Premier Modular Railroad Crossings

Product Catalog

HEIDELBERGCEMENT Group

Topic

Section.Page

Premier Railroad Crossing ....................................................................................... 10.0 Cover Page ..................................................................................................................... 10.1 Index ............................................................................................................................... 10.2 General Notes ......................................................................................................10.3 - 10.4 Typical Section and Superelevated Section .................................................................... 10.5 Curved Alingments (Diverged Units) ............................................................................... 10.6 Curved Alingments (Tapered Units)) ............................................................................... 10.7 Boot and Optional Fillers ................................................................................................. 10.8 4' - 0" Concrete Unit (Isometric View) ............................................................................. 10.9 4' - 0" Concrete Unit (Plan View) ...................................................................................10.10 8' - 0" Concrete Unit (Isometric View) ........................................................................... 10.11 8' - 0" Concrete Unit (Plan View) ...................................................................................10.12 4' - 0" Premier Plus Unit (Isometric View) ..................................................................... 10.13 4' - 0" Premier Plus Unit (Plan View) ............................................................................. 10.14 8' - 0" Premier Plus Unit (Isometric View) ..................................................................... 10.15 8' - 0" Premier Plus Unit (Plan View) ............................................................................. 10.16

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Premier Modular Railroad Crossing Page Index

10.2

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Premier Notes
The following notes shall apply unless noted otherwise on the plans or specifications. In the case of conflict with the plans or specifications, the more restrictive requirements shall apply.

Reference Specifications:
HIGHWAY LIVE LOADING, AASHTO LRFD Bridge Design Specifications, Section 36 Standard design capacity is HS20. RAIL LIVE LOAD AND GENERAL DESIGN AREMA MANUAL FOR RAILWAY ENGINEERING. Standard design capacity is Cooper E80.

Concrete
1. Aggregate conforms to ASTM C33. 2. Portland cement conforms to ASTM C150. 3. Fly ash conforms to ASTM C618. 4. Minimum compressive strength (at 28 days) = 7,000 p.s.i. unless greater strength is required by project specifications.

Reinforcing Steel
1. All bar reinforcing steel conforms to ASTM A706. 2. Welded wire fabric conforms to ASTM A497, 65 KSI. 3. Concrete cover of reinforcing steel conforms to AREMA Standard.

Installation
1. Prior to dismantling the track assembly, stake out the alignment for the new crossing with offsets located every four track feet. 2. Remove existing track assembly including all rail, hardware, ties, and ballast. Remove subgrade below the ballast to the hardpan. 3. Inspect for proper drainage and deficient subgrade. Remove any deficient subgrade material. The overall excavation should be at least 10 feet wide to accommodate the new construction. 4. Prepare the new subgrade with clean granular material or a controlled low strength material (CLSM or flowable fill). The top 6 inches of the subgrade is formed and screeded level. Granular material is placed in four inch lifts to finished top of subgrade. This material is compacted to 95% proctor density. Screed top of subgrade to level. The subgrade is compacted again which will typically create a 3/4 inch gap to the top of subgrade. Compact 3/8 inch minus crushed stone (screenings) to top of subgrade. The subgrade is now complete for the granular subgrade option. If using CLSM, place the CLSM to the top of the leveling form. Screed the CLSM and allow to cure. For this option, the subgrade is complete. 5. Establish the centerline of the existing track. Mark the centerline at the bottom of the premier module, For a curved alignment, use offsets from centerline at four foot increments. Reference curve data chart for proper module spacing. 6. When placing modules for tangent track use 1/4 inch shims between modules. When placing modules on a curved alignment, refer to the curved data chart. Gaps are required between modules to prevent spalling. Make note at this time if beveled ends are used in the crossing. 7. Remove both center panels together and stack outside the immediate working area. Clean threaded inserts of fallen debris and protect the inserts to prevent debris from filling the insert during installation. Pull rail into position by pulling the rail from the middle of the existing track and through the middle of the modules. This ensures that a mishandled rail does not chip the exposed portion of the module. (Notes continued on next page.)

