rosehill level crossing systems - rosehill … · page 2 rosehill rail rubber level crossing...

ROSEHILL LEVEL CROSSING SYSTEMSTECHNICAL SPECIFICATIONS

RUBBER CROSSING SYSTEMS

ROSEHILL RAIL RUBBER LEVEL CROSSING SYSTEMS

PAGE 5 PRODUCT INTEGRITY STATEMENT

PAGE 6 MANUFACTURE OF RAILWAY CROSSING SYSTEMS

PAGE 7 ROSEHILL RAIL LEVEL CROSSING CODES

PAGE 7 TECHNICAL SPECIFICATIONS & TEST RESULTS

PAGE 8 REQUIRED INFORMATION FOR QUOTATION PURPOSES

PAGE 9 RAIL CROSSING SYSTEMS SAFETY ISSUES

PAGE 10 INSTALLATION & MAINTENANCE INSTRUCTIONS

PAGE 11 CROSSING DRAWING - CONCRETE EDGE BEAM

PAGE 12 CROSSING DRAWING - PLASTIC EDGE BEAM

PAGE 13 RISK ASSESSMENT FORM

Please check that this document has not been superseded by new editions.

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CONTENTS

ROSEHILL LEVEL CROSSINGS

All crossing panels are made from recycled rubber, together with the unique Rosehill polyurethane binder. As the whole of the panel is made from rubber and the polyurethane, there are no interfaces within. Each panel is solid throughout with no internal voids, consequently there is no possibility of de-lamination occurring.

This full depth rubber panel system then spreads loadings by way of the sleepers, which reduces shock loads. The panels are moulded to fit the exact shape of the sleeper, fastenings and rail type avoiding the need for packings which could damage the infrastructure, or work loose.

This principal has been independently tested by the Railway Technical Research Institute in Tokyo (2014) and confirmed as not having any adverse affect on the infrastructure or it’s surroundings.

The crossing systems 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 field panels (often referred to as the cess panels) are placed on the outside of the rails and kept in place by an edge beam (concrete, plastic (PVC) or steel). In the case of Track Access Points ballast, concrete or asphalt will keep the field panels in place.

Every crossing panel is marked when moulded to clearly identify the crossing grade, rail type, sleeper type, fastener and year of manufacture. This makes it easy to check on-site that the panels meet the required specifications. Individual panels can be easily removed for inspection or maintenance without having to dismantle the entire crossing.

Rosehill Lifting Pins have been designed in-house specifically for use with both crossing systems and each set is accompanied by the appropriate test certificate and instructions for use and maintenance. Two sets can be used in tandem to install the gauge panels simultaneously helping to reduce track possession times.

Rosehill crossings can be provided for most unusual specifications such as check rails, double check rails and radii down to 25m. Also crossings are manufactured for any gauge, sleeper and rail section.

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ROAD Two grades are available:

1. NORMAL suitable for most crossing situations. 2. EXTREME CONDITION suitable for all vehicular crossing situations, particularly where heavy loads and acute angles are encountered such as dockland areas with constant heavy goods traffic.

AGRICULTURAL for agricultural traffic and light commercial use.

PEDESTRIAN for foot traffic only.

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

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CONNECT - CROSSING SYSTEMOVERVIEW

Originally designed for heavy traffic and extreme situations, the Rosehill Connect system can be employed universally in any road crossing or track access application.

The panels are held together laterally (along the line of the track) by flanged bolts. These must be installed to the correct torque setting (180-200 Nm). End restraints must be fitted at both ends and set to the correct torque setting. At both ends of a crossing a deflector plate (sometimes referred to as a chain guard) must be placed in the middle of the gauge area to protect the ends of the crossing from damage, by anything that may be hanging down from rolling stock.

BASEPLATED - CROSSING SYSTEMOVERVIEW

Ideal for shorter crossings and for cut to fit solutions in turnouts, tight curves and fitting around existing infrastructure fittings.

The panels are held together laterally (along the line of the track) by baseplates which have turrets. A winged turret baseplate should be placed over a sleeper at the centre line of the roadway to retain the crossing in place. Turret baseplates are used elsewhere in the crossing to connect all of the panels together.

On a skewed crossing, where the road is not at 90° to the track, two or more rows of winged turret baseplates may be fitted, to prevent any possibility of panels movement. As with the Connect crossing system, chain guards must be placed in the middle of the gauge area to protect the ends of the crossing from damage by anything that may be hanging down from rolling stock.



