # 3 / Removal of old pavement surface Remove pavement surface up to approx. 1.8 m from the outer rail of each track.

3 innostrail installation instructions page 3/6 last update: # 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. Clean sleepers and rails # 4 / installation of panels After cleaning, lubricate rail base, kerbstones and innostrail panels with lubricant to make installation easier and ensure more effective compression of the panels. For wooden sleepers: Nail sleeper protectors under the inner panels (using at least 6 of the clout nails supplied). The outside (using at least 4 of the clout nails supplied on each piece) so that they are flush with sleeper surface. Since the material can become distorted by strong sunshine, only install according to the work progress. When installing the inner and outer panels, start at the crossing centre and then continue to both sides. Inserting the movement stopper. The movement stopper surrounds the sleeper from above. The vertical profile fits in the panel joint to prevent lateral creep. The movement stopper should not be located directly below wheel paths, but rather should be installed between them. Insert the first two panels in the crossing centre. Bend each inner panels with the excavator bucket until the lip can slip under the rail head, then push the panel down. Alternatively, (if there is not excavator available): Compress the inner panel with the installation lever and knock the lip under the rail head with the plastic hammer. Tap on all panels serval times with plastic sledge hammer immediately after installation to ensure stress-free fit. Connect the first two panels with the centre rods, by turning them counterclock wise (centre rods: marked in red). It is essential to ensure that the panels are under even tension. A torque wrench may also be used (torque approximately 100 Nm). Check the position of the first two panels in place using a angle gauge and correct with a plastic sledge hammer if necessary (90 to the rail). When connecting to roads with kerbstones, the outer panels must be inserted under the rail head first and then knocked down against the face of the kerbstone.

innostrail installation instructions page 4/6 last update: 01.12.2009 Fit the next two inner- or the next outer panels and secure with 1.80 m standard tie rods respectively.

If the crossing ends up with an uneven number of panels, the last panel must be fastened with special 0.9 m long tie rods.

4 innostrail installation instructions page 4/6 last update: Fit the next two inner- or the next outer panels and secure with 1.80 m standard tie rods respectively. After installing the last inner panel, place the deflection plates for the tongue or groove in position first of all before the last tie rods are inserted. If the crossing ends up with an uneven number of panels, the last panel must be fastened with special 0.9 m long tie rods. OPTIONAL End restraint as anti-creep device in case of higher longitudinal forces, as well as diagonal traffic (crossing angle < 75 and > 105 ). # 5 / Road Connection with T-kerbstone A) Concrete Foundation with Poured Concrete (longer road closure time needed) Excavate the road to the depth required on both sides of the track over the whole length of the crossing and approx. 1.8 m wide (request installation drawing). Set up shuttering in front of the sleeper ends to keep the track ballast clear from the foundation. The foundation strip now to be installed using concrete 250 kg/cm² or better (depth approx. 30 cm, width approx. 40 cm) serves as a support for the kerbstones. It should be noted that a relatively long curing time is necessary. In this case, we recommend the use of accelerators to shorten the 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 innostrail installation drawing). The support layer for the subbase blocks should be a firmly compacted crushed rock/clay mixture cm thick or dry lean concrete.

innostrail installation instructions page 5/6 last update: 01.12.

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.

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

5 innostrail installation instructions page 5/6 last update: 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. 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. Connection to the Road Surface The bituminous bearing layer must be installed in two charges and compacted separately (2) and (3). Then the bonding layer is applied (4). An approx. 4 cm thick wearing course (5) completes the connection with the road. A permanently flexible jointing compound or a Tok tape must be installed between the T-kerbstone and the wearing course (5). Essentially, the procedure used must comply with the code of practice for standardising the superstructure when renewing road surfaces from the road authority. (5) Wearing course (4) Bonding layer (3) Bituminous bearing layer (2) Bituminous bearing layer (1) Sub-structure (5) (4) (3) (2) (1)

innostrail installation instructions page 6/6 last update: 01.12.2009 # 6 / Removal for track maintenance Apply liquid wrench or lubricant to the rail web 5 minutes in advance.

6 innostrail installation instructions page 6/6 last update: # 6 / Removal for track maintenance Apply liquid wrench or lubricant to the rail web 5 minutes in advance. Remove tie rods and deflector plate Vibrate the first inner panel and separate with crow bar from adjacent panel, until tongue-groove joint is open. Compress the inner panel with excavator and lift it from the track. NOTE Please read the installation instructions carefully and install your innostrail crossing in accordance with our manufacturer s guidelines or request our assistance. We can only provide a guarantee/warranty if the installation complies with our stipulations.

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

STRAIL - installation instructions Subject to technical changes / December 2009 STRAIL level crossing systems & STRAILastic track damping systems Gummiwerk KRAIBURG Elastik Gmbh / D-85429 Tittmoning Goellstrasse