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Premier Modular Railroad Crossing General Notes

10.3

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Premier Notes
Installation

(Continued)

(Continued)

8. After the rail is in position, lift it high enough to install the rubber boot. Unroll the boot and position the boot under the rail. Unfold the boot. Apply the rail boot continuously from one end of the rail to the other. Applying the boot from more than one location will create a bubble between the boot and the rail. Make sure the high side edge of the rubber boot is toward the field side of the rail. 9. Apply lubrication (Module rail slick) to the rail seat of the module. 10. Place the rail snug into the rail seat. Place track jacks end-to-end and jack the rail into the rail seat. Use two sets of track jacks at 4 to 8 foot intervals and leapfrogging the jacks as you install the center panels. On extreme degree curves, leapfrog the track jacks in 4 foot intervals. 11. Install the center panels simultaneously and align the holes for the anchor bolts. 12. Install the anchor bolts by hand first, and then tighten them to 125 lbs. per foot maximum. OVER TIGHTEN. DO NOT

13. At the ends of the crossing, cut the rail boot flush and install two rail anchors per rail at each end of the module. 14. Inform the contractor placing the asphalt that roller equipment will damage the Premier Modules.

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Premier Modular Railroad Crossing General Notes

10.4

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Premier Unit Leveling Gravel or Stone Dust 3/ " or Less 8

Roadway Surface Roadway Subgrade

New Granular Material Compacted Exsisting Hard Pan Compacted or Undisturbed Native Soil

Granular Material

Premier Unit CLSM or Flowable Fill

Roadway Surface Roadway Subgrade

New Granular Material Compacted

Exsisting Hard Pan

Compacted or Undisturbed Native Soil

CLSM or Flowable Fill

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Premier Modular Railroad Crossing Typical Section

10.5

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Center Panel Anchor Bolt Typical (2) Each Panel 2 Ton Ring Clutch Lifting Anchor Typical (1) Each Panel Divergence (Gap) 4' - 0" O.D. Center Panel x 4' - 0"

8' - 0" O.D.

4' - 0" Recessed Diamond Pattern Typical (4) Places Base Panel x 4' - 0"

4' - 0" Symmetrical Units

Notes: (1.) Premier units may be laid referring to the "Curve Data

Chart" for Divergence (Gap).

(2.) Tapered sections may be used to reduce divergence. (3.) Taper shortens one side of 4' - 0" section by 1 inch.
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Premier Modular Railroad Crossing Curved Alingments (Diverged)

10.6

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Center Panel Anchor Bolt Typical (2) Each Panel 2 Ton Ring Clutch Lifting Anchor Typical (1) Each Panel Divergence (Gap) 4' - 0" O.D. Center Panel x 4' - 0"

8' - 0" O.D.

3' - 11" Recessed Diamond Pattern Typical (4) Places Base Panel x 4' - 0"

4' - 0" Tapered Units

Notes: (1.) Premier units may be laid referring to the "Curve Data

Chart" for Divergence (Gap).

(2.) Tapered sections may be used to reduce divergence. (3.) Taper shortens one side of 4' - 0" section by 1 inch.
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Premier Modular Railroad Crossing Curved Alingments (Tapered)

10.7

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossing - Curve Data Chart Symmetrical Module

Curve Curve Radius (degrees) (ft.) 1 2 3 4 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5729.7 2864.9 1910.1 1432.7 1146.3 955.4 881.9 819.0 764.5 716.8 674.7 637.3 603.8 537.7 546.4 521.7 499.1 478.3 459.3 441.7 425.4 410.3 396.2 383.1 359.3 338.3 319.6 302.9 287.9 274.4 262.0 250.8 240.5 231.0 222.3 214.2 206.7 199.7 193.2 187.1 181.4 176.0 171.0 166.3 Low Side Gap (in) 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 1/ 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

48" Tapered to 47" Module

Low Side Gap (in) 0.859 0.792 0.724 0.690 0.657 0.624 0.591 0.568 0.525 0.492 0.459 0.426 0.393 0.360 0.327 0.294 0.261 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 7/ 8 13/ 16
3/ 11/ 5/ 5/ 9/ 9/ 4 16 8 8

High Side Gap (in) 0.327 0.395 0.462 0.530 0.564 0.597 0.631 0.665 0.699 0.733 0.767 0.801 0.835 0.869 0.903 0.937 0.971 1.005 16 3/ 8 7/ 16 1/ 2 9/ 16 9/ 16 5/ 8 11/ 16 11/ 16 3/ 4 3/ 4 13/ 16 13/ 16 7/ 8 7/ 8 15/ 16 5/