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The Rosehill Rubber Level Crossing System has been developed over a twenty year period by Rosehill Polymers Limited, to provide better safety features, improved performance and easier on-site installation.

The development is not only in achieving the above features in the crossings themselves but in the method of manufacture and the machinery needed to produce them economically.

Instead of vulcanisation, which is a very long process and uses huge amounts of energy, Rosehill Polymers utilises various grades of recycled rubber (from tyres etc) and a specially developed polyurethane system which bonds the rubber particles under pressure, without heat, into the finished panel. The machinery to produce the panels was designed and built ‘in house’ and produces a hard wearing, bespoke rubber crossing system which can be made to fit any rail type, track gauge and sleeper (whether concrete, wood or steel) anywhere in the world.

The skid resistance has been improved by introducing a particular type of recycled rubber and with a further application of polymers the transfer of electricity from rail to rail has been eliminated, thus preventing interference with automatic crossing barriers, track circuits, etc.

Other safety features include a surface structure designed to disperse water and break up ice. A simple baseplate fastener, which holds the panels together, prevents gapping and accidents to cyclists and pedestrians but allows easy access for track inspection and maintenance.

The system has national approval in the UK and that of many other rail networks, and has been successfully installed throughout Great Britain, Ireland, most of Europe, the Middle East, Japan, Australia & New Zealand, etc

In 2002 the level crossing system was awarded a Queens Award to Industry in the Innovations category. Further developments are ongoing but the current range includes Heavy Duty, Track Access, Agricultural, Pedestrian and a special panel for extreme conditions.

PRODUCT INTEGRITYSTATEMENT

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MANUFACTURING

Manufacture is controlled by detailed operating instructions issued by the Technical Director. All associated documentation, including technical specifications and bills of materials are controlled by documented procedures as detailed in the company Quality Systems Manual which conforms to the International standard ISO 9001:2000. The approved quality system also provides control and direction for all activities necessary to achieve product realisation.

The manufacturing process is computer controlled and operated by fully trained and experienced operatives. The plant and machinery used in the manufacturing process has been designed and built specifically for the production of railway systems and is maintained under contract by specialist engineers.

TRACEABILITY

Each manufactured panel is clearly marked with a unique Panel Identification Number.

For example: 23 - 06 - 14 - 11 (i) (ii) (iii) (iv)

Where (i), (ii}, (iii) denote the date of manufacture, 24 hours midnight to midnight (day, month, year)and (iv) represents the actual panel number from the sequence of manufactured panels on that given date.

Therefore: 23 - 06 - 14 - 11 represents the eleventh panel manufactured on the 23rd of June, year 2014.

Traceability of crossing panels allows the technical department to map the history of each panel from the finished article back to the retained engineering drawings. This method of traceability encompasses all of the production data generated and recorded during the production process.

If any faults are detected at a later stage, such as installation or routine site inspections, then the unique panel identification number allows Rosehill Polymers to determine precise details relating to manufacture.

Such details include, the exact date and sequence of manufacture, the weight and ratio of materials used in the construction of the panel, whether additional surface processes were used to achieve skid resistance and high abrasion resistance, together with the actual panel dimensions obtained from the first moulding. The observations of the process operator in relation to the visual appearance of the panel are also recorded.

The collated and recorded information enables Rosehill Polymers to carry out a full investigation if there is evidence of product failure or ill fitment.

MANUFACTURE OF RAILWAY CROSSING SYSTEMS

The following system is in place to specify Rosehill railway crossing panels:

1 PREFIX RH Denotes panel designs.

2 DRAWING NUMBER Example - 0208 - this is the specific detail drawing for a particular panel. Panel designs exist for most combinations of Rail/Fastening/

Sleeper – gauge.

3 PANEL TYPE GP Denotes gauge panel. FP Denotes field panel.

4 CROSSING/PANEL GRADE P Footpath used for pedestrian crossings, not vehicles of any kind. A Agricultural used for farm or occupational

vehicular traffic. N Normal used for standard road traffic. TC Extreme duty used in docks, ports or any

frequent heavily loaded vehicular traffic.

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ROSEHILL RAIL LEVEL CROSSING CODES

SPECIMEN

ONLY

Independent Test Summary – Rodded Extreme Issue 2 24.02.15

All Rosehill rubber level crossing panels are independently tested to national and international standards and specifications. Summary data sheets are included with this document as appropriate.

