installation & maintenance guide - railway level crossing ... · rosehill level crossings •...

INSTALLATION& MAINTENANCE GUIDEROSEHILL ROAD CONNECT

RODDED CROSSING SYSTEM

ROSEHILL LEVEL CROSSINGS

Please take the time to read this

document carefully before the

installation or maintenance of any

Rosehill Rail level crossing system.

It will save you valuable time

during installation.

Following these instructions will

enable you to install the crossing

quickly and correctly so that you

get the optimum lifespan from

the system.

Please check you are using the current version of this document, available at: www.rosehillrail.com/downloads/instructions

PAGE 2 ROSEHILL RAIL LEVEL CROSSINGS PRODUCT OVERVIEW

PAGE 3 INSTALLATION ACTIVITIES

PAGE 4 CROSSING PANELS GAUGE PANELS FIELD PANELS

PAGE 5 END RESTRAINTS

PAGE 8 DEFLECTOR PLATES

PAGE 9 PLASTIC OR STEEL EDGE BEAM INSTALLATION

PAGE 10 ROSEHILL RAIL RUBBER OR CONCRETE EDGE BEAM INSTALLATION

PAGE 11 TOOLS & EQUIPMENT

PAGE 13 MAINTENANCE & DISPOSAL

PAGE 14 FURTHER INFORMATION PRODUCT FAMILIARITY ISO 9001 PROTECTING THE ENVIRONMENT DESIGN RIGHTS

1ISSUE 04/01/16RR

CONTENTS


Rosehill Rail panels are available in the following grades each one designed for a specifi c purpose. They are made to measure each specifi c crossing and can be made to fi t any gauge, rail and sleeper.

The crossing system consists of panels which are 1.8m in length to minimise the number of joints. Two panels are designed for the gauge area and then fi eld panels (often referred to as the cess panels) are placed on the outside of the rails and kept in place by an edge beam (rubber, concrete, plastic (PVC) or steel). In the case of Track Access Points ballast, concrete or asphalt will keep the fi eld panels in place.

The panels are held together laterally (along the line of the track) by fl anged bolts. These must be installed to the correct torque setting (210 Nm).

End restraints must be fi tted at both ends of the crossing.

At both ends of a crossing a defl ector plate (sometimes referred to as a chain guard) must be placed in the middle of the gauge area.

Rosehill Rail can provide crossings for the mostunusual specifi cations such as check rails and doublecheck rails. Also, we can make for any gauge, sleeper and rail section.

2

EXTREME for heavy duty road crossings.

ROAD standard grade for roads.

AGRICULTURAL for agricultural traffi c and light commercial use.

PEDESTRIAN for foot traffi c only.

TRACK ACCESS PANELS work-site use for crossing tracks, or for on/off tracking of road/rail vehicles.

ISSUE 04/01/16RR


PRODUCT OVERVIEW

The Rosehill Road Connect level

crossing panels are made from

quality controlled recycled rubber.

The crossing system consists of panels which are 1.8m in length to minimise the number of joints. Two panels are designed for the gauge area and then fi eld panels (often referred to as the cess panels) are placed on the outside of the rails and kept in place by an edge beam (rubber, concrete, plastic (PVC) or steel). In the case of Track Access Points ballast, concrete or asphalt will keep the fi eld panels in place.

At both ends of a crossing a defl ector plate (sometimes referred to as a chain guard) must be placed in the middle of the gauge area.

Rosehill Rail can provide crossings for the mostunusual specifi cations such as check rails and doublecheck rails. Also, we can make for any gauge, sleeper and rail section.

PEDESTRIAN for foot traffi c only.

TRACK ACCESS PANELS work-site use for crossing tracks, or for on/off tracking of road/rail vehicles.


• Visually check that the panels have not been damaged in transit.

• The rail, sleeper, fi xing and crossing type are all imprinted on each panel, check that these meet specifi cations.

• Sleepers must be correctly spaced at 600mm centres ±40mm (although not cumulative).

• Ensure that the rails, clips and sleepers are clear of any debris, and that all ballast is just below or fl ush with the top of the sleepers, rake fl at/fl ush if necessary.

• Identify the centre of the crossing and mark with a suitable indelible marker. If required, the road should be cut back to allow the installation of the edge beam.

• Install panels using the Rosehill Rail lifting pins, or another approved and safe method.

• Check that the panels fi t correctly, without fouling on rail or fi xings.

• Secure panels together using the bolts provided.

• Check that all panels are level without vertical steps.

• Ensure that panel connecting bolts (as supplied) are correctly fi tted and tightened to 210 Nm.

• Check that the fi eld or cess panels fi t tightly between rail and edge beam/ballast infi ll.

• Check that defl ector plates (chain guards) are correctly fi tted in accordance with the direction

of rail traffi c.