High Side Gap (in) 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.327 0.386 0.453 0.519 0.586 0.653 0.719 0.786 0.852 0.919 0.985 1.051 1.118 1.184 1.250 1.317 1.382 1.448 1.514 1.580 1/ 4 1/ 4
1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 5/ 16 5/ 8 7/ 16 1/ 2 9/ 16 5/ 8 11/ 16 3/ 4 7/ 8 15/ 16

16

1 1 -

16 1/ 2 1/ 2 7/ 16 7/ 16 3/ 8 3/ 8 3/ 8 5/ 16 5/ 16 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4 1/ 4

1 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 1/2 1 5/8 1 3/4

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Premier Modular Railroad Crossing Curve Data Chart

10.8

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Rail

Rail Boot

Rail with Standard Boot

Standard Flangeway Filler (Optional for Transit Applications)

Rail

Rail Boot

Rail with Boot & Flangeway Filler

Walkway Flangeway Filler (Optional for Transit Applications in Walkway Area, Provides an ADA Approved Crossing)

Rail

Rail Boot

Rail with Boot & Walkway Filler

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Premier Modular Railroad Crossing Boot & Optional Fillers

10.9

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Base Panel x 4' - 0"

2 Ton Ring Clutch Lifting Anchor Typical (1) Place Center Panel x 4' - 0" Center Panel Anchor Bolt Typical (2) Places

Recessed Diamond Pattern Typical (4) Places

4' - 0" O.D. 8' - 0" O.D.

4' - 0" O.D. Rail and Rail Boot Not Shown for Clarity 2 Ton Ring Clutch Lifting Anchor Typical (2) Places

6" Ref.

3' - 6" 2 Ton Ring Clutch Lifting Anchor Typical (2) Places

6" Ref. Varies 45

1 1/2" Lifting Hole Typical (2) Places 4' - 0" O.D.

Base Panel x 4' - 0"

Optional Beveled Edge Detail

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Premier Modular Railroad Crossing 4' - 0" Premier Unit (Isometric View)

10.10

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

8' - 0" O.D. Base Panel x 4' - 0" Center Panel x 4' - 0"

2 Ton Ring Clutch Lifting Anchor Typical (1) Each 4' - 0" O.D.

4' - 0" O.D.

Rail (Boot Not Shown for Clarity)

Plan View
Base Panel x 4' - 0" 1' - 7 3/4" 56 1/2" (4' - 8 1/2") Track Gauge 1' - 7 3/ " 4

3/ " Anchor Bolt 4 Typical (2) Each Panel

Rail (Boot Not Shown for Clarity)

3/ " Anchor Bolt 4

Typical (2) Each Panel

A 6"

Base Panel x 4' - 0" B

1/ " 2

Center Panel x 4' - 0"

Section A-A
Panel Geometry: 100 RB Pound Rail 100 RE/105 Dudly Rail 112/115 Pound Rail 132/136 Pound Rail A (in.) 5 3/4 6 6 13/16 7 5/
16

B (in.) 2' - 4 5/8 2' - 4 5/8 2' - 4 3/4 2' - 5

Base Wt. (Lbs.) 3,450 3,500 3,600 3,700

Center Wt. (ea.) (Lbs.) 525 550 600 650

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Premier Modular Railroad Crossing 4' - 0" Premier Unit (Plan View)

10.11

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Base Panel x 8' - 0"

2 Ton Ring Clutch Lifting Anchor Typical (2) Places Center Panel x 8' - 0"

Recessed Diamond Thread Pattern Typ. (4) Places

Center Panel Anchor Bolt Typical (2) Places

8' - 0" O.D. 8' - 0" O.D. 1 1/2" Lifting Hole Typical (2) Places

Rail and Rail Boot Not Shown for Clarity

2 Ton Ring Clutch Lifting Anchor Typical (4) Places

6" Ref.

7' - 6" 2 Ton Ring Clutch Lifting Anchor Typical (4) Places

6" Ref. Varies 45

Base Panel x 8' - 0" 8' - 0" O.D.

