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TraCastTM Installation Instructions

Track Preparation

  1. Remove existing crossing surface to a minimum width of 9', allowing clearance on each side of the 7'11" wide TraCastTM Modules.


  2. Remove rails, ties and ballast to a distance of 5' beyond each end of the crossing.


  3. Remove all fouled materials and replace with select compacted backfill.


  4. Install subsurface drainage at each edge of crossing to maintain full bearing value of foundation.


  5. Prepare a fine graded surface, compacted to 95% maximum density, 15" below top of rail. Spread and compact 1 1/2" layer of 1"-minus crushed base rock. Spread loose layer of minus 1/4" crushed rock and screed to surface elevation 13 1/4" below top of rail. If any loose fill exceeds 1", compact with plate tamper.


  6. In case of unstable ground conditions, excavate 25" below top of rail and compact surface to 95% of maximum density. Place and compact 6" of 1"-minus crushed rock base. Place three lifts of asphaltic concrete, compacted to 90% of relative density, to an elevation 14" below top of rail. Spread loose layer of 1/4"-minus crushed rock and screed to 13 1/4" below top of rail.

Installation Steps

  1. Mark the centerline of the track and begin placing TraCastTM modules from end of crossing, being careful to match alignment of rail troughs. If trough surfaces of adjoining panels mismatch by more than 1/8", lift module and adjust fines to correct module heights.


  2. Lay rail alongside troughs and place the rubber rail boot around the rail. Lubricate the bottom of the rail trough and set the rail into the rail trough.


  3. Using lining bars, porta-power jacks or other devices, slide the booted rail tightly into the molded field recess to obtain gauge.


  4. Install the insulated rail clips and bolt into the 3/4" inserts to fasten the rail in the rail trough while maintaining gauge of 56 1/2 inches.


  5. Hand tighten GripTiteTM nuts snugly into the 1/2" inserts in the rail trough.


  6. Lubricate GripTite nuts, GripTite locking cavities and edge of trough and force RailGuardTM panels down over GripTite nuts.


  7. After rail is connected to existing track, space the first tie 4" away from the module to allow bar tamping and room to apply double rail anchors.


  8. Sub-base materials for road approaches must be compacted to 95% of maximum density before paving to ensure a high performance interface with the TraCastTM panels.
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