rosehill base plate installation maintenance
DESCRIPTION
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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
Body impact, severe trauma
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
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
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
Body impact, severe trauma
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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www.rosehillrail.com
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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
All i
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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