Rosehill Base Plate Installation Maintenance

PROVEN ENGINEERING EXCELLENCE

INSTALLATION & MAINTENANCE INSTRUCTIONSFOR THE ROSEHILL RUBBER RAIL CROSSING PANEL

BASE PLATE PANEL SYSTEM

DESIGNED & MANUFACTURED IN THE UK BY ROSEHILL RAIL

www.rosehillrail.com

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Please take a few minutes to read through this brochure as it will save you valuable time during installation. Following these instructions will enable you to install the crossing quickly and correctly so that you get the optimum lifespan from the system.

CHECK LIST OFREQUIREMENTS

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» Full Rosehill consignment of panels,

base plates and edge beams.

» Diagram showing layout of panels and

position of winged baseplates.

» Dry mix concrete, standard mix using

Portland cement and aggregate. Note: only

use 20% of the normal water content.

Approximate requirement – 5 cubic metres,

depending on actual width and depth of

trenches.

» Asphalt to match with the existing

road surface.

» Rosehill rubber panel paint for applying

the road markings.

» Vibratory compacter.

» A minimum of 4 crowbars, 30mm diameter

x 1800mm long.

» Sweeping brushes, shovels etc.

» 4.5/5kg sledge hammer.

» 1.5kg club hammer.

» A petrol chain saw with a new, sharp blade

– 4.4kw x 60cm minimum.

» French chalk for marking out the panels,

for any cutting that may be required.

» Tape measures: 1 x 20m and 1 x 5m.

» Soapy water / washing up liquid,

assists fitting of baseplates and panels

by reducing friction.

» Rosehill lifting pins are recommended

for lifting and manoeuvring the

crossing panels.

INSTALLATION INSTRUCTIONS


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» Remove the existing crossing panels.

» Check sleeper spacings, sleepers must

be at 600mm centres, adjust if necessary

and tamp ballast.

» Prepare trenches 500mm deep x 350mm

wide at both ends of sleepers, for the length

of the crossing.

» Rake ballast level with the top of the sleepers

in 4’-0” area.

» Clear debris away from the rail clips and the

top of all sleepers.

» Measure to determine the centre of the crossing.

Work to the left and right from the centre.

» Position baseplates adjacent to relevant

sleepers, note the position of the winged

base plates.

» Starting in the centre of the crossing,

fit gauge panels.

» Starting in the centre of the crossing,

position the field panels with front edge

touching the rail head.

» Lay approximately 200mm depth of dry mix

concrete in trenches for edge beams, compact

and adjust if necessary to measure 305mm

from rail top.

» Layout all edge beams, top edge must be 5mm

below the top of the field panels.

» Wedge the edge beam and field panels tightly

against the rail head using timber packed

between the edge beam and road excavation.

Timber from delivery pallets can be used for

this purpose.

» Fill above and behind the edge beams with

dry mix concrete and compact to approx 70mm

from the road surface to allow for asphalt.

» Fill remaining groove with compacted asphalt,

take care not to damage the field panels.

The asphalt must finish level with the top of

the field panels and edge beams.

» Clear away all debris.

STANDARD BASE PLATE - TYPE SR

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» Standard Turret Base Plate - Type SR

Available with or without rubber pad

Codes S - Standard turret base plate without rubber

SR - Standard turret base plate with rubber back

Standard finish - galvanised

Mass - Type SR 5kg

» Winged Turret Base Plate

Code SR 270

Mass - 5.5kg

All sharp edges

removed

To suit sleeper width

Bonded rubber pad

Sleeper Outline

LOW PROFILE BASE PLATE - TYPE LR


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» Low Profile Turret Base Plate - Type LR

