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HOME > PRODUCTS > EMBEDDED CONCRETE-RUBBER (ECR)
| Embedded Concrete-Rubber (ECR) Installation Instructions |
 Track Preparation
- The track structure should be constructed per the surface data sheet.
- For best results, use new ballast, ties, and rail.
- Ties should be of good quality and in the same plane. Ties that are twisted or not set flat must be adzed or replaced.
- Ties must be placed center-to-center (c-c) as follows:
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| Panel Length |
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Timber Tie |
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Concrete Tie |
| 8-foot |
19 3/16" c-c |
24" c-c |
| 9-foot |
18" c-c |
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| 9-foot 9-inch |
19 1/2'' c-c |
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| 10-foot |
20" c-c |
24" c-c |
| 12-foot |
18" c-c |
24" c-c |
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- Rails should be welded. Grind welds smooth to avoid interfering with panels.
- Make certain that track gauge is 56 1/2".
- Sweep the ties and rail to remove ballast and debris which may interfere with seating of the panels.
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Installation Steps
- If ordered, gauge abrasion pads should be centered on the ties, field abrasion pads should be placed even with the outer edge of the ties. For timber ties, fasten the abrasion pads to the ties with the nails provided with the order. For concrete ties, abrasion pads must be glued in place.
- Lubricate the underside of the rubber flangeway and the top of the adjoining rail with soapy water or pipe slick.
- Install the first gauge panel, starting at the center of the crossing. Make sure the ends of the panels are centered on ties. Install the gauge panel by tipping the panel enough to place a flangeway beneath the rail head. Slowly lower panel until the opposing flangeway rests on the rail head.
- Pull the panel towards the installed side. Then, force the opposing flangeway beneath the rail head with the use of a spike maul or lining bar. Do not hit the concrete panel.
- Install the remaining gauge panels.
- Begin installing field panels at the center of the crossing. Place the rubber nose of the panels against the rail. Make sure that the panel ends are centered on ties.
- Install the remaining field panels.
- For lagged installation, predrill the wood ties with a 1/2'' drill bit and install 3/4'' timber screws using a Torx bit and air impact wrench. Apply pressure to hold the field panels tight against the rail while drilling and fastening.
- If ordered, install end-restraints. Do not span the gap of the gauge panel frame.
- For welded installation, tack weld the gauge panels with four 3-inch skip welds and the field panels with three 3-inch skip welds.
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