Optional Beveled Edge Detail

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Premier Modular Railroad Crossing 8' - 0" Premier Unit (Isometric View)

10.12

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

8' - 0" O.D. Base Panel x 8' - 0" Center Panel x 8' - 0"

3/ " Anchor Bolt 4 Typical (2) Each Panel

8' - 0" O.D. 2 Ton Ring Clutch Lifting Anchor Typical (2) Each

Plan View
Rail (Boot Not Shown for Clarity) Rail (Boot Not Shown for Clarity) 1' - 7 3/4" 56 1/2" (4' - 8 1/2") Track Gauge 1' - 7 3/4"
3/ " Anchor Bolt 4 Typical (2) Each Panel

A 6"

Base Panel x 8' - 0" B

1/ " 2

Center Panel x 8' - 0"

Section A-A
Panel Geometry: 100 RB Pound Rail 100 RE/105 Dudly Rail 112/115 Pound Rail 132/136 Pound Rail A (in.) 5 3/ 6 6 13/16 7 5/16
4

B (in.) 2' - 4 5/8 2' - 4 5/8 2' - 4 3/4 2' - 5

Base Wt. (Lbs.) 6,900 7,000 7,200 7,400

Center Wt. (ea.) (Lbs.) 1,050 1,100 1,200 1,300

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Premier Modular Railroad Crossing 8' - 0" Premier Unit (Plan View)

10.13

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Base Panel x 4' - 0"

Plastic Filler Panel Typical (2) Places

Recessed Diamond Pattern Typical (4) Places

3/ " 4

Anchor Bolt Typical (3) Each Panel

4' - 0" O.D. 8' - 0" O.D. 4' - 0" O.D. Rail and Rail Boot Not Shown for Clarity 2 Ton Ring Clutch Lifting Anchor Typical (2) Places

6" Ref.

7' - 6" 2 Ton Ring Clutch Lifting Anchor Typical (4) Places

6" Ref. 45

1 1/2" Lifting Hole Typical (2) Places 4' - 0" O.D.

Base Panel x 4' - 0"

Optional Beveled Edge Detail

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Premier Modular Railroad Crossing 4' - 0" Premier Plus Unit (Isometric View)

10.14

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Base Panel x 4' - 0"

8' - 0" O.D.

4' - 0" O.D.

Plastic Filler Panel Typical (2) Places

Rail (Boot Not Shown for Clarity)

4' - 0" O.D.

Typical (2) Each Panel

3/ " Anchor Bolt 4

Plan View
Rail (Boot Not Shown for Clarity) 1' - 7 3/4" 56 1/2" (4' - 8 1/2") Track Gauge 1' - 7 3/4"
3/ " 4

Anchor Bolt Typical (3) Each Panel

13"

Section A-A

Rail Clip Typical (2) Each Rail

Rail Clip Pocket Typical (2) Each Panel

Center Panel Geometry: 112/115 Pound Rail 132/136 Pound Rail

A 6 13/16" 7 5/16"

Weight 4,900 lbs. 4,900 lbs.

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Premier Modular Railroad Crossing 4' - 0" Premier Plus Unit (Plan View)

10.15

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

Base Panel x 8' - 0"

Plastic Filler Panel Typical (2) Places

Recessed Diamond Pattern Typical (3) Places

3/ " 4

Anchor Bolt Typical (6) Each Panel

8' - 0" O.D.

8' - 0" O.D.

1 1/ " Lifting Hole 2 Typical (2) Places

Rail and Rail Boot Not Shown for Clarity

2 Ton Ring Clutch Lifting Anchor Typical (4) Places

6" Ref.

7' - 6" 2 Ton Ring Clutch Lifting Anchor Typical (4) Places

6" Ref. 45

Base Panel x 4' - 0" 8' - 0" O.D.

Optional Beveled Edge Detail

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Premier Modular Railroad Crossing 8' - 0" Premier Plus Unit (Iso. View)

10.16

03-04-08
HEIDELBERGCEMENT Group

Premier Modular Railroad Crossings

8' - 0" O.D. Base Panel x 8' - 0"

Plastic Filler Panel Typical (2) Places 8' - 0" O.D.

Rail (Boot Not Shown for Clarity)

3/ " 4

Anchor Bolt Typical (6) Each Panel

Plan View
Rail (Boot Not Shown for Clarity) 1' - 7 3/4" 56 1/2" (4' - 8 1/2") Track Gauge 1' - 7 3/4"
3/ " 4

Anchor Bolt Typical (6) Each Panel

13"

Section A-A
Rail Clip Typical (4) Each Rail

Rail Clip Pocket Typical 4) Each Panel

Center Panel Geometry: 112/115 Pound Rail 132/136 Pound Rail

A 6 13/16" 7 5/16"

B 9,800 lbs. 9,800 lbs.

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Premier Modular Railroad Crossing 8' - 0" Premier Plus Unit (Plan View)

10.17

03-04-08
HEIDELBERGCEMENT Group