CROSSING

INSTALLATION

GUIDE

For additional assistance please contact:

Scott Craig: Office: 740-370-4300

Mobile: 740-352-3875
 ROCLA CROSSINGS INSTALLATION PROCEDURES

1) INSPECT ARRIVING MATERIAL

Fully inspect crossing materials upon arrival to job site and prior off-loading IF ANY
SHIPPING DAMAGE IS NOTICED IMMEDIATELY CONTACT (Scott Craig) at
740-370-4300. Check the Bill of Lading and match it up to the material on site. Count the
panels, inspect hardware boxes, and attached rubber flange-way sections.

2) CROSSING ROADBED

In order for the track structure and crossing to withstand both vehicular and rail traffic loadings
– the soil in the area must be evaluated. Any conditions such as poor drainage, moisture laden
soils, or soils prone to cause track settlement must be corrected. ROCLA will not warrant any
crossing materials if poor soil conditions are not fully corrected. Concrete has a high
compressive strength but a very low tensile strength. Uneven tie settlement and or tie pumping
will cause the panels to try to bend or flex under load. No reinforced concrete can take this type
of loading without eventual failure. The track structure is no stronger than the foundation on
which it sits.

3) CROSSING BALLAST

The installer is responsible for establishing the proper sub-ballast and tie ballast depth. Site
variables such as soil conditions, type of ballast available, are all variables known only to the
local installer. The installer is fully responsible for designing the crossing foundation so any tie
settlement, which may occur, under traffic loads, will be less than 1/8 inch at any point in the
crossing.

4) TIE SPACING

FOR ROCLA CROSSINGS IT IS CRITICAL THE TIE SPACING BE SET AT 19 1/2

INCHES. The lag screw holes, cast into each field and gage panel for wood ties, are spaced to
match the 19 ½” tie spacing.

5) TIE TAMPING

For full width ROCLA crossings on 10’-0” long ties it is extremely important that the crosstie
be tamped at its outermost end in addition to the usual tamping pattern directly under the rail
seat. Without this tie end ballast tamping there is no support for the tie end. As traffic impacts
the field panel outer edge and the force is carried down to the tie, the ballast must support the
load or the entire crossing structure will rock side to side. This is extremely important in high
speed, heavy truck areas. Early panel failure can occur if the tie ends are not solidly tamped
(see sketch).
6) CLEAN TIE SURFACES

Once tamping is complete sweep the tie surfaces as clean as possible. Remove any ballast
pieces that may interfere with the panels laying flush on the tie surfaces. Be sure ballast in the
crib areas is lower than the top of the ties to prevent it from keeping the panel from fully resting
on the tie surface.

7) RUBBER ABRASION PADS ON TIES – (TIMBER TIES)

Pads provided per tie: (2 each 9” x 9” x ¼” and 4 each 5” x 9” x ¼”). The 9” x 9” pads to be
installed in the gage area with the placement of each being up against the tie plate on each side.
The 5” x 9” pads to be placed 2 each on the field side, with one being placed on the very end of
the tie and the other against the plate.

The abrasion pads are to be nailed to the tie surface. There are six pads per tie – two on each
field side of the rail and two on the gage side (see attached sketch for location). Nails are
provided with the crossing. If the crossing is long, using an air powered nail gun can save
considerable time over nailing by hand. Use two nails on each pad. Sweep tie surfaces clean
before applying pads.

8) PANEL LAYOUT

Before installing any panels establish the center of the crossing with respect to the road center
and mark this point. At the center point the panels will be laid outward to each end of the
crossing. Working from the crossing middle to each end is very important with all crossings
reducing any accumulation of error as the panels are laid end to end.

9) HANDLING PANELS

USE APPROVED CHAIN AND HOOKS TO LIFT AND HANDLE THE PANELS. It is
best to use a machine that can easily handle and maneuver each panel into position. Leave the
chain sling long enough to be able to swing and maneuver the panels by hand. This helps
speed setting panels into final position. A backhoe can handle the 8’-0” panels fairly easily.
The 11’2” and 12’-0” gage panels will be more of a challenge for a backhoe. A larger piece of
equipment can save installation time. Panel weights are listed below:

12’-0” gage panels 4900 lbs. 12’-0” field panels NA

11’-2” gage panels 4550 lbs. 11’-2” field panels 2450 lbs.
8’-1 1/2” gage panels 3400 lbs. 8’-1 1/2” field panels1800 lbs.
16’3” field panels 3600 lbs.

10) GAGE PANEL INSTALLATION

Locate the mid point of the crossing. Position the panel so that its end lies in the center of the
tie. All anchors can be left in place. Carefully lower the panel at an angle where the backside
attached rubber is completely under the rail head. Lower the front side of the panel into
position. Once both sides of attached rubber are under each rail head place it into final
 position. To make sure the panels are square, each corner from the concrete to the rail head
should be a 3” gap. Repeat process for the next panel. Lining bars can be used to jockey the
panels side to side. Use a track jack to butt the panels tightly together. Check to see if the lag
holes are lining up with the crossties. This insures the tie spacing is correct. Once these first
two panels are in place and tie spacing looks good these panels can be lagged.

11) FIELD PANEL INSTALLATION

Slide the concrete field panel with attached rubber up to the rail. Before lagging the into final
position use the backhoe bucket to snug the panel and rubber up to the rail once in position
place one lag screw at each end of the panel to hold it in place. Again, start in the middle and
work out to each end. Install the next panel and butt it firmly to the one just installed.

12) LAG SCREWS

When installing the ¾” diameter lag screws it is good practice to prebore each lag screw hole.
This reduces the chance of tie splitting and requires less driving force. Place a compression
washer and a regular washer under the lag head. The rubber washer goes against the concrete.
Do not over tighten the lags. They need to be installed very firm but not to the point of extreme
tightness.

13) ROADWAY ASPHALT APPROACHES

Good asphalt approaches are critical to a good riding and long lasting crossing. The
Asphalt adjacent to the field panels must be at or just slightly above the crossing surface. It is
very important that over time the asphalt does not settle below the crossing surface. The
impact caused by the vehicle tires climbing or impacting the outer crossing edge will cause
problems, so the smoother the transition the better the crossing and its performance.

14) CROSSING MAINTENANCE

About one to two weeks after the crossing is opened to traffic, a full inspection of the crossing
should be made. Look for loose or rocking panels or any signs of problems in the overall track
structure. Lag screws need to be re-tightened, this will allow the lags to reseat themselves.
The same inspection procedure needs to be done one month later. If at any time panel or track
structure problems occur – make every effort to immediately find and correct the problem.
Once problems begin they get worse very fast and lead to major repair costs as well as traffic
disruptions.

15) ROCLA CONTACTS

For any technical questions regarding ROCLA crossings you may contact the following:

Scott Craig
Office: 740-370-4300
Mobile: 740-352-3875