TECHNICAL SPECIFICATIONS& TEST RESULTS


1 The gauge.

2 The fastener type.

3 The rail type and profile.

4 Sleeper type and dimensions.

5 Base plate (if fitted).

6 Position of crossing relative to the road. That is the angle of the crossing in relation to the road.

7 Is the crossing on a curve? In which case has the gauge been widened

throughout the length of the curve and what is the actual measurement of the gauge?

What is the radius of the curve?

8 The width of the road plus the width of the crossing not forgetting any footpath areas for

pedestrians if these are needed or specified. A sketch or photograph would be useful.

9 It is essential to know the type and volume of traffic. This will help us to confirm that the correct grade of panel has been chosen for each

crossing. For example, if the crossing is subject to constant heavy goods traffic or on a severe skew or angle to the road the extreme condition panel would be required. It is most important to take into account any situations which are

unusual or which could put an extraordinary strain on the crossing. If the wrong type of panel is fitted the warranty would be invalid.

10 Any additional items to be supplied by Rosehill, for example, angle edge beams, end restraints.

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REQUIRED INFORMATIONFOR QUOTATION PURPOSES


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LIFTING & TRANSPORTATION

Level crossing panels are supplied in a wide range of sizes, however a typical field panel weights - 160kg and a gauge panel - 260kg.

Panels are supplied band strapped to a wooden pallet, approximately 5 gauge panels or 10 field panels to a pallet.

It is, therefore, necessary to use some form of mechanical handling plant for offloading purposes.Individual panels can be manually lifted, two bars inserted through holes in each panel enabling 4 persons to manoeuvre the panel into position. Mechanical lifting using plant such as a JCB, forklift etc, is preferable and frequently used.

CDM/HEALTH & SAFETY REQUIREMENTS

All employees - minimum PPE safety boots, overalls, gloves. Depending on the site and method of lifting employed, hard hats and safety glasses may be necessary.

A suitably skilled person should be nominated as being responsible for the installation and a safety supervisor should also be nominated.

All lifting equipment must be suitable for the purpose and currently certified.

Riggers/operators must be suitably qualified.

RISK ASSESSMENT

A basic risk assessment covering a typical installation has been prepared. This should be reviewed to determine if all hazards peculiar to the site have been addressed.

PREPARATION

Ensure that the rails, clips and sleepers are clear of any debris, and that all ballast is below or flush with the top of the sleeper, rake flat / flush if necessary. Identify the centre of the crossing and mark with a suitable pen. Note the position of the sleepers; these must lie at 600mm centres in order to correctly support the ends of each panel.

Offload the panels, edge beams and baseplates to a suitable position adjacent ·to the crossing.

Excavate for the angle edge beams to a depth of 515mm from road/rail top, to allow for the height of the edge beam and 200mm of dry-mix concrete below. Lay out the turret baseplates on the sleepers in approximate position. These link each panel within a rank; one central baseplate will have wings to straddle a sleeper, locating the crossing along the track.

RAIL CROSSING SYSTEMSSAFETY ISSUES


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INSTALLATION & MAINTENANCE INSTRUCTIONS

INSTALLATION& MAINTENANCE GUIDEROSEHILL PUBLIC VEHICULAR ROAD CROSSINGS

BASEPLATED LEVEL CROSSING SYSTEM

INSTALLATION& MAINTENANCE GUIDEROSEHILL TRACK ACCESS POINTS

BASEPLATED CROSSING SYSTEM

INSTALLATION& MAINTENANCE GUIDEROSEHILL PEDESTRIAN CROSSING SYSTEM

BASEPLATED CROSSING SYSTEM

Installation and maintenance guides are available for all versions of the Rosehill Rail Baseplated system.

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Rosehill Rail is a Division of the Rosehill Polymers Group

Sales Enquiries

Phone +44 (0)1422 317 482

Fax +44 (0)1422 316 952

Email [email protected]

Technical Support

Email [email protected]

All information is correct at time of going to press. © Rosehill Polymers Limited - 2015.

» ROSEHILL RAIL CONTACTS

Spring Bank Mills

Watson Mill Lane

Sowerby Bridge

West Yorkshire HX6 3BW

United Kingdom

www.rosehillrail.com

rosehill level crossing systems - rosehill … · page 2 rosehill rail rubber level crossing...

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