STRAIL Installation Instructions

STRAIL - installation instructions
Subject to technical changes / December 2009

STRAIL level crossing systems & STRAILastic track damping systems
KRAIBURG Elastik GmbH / D-85429 Tittmoning Goellstrasse 8
Phone + 49 (0)8683/701-0 Fax +49 (0)8683/701-126 info@strail.de www.strail.com www.strailastic.com
STRAIL level crossing systems / D-85429 Tittmoning phone +49(0)8683/701-0 info@strail.com www.strail.com
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.
Our know-how in rubber processing and railway track technologies have made us a leading manufacturer in
this feld. STRAIL is a technologically mature and feld-proven system providing exceptional safety and durabi-
lity.
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 - 600 mm: approx. 135 kg
Inner panel - 1,200 mm: approx. 270 kg
Outer panel: approx. 107 kg
fller block: approx. 12 kg
(Weight vary for diferent gauges and track designs)
NOTE > Please complete the checklist provided and return it to STRAIL well in advance before installation. Con-
sult 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 fullled/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 re-
quire diferent panel thickness.
Fill in track ballast fush with sleepers surface and compact.
Measure the length of the crossing and mark of both ends and the centre point.
Check entire area of level crossing using a sufciently 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!
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 confgurations 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 fatly, 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 of of track bed.
Visually inspect fastenings; retighten if they are loose and replace any damaged or missing
fastening hardware.
# 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. 26 - 28
cm below the top of the rails. (see STRAIL installation drawing) The support layer for the subbase blocks should
be a frmly compacted crushed rock/clay mixture 10 - 15 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 fush 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 di-
mensional 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.
# 6 / INSTALLATION OF PANELS
Please sketch a layout plan before starting the job.
Clear all foreign material of of sleepers and rails and use a
tape measure to check for correct sleeper separation.
Lubricate rail base, kerbstones, fller 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 fller blocks. Please note that inner fller blocks are
marked I and outer fller blocks are marked A. Most
outer panel types come without fller blocks!
Install movement stoppers over the sleepers.
The ridge located in the centre of the movement stopper
fxes 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 frst 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 frst 2
inner panels. Tighten all tie rods with uniform tightness.
Use an angle gauge to check the positions of the frst 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 defection
plate before screwing in the last tie rods. Please note that
one type of defection plate is used to connect to tongue,
and another type of defection plate is used to connect to
groove profles.
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 ft.
OPTIONAL
End restraint as anti-creep device in case of higher longitudinal forces, as well as diagonal trafc (crossing angle
< 75 and > 105).
# 7 / ROAD CONNECTION WITH ASPHALT
Before installing the outer panels, apply and thoroughly
compact the bearing subbase fush 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.
For any procedures, dimensions or materials not specifed here, follow your national specifcations for road sur-
face renovation (e.g. in Germany: RstO-E - Guidelines for Road Surface Renovation / Draft 2001)
(3)
(2)
(1)
(1)
# 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, frst 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.

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Subject to technical changes / December 2009

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