• Check that the end restraints are correctly fi tted.

NOTCHING OUT

In some circumstances it will be necessary to notch a relief in the rubber ‘lip’ (where it sits into the fl ange of the rail) where it falls in line with rail clips, chairs, welds, fi shplates, etc. This is a small cutout that can be achieved by using the most appropriate cutting tool.

3ISSUE 04/01/16RR

INSTALLATION

INSTALLATIONACTIVITIES

Offl oad the crossing panels, end restraints, edge beams and defl ector plates to a suitable

position next to the crossing.

Pull out the locking mechanism on the handle.

Twist the grip to set the correct setting.

Set the torque wrench to 210 Nm.

Push in the locking mechanism to lock the setting.

SETTING THE TORQUE WRENCH


GAUGE PANELS (4 FOOT PANELS)

Start at the centre of the crossing installing the gauge panels in pairs between the rails. We recommend using two sets of Rosehill Rail lifting pins in tandem, as this will make for a speedy installation.

Using Rosehill Rail lifting pins, manoeuvre the two gauge panels into the rail fl anges. Slowly lower both panels, ensuring that the panels are level together.

For manual installations, position one panel into the gauge against the rail. To ease the installation of the opposite panel insert two rail slewing bars into the holes already cast into the panel and pull back towards the nearest rail. This will lift the panel slightly allowing the correct positioning of the opposing panel - then simply allow both panels to be lowered into place.

Ensure that the wheel fl ange-ways are aligned and unobstructed.

Ensure that the panels are tight against each other ready for the insertion of the connecting bolts.

Tighten the nuts using the ratchet and ring spanners until both ends are fi rmly clamped together without gaps. Check the fi rst bolt in each panel to ensure it is still tight. (Bolts M16 – 2 bolts per linkage provided). Tighten to 210 Nm.

NOTE It is important to bolt the panels together as soon as they are in position, not after the entire row is in place.

FIELD PANELS (CESS PANELS)

Determine the centre of the crossing, start with the centre panels and work out in either direction. Position both rows of panels and bolt together as shown in the photo. It is important to bolt the panels together as soon as they are in position not after the entire row is in place.

Using Rosehill Rail lifting pins, manoeuvre the panel with the edge having the pre-moulded reliefs, into the rail fl ange. Lower the panel to it’s correct position.

Inspect the installed panels and ensure that they are laid fl at, uniform and sit at the correct height.

Ensure that the panels are tight against each other ready for the insertion of the connecting bolts.

Fit the rubber plugs in the lifting holes of all panels to prevent ingress of solids and/or water.

4ISSUE 04/01/16RR

INSTALLATION

CROSSINGPANELS

Start at the centre of the

crossing, installing the panels

in pairs between the rails.


5ISSUE 04/01/16RR

INSTALLATION

Each end restraint is delivered from the factory as above.

Assemble the end restraint prior to connecting to the crossing and rails. Ensure the assembly is 950mm long as indicated above.

END RESTRAINTS

950mm

Welded dots to identify left hand thread.

Right hand threaded bar.

Left hand threaded bar assembled


6ISSUE 04/01/16RR

INSTALLATION

1 2

3 4

Fit the eye bolt at the panel end and secure with the M16 nut (images 1 and 2).

Clear away ballast locally and fi t the clamp assembly to the foot of the rail (images 3 and 4).

When assembling the end restraints, the gold nut attaches to the end with the two gold markers (left-hand thread). The silver nut attaches to the opposite end (right-hand thread).

END RESTRAINTS


7ISSUE 04/01/16RR

INSTALLATION

5 6

7 8

Fit the shackle pin at the rail clamp end (image 5) and adjust the length of the end restraint by rotating the nylon body (image 6).

Tighten the locking nuts (image 7) and fi t the rubber cover plate (image 8). Ensure that all end restraints are equally tensioned, and that all shackle pins and locking nuts are correctly tightened.

END RESTRAINTS


8ISSUE 04/01/16RR

INSTALLATION

DEFLECTORPLATES

DEFLECTOR PLATES (CHAIN GUARDS)

Once all panels have been fi tted, defl ector plates must be attached to each end of the crossing, in the gauge area (see photo), using the connecting bolts supplied. Defl ector plates protect the ends of the crossing from damage by anything hanging down from rolling stock.


The dimensions of the beam are 200mm x 300mm x 10mm. The 200mm leg is normally horizontal and should be facing away from the track sitting on compacted lean mix concrete leaving the top of the vertical face pressed against the Rosehill Rail fi eld panel, level or no more than 5mm below, the top of the panel.

For the edge beam foundations, use lean mix concrete, standard mix using Portland cement and aggregate. Note: only use 20% of the normal water content.

A further layer of lean mix is then placed on top of the horizontal base – leaving suffi cient allowance for the fi nal road surface of asphalt, or other appropriate material.