Available with or without rubber pad

Codes L - Low profile turret base plate without rubber

LR - Low profile turret base plate with rubber back

Standard finish - galvanised

Mass - Type LR 4kg

» Winged Low Profile

Base Plate

Code LR 240

Mass - 4.5kg

Bonded rubber pad

All sharp edges

removedTo suit sleeper width

ANGLED CROSSING ASSEMBLY

» Base Plate Positions

Skew Angle 0˚ to 30˚

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Winged Base Plates

Type SR 320

Standard Base Plates

Type SR

» Base plates are

not fixed to sleepers

EDGE BEAM INSTALLATION


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» Concrete Edge Beam

Interface between road and rubber panels

» PP (Polypropylene) Angle Edge Beam

Interface between road and rubber panels

Concrete Edge Beam

Compacted Asphalt

Compacted Dry Mix Concrete

200 x 300 x 10 PP (Polypropylene) Angle Edge Beam

Compacted Asphalt

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» On completion of the crossing a deflector plate can be attached if required.

This is fixed by two M10 x 75mm hexagonal head self tapping lag screws in the centre

of the gauge panels.

» Manufactured from 3mm

galvanised sheet steel

BSEN 14142 2000 DX51D+Z

DEFLECTOR PLATESCHAIN GUARDS

2 off - HEX Head LAG Screw

M8 x 80 LG

ROSEHILLSAFE LIFTING PINS


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» Rosehill have designed in-house, a new

set of safe lifting pins, specifically

developed to assist in the lifting of our

rubber crossing panels. These innovative

lifting pins lock in position and can’t fly out

during lifting.

The lifting pins, supplied in pairs, have been

tested to a safe working load of 350kg and can

be used to lift individual panels, or two sets can

be used in tandem to install both gauge panels

together for even faster installations.

ROSEHILLPANEL MARKING PAINT

» Rosehill Panel Marking Paint is a polyurethane system which has been formulated

in-house by our chemists to provide good mechanical properties, high tensile

strength and elongation.

Its flexibility enables it to move with atmospheric changes

and is more durable than acrylic based products.

When applied correctly it will also have a longer lifespan

between applications.

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HAZARD HAZARD EFFECT

SEVERITY

MINIMISE RISK BYRESIDUAL

RISKH/E Prob Risk

Pallet/Stack of panels dropped or toppled

Body impact, severe trauma

H L M a Ensure traffic (Fork truck/JCB etc) does not collide with panel stackb Wearing of safety boots, helmets, etc.c Provision of adequate site supervision

L

Individual panel dropped Body impactMusculo-skeletal injuries

H L M a Ensure drivers have adequate trainingb Ensure personnel are aware of mechanical handling equipmentc Ensure site personnel wear suitable PPE - particularly safety boots

L

Trapping or crushing during handling of panels

Musculo-skeletal injuries.Cuts or bruising

M M M a Ensure drivers have adequate trainingb Ensure personnel are aware of mechanical handling equipmentc Ensure site personnel wear suitable PPE - particularly safety boots

Fire Burns, smoke inhalation

M L M a Removal of surplus flammable material near work areab Containment of flammable materialsc Provision of fire fighting equipment

L

Use of Power tools during Installation.Welding/burning.Grinding, disk cutting

Eye damage, fumes,cuts and burns

M M M a Screen adjacent personnel from arc flashb Ensure use of suitable eye protectionc Provision of fire fighting equipment

L

Noise

Vehicular movements.Collision between Fork Lift Truck /JCB etc. & Personnel

Ear damage

Body impact, severe trauma. Trapping and crushing

M

H

M

L

M

M

a Wear suitable ear protection

a Ensure all site personnel are advised of vehicular movements b Ensure adequate supervision of installationc Ensure that drivers are suitably trained

LL

Railway/Road Traffic.Impact with site personnel or equipment


H M H a Ensure all relevant authorities are aware of impending work locationb Install adequate warning notices or barriersc Ensure adequate site supervisiond Ensure site personnel wear suitable PPEe Ensure sufficient track access time has been allowed

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Risk Assessment No. RA1002

Assessor R Kaye

Date 01 . 06 . 2011

Project Railway Crossing Products

Equipment Covered Transport / Handling / Installation

of Level Crossing Panels

Notes

Ensure that a suitably trained first-aider is appointed

for each installation.

Ensure that a first aid kit is available.