1 Prepare trenches for the edge beams - 350mm wide x 500mm deep.

2 Lay approximately 250mm depth of dry mix concrete in trenches for the edge beams,

compact and adjust if necessary to measure 300mm from the rail top depending on the orientation of the edge beam (image 1).

3 Layout all edge beams, top edge must be level with the top of the fi eld panels or no more than 5mm below the top of the panel (image 2).

4 Wedge the edge beam and fi eld panels tightly against the rail head using timber packed between the edge beam and road excavation. Timber from delivery pallets can be used for this purpose.

5 Fill behind the edge beams with lean mix concrete and compact to leave suffi cient allowance for the fi nal road surface (image 3).

6 Fill the remaining void with compacted asphalt/ road surface, take care not to damage the fi eld panels. The road surface must fi nish level with the top of the fi eld panels and edge beams.

Where edge beams are to be installed, a vibratory compactor will be required.

9ISSUE 04/01/16RR

EDGE BEAM INSTALLATION

PLASTIC OR STEEL EDGE BEAMS

Image 1. Lay the dry mix concrete for the edge beams and compact.

Image 2. Top of the edge beam must be level with the top of the fi eld panels.

Image 3. Fill behind the edge beams with lean mix concrete and compact.

Compacted Lean Mix (semi-dry) Concrete

200 x 300 x 10mm Plastic (PVC) Angle Edge Beam

Compacted Asphalt


For the edge beam foundations, use lean mix concrete, standard mix using Portland cement and aggregate. Note: only use 20% of the normal water content.

1 Calculate the position of the edge beams where possible, to avoid the wheel paths of road vehicles over the joints. It is advised that this is done prior to ordering.

2 Prepare trenches for the edge beams - 550mm wide x 600mm deep.

3 Pour suffi cient lean mix concrete, compacted to 270mm deep, leaving 330mm from the rail top (image 1). Compact concrete using a

vibratory compactor.

4 Lift the edge beam into position using appropriate lifting equipment. Install the edge beams to avoid the wheel paths of road vehicles over the joints (image 2).

5 Check the height requirements with a level, against the beam and the top of the rail (image 3).

6 Install Rosehill Rail fi eld panels at either end of the beam and adjust the position of the beam to ensure a tight fi t of the panels against the rail.

10ISSUE 04/01/16RR

EDGE BEAM INSTALLATION

Image 1. Level the concrete foundation.

Image 2. Lifting the edge beams. Image 3. Level the beam with the top of the rail head.

ROSEHILL RUBBER OR CONCRETE

EDGE BEAMS

6 Install Rosehill Rail fi eld panels at either end of the beam and adjust the position of the beam to ensure a tight fi t of the panels against the rail.ensure a tight fi t of the panels against the rail.

Rosehill Rubber / Concrete Edge Beam

Compacted Asphalt


11ISSUE 04/01/16RR

INSTALLATION

TOOLS & EQUIPMENT

Required for the safe installation

and removal of Rosehill Rail

rubber crossing panels.

Although the panels can be handled manually it is advisable to have mechanical equipment (compact excavator or tele-handler) or some other form of approved lifting machinery to move the panels. Such items of plant must meet the legal requirements of the country/railway administrator concerned.

Rosehill Rail recommends the use of Rosehill Rail Lifting Pins to make the moving of panels much easier. They can be used to lift individual panels, or two sets can be used in tandem to lift both gauge panels together for even faster installation, or removal. Other non-approved devices may damage the crossing panels or lead to accidents or injuries.

Other essential equipment includes:

• Four rail slewing bars will be needed to ‘encourage’ panels into the correct location if necessary.

• Wire brushes will be required to remove general debris from the inside of the rail fl ange so that the panels will sit neatly on that fl ange-way.

• A bucket of soapy water and a large paint brush are advisable – paint the mixture onto the area of the rubber panel where it meets another rubber panel; the soapy water provides suitable lubrication for the panels to slide into place easily.

• Two 14lb rubber mallets are required to help the panels settle into their correct position.

• Shovels will be needed to level ballast and to shovel the concrete mix (where required).

• Vibratory compactor.

• Rosehill Rail Lifting Pins.

• Standard Rosehill Rail toolkit (top left) and common handtools.

Rosehill Rail Standard Toolkit


ROSEHILL RAIL LIFTING PINS

Rosehill Rail has designed lifting pins, specifi cally developed to assist in the lifting of our rubber crossing panels. These are the only lifting pins approved for use with Rosehill Rail crossing panels. Use of other lifting pins may invalidate the crossing warranty.

Tested to a safe working load (SWL) of 350kg, each set of lifting pins is supplied with appropriate LOLER certifi cation. Rosehill Rail Lifting Pins can be used to lift individual panels, or two sets can be used in tandem, to lift both gauge panels together for even faster installation, or removal.

See separate instructions for the use, maintenance and care of Rosehill Rail lifting pins.

USE OF SUITABLE LIFTING EQUIPMENT

Before use, check the rated lifting capacity of the equipment intending to be used, against the SWL of the lifting pins, to ensure suitability for lifting Rosehill Rail crossing panels.

Before using the Rosehill Rail Lifting Pins always:

• Check that the slings are free from cuts, abrasions and are not twisted.

• Keep the pins clean from grease, or any other lubricating material.

• Ensure that the pins are clean and dry.

When using the lifting pins always stand clear and do not hold onto the straps when panels are being lifted.

12ISSUE 04/01/16RR

INSTALLATION

Rosehill Rail has designed lifting pins, specifi cally developed to assist in the lifting of our rubber crossing panels. These are the only lifting pins approved for use with Rosehill Rail crossing panels.

TOOLS & EQUIPMENT


MAINTENANCE

In accordance with the inspection regime set by the relevant Railway Authority/crossing owner, visually inspect the crossing to ensure the panels are correctly positioned and that the panels are at the correct height.

When inspecting individual sleepers and/or the track bed remove the rubber cover plates and release the connecting bolts. Prise out the rubber plugs, insert the Rosehill Rail lifting pins and remove the panel(s).

For manual applications, insert rail slewing bars – pull the bars back towards the nearest tarmaced or concreted area perpendicular to the track. The panel edge that is located in the centre of the gauge area should now be being levered up. It should now be possible to lift the panel to a safe area and visually inspect the rail infrastructure. Applying soapy water to the edges of the panel will facilitate its removal and its replacement.

Renew the connecting bolts and tighten to the correct torque. Refi t the end restraints using new bolts and nuts and tighten to the correct torque. Make sure that the panels still are correctly supported, that there are no visual signs of damage and that when reinstalled there is minimal vertical movement with the passing of vehicular traffi c.

Correct any such deterioration as a matter of urgency as this could be detrimental to the life of the crossing panels and may affect any warranty.

REMOVING PANELS

DO NOT use lifting pins to extract a panel until it is completely free from obstructions and adjacent panels. Instead, insert crowbars into the lifting holes within the panel and ease the panel back so it is free from obstruction, then insert pins and continue to lift the panel(s) correctly. Note: installed panels will be connected to adjacent panels by bolts.

DISPOSAL / RECYCLING OF PANELS

As our panels are made from recycled material then it is natural that they can be recycled again in some other applications. A company with a large enough shredder can reduce a panel to granules which can be put to a multitude of uses. Specialist companies are usually located in each country.

13ISSUE 04/01/16RR

INSPECTIONS

MAINTENANCE & DISPOSAL


14ISSUE 04/01/16RR

FURTHERINFORMATION

PRODUCT FAMILIARITY

Rosehill Rail offer product familiarity courses for all of our rubber crossing systems and anti-trespass panels. You can attend a course at our dedicated training facility in Sowerby Bridge, or courses can be arranged on-site to suit your staff.

It is expected that all installation staff are suffi ciently familiar and competent to install Rosehill Rail products in accordance with the recommended instructions, in order to maintain product integrity and to comply with warranty requirements.

ISO 9001

Rosehill Rail operates to ISO 9001 standards at all of its sites. We are audited by various railway administrations annually.

PROTECTING THE ENVIRONMENT

Rosehill Polymers Limited is committed to a policy of continual improvement in respect of the quality and level of service offered to its customers.

An integral part of this commitment is to carry out all business activities in a manner that safeguards the environment, the health and safety of all employees and the neighbouring community.

This Environmental Policy carries the full support of Rosehill senior management and is reviewed periodically for continuing suitability.

The company will actively:

• Comply with legal and regulatory requirements.

• Utilise recycled materials in manufacturing processes.

• Raise awareness and train employees in environmental matters.

• Aim to minimise the use of all raw materials.

• Reduce to an absolute minimum all energy and heat used in manufacturing.

• Encourage the recycling of packaging materials.

• Minimise waste.

• Assist customers to use our products in an environmentally sensitive way.

DESIGN RIGHTS

All components in our level crossing systems are designed by Rosehill Rail, a division of Rosehill Polymers Limited.

Rosehill Rail is a division of the Rosehill Polymers Group

Sales Enquiries

Phone +44 (0)1422 317 473

Fax +44 (0)1422 835 786

Email [email protected]

Technical Support

Email [email protected]

ISSUE 04/01/16RR All information is correct at time of going to press. © Rosehill Polymers Limited - 2016.

» ROSEHILL RAIL CONTACTS

Beech Road

Sowerby Bridge

West Yorkshire

HX6 2JT

United Kingdom

www.rosehillrail.com

installation & maintenance guide - railway level crossing ... · rosehill level crossings •...

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