For Severity and Risk ratings

Use High H, Medium M, or Low L

Hazard Effect (H/E) X Probability (Prob) = Risk


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RISKASSESSMENT FORM

HAZARD HAZARD EFFECT

SEVERITY

MINIMISE RISK BYRESIDUAL

RISKH/E Prob Risk

Pallet/Stack of panels dropped or toppled


H L M a Ensure traffic (Fork truck/JCB etc) does not collide with panel stackb Wearing of safety boots, helmets, etc.c Provision of adequate site supervision

L

Individual panel dropped Body impactMusculo-skeletal injuries

H L M a Ensure drivers have adequate trainingb Ensure personnel are aware of mechanical handling equipmentc Ensure site personnel wear suitable PPE - particularly safety boots

L

Trapping or crushing during handling of panels

Musculo-skeletal injuries.Cuts or bruising

M M M a Ensure drivers have adequate trainingb Ensure personnel are aware of mechanical handling equipmentc Ensure site personnel wear suitable PPE - particularly safety boots

Fire Burns, smoke inhalation

M L M a Removal of surplus flammable material near work areab Containment of flammable materialsc Provision of fire fighting equipment

L

Use of Power tools during Installation.Welding/burning.Grinding, disk cutting

Eye damage, fumes,cuts and burns

M M M a Screen adjacent personnel from arc flashb Ensure use of suitable eye protectionc Provision of fire fighting equipment

L

Noise

Vehicular movements.Collision between Fork Lift Truck /JCB etc. & Personnel

Ear damage

Body impact, severe trauma. Trapping and crushing

M

H

M

L

M

M

a Wear suitable ear protection

a Ensure all site personnel are advised of vehicular movements b Ensure adequate supervision of installationc Ensure that drivers are suitably trained

LL

Railway/Road Traffic.Impact with site personnel or equipment


H M H a Ensure all relevant authorities are aware of impending work locationb Install adequate warning notices or barriersc Ensure adequate site supervisiond Ensure site personnel wear suitable PPEe Ensure sufficient track access time has been allowed

L

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PROTECTINGTHE ENVIRONMENT

Rosehill Polymers Limited is committed

to a policy of continual improvement

in respect of the quality and level of

service offered to its customers.

An integral part of this commitment is

to carry out all business activities in a

manner that safeguards the environment,

the health and safety of all employees

and the neighbouring community.

This Environmental Policy carries the

full support of Rosehill senior management

and is reviewed periodically for

continuing suitability.

The company will actively:

» Comply with legal and regulatory

requirements

» Utilise recycled materials in manufacturing

processes

» Raise awareness and train employees in

environmental matters

» Aim to reduce the use of all raw materials,

energy and supplies

» Encourage the recycling of packaging

materials

» Minimise waste

» Assist customers to use our products in

an environmentally sensitive way.

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» Design Rights - All components

in our level crossing systems

are designed by Rosehill Rail

(a Division of Rosehill Polymers

Limited), including those supplied

under other names by our

global distributors.

DESIGN RIGHTS

CERT NO. 2179

PA G E l 12

DESIGNED & MANUFACTURED IN THE UK BY ROSEHILL RAIL

Rosehill Rail is a Division of Rosehill Polymers Limited

» ROSEHILL RAIL SALES

Spring Bank Mills

Watson Mill Lane

Sowerby Bridge

West Yorkshire HX6 3BW

United Kingdom

Phone +44 (0)1422 839 456

Fax +44 (0)1422 316 952

Email [email protected]

Web www.rosehillrail.com

www.rosehillpolymers.com

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ROSEHILL RUBBER RAIL CROSSING PANELS

» ROSEHILL RAIL MANUFACTURING

Rose Hill Mills

Beech Road

Sowerby Bridge

West Yorkshire HX6 2JT

United Kingdom

Phone +44 (0)1422 839 610

Fax +44 (0)1422 835 786

Email [email protected]

Web www.rosehillrail.com

www.rosehillpolymers.com

Documents

Rosehill Base Plate Installation Maintenance