Presents The Complete Product Line of - SEPTAApr 17, 2017 · rail block-out height equals rail height grout plugs (3 typical) 1:40 rail cant to center. 3/16" uhmw polyethylene nylon

Quality... Strength.... Durability...

and

MAINTENANCE FREE!

The Complete Product Line ofPresents

A (Plants Nationwide)1-888-965-3227

(Plants Nationwide) 1-888-965-3227

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INDEX

Benefits of StarTrack . . . . . . . . . . . . . . . . . . . . . 4

StarTrack II x 5’-0”. . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6

StarTrack II-HD . . . . . . . . . . . . . . . . . . . . . . . . 7, 8

StarTrack II x 7’-6” . . . . . . . . . . . . . . . . . . . . 9, 10

StarTrack II x 17’-6” . . . . . . . . . . . . . . . . . . 11,12

Star Track Inspection Pit . . . . . . . . . . . . . . 13,14

Startrack Base Options. . . . . . . . . . . . . .15,16

Industry, Intermodal . . . . . . . . . . . . . . . . . . .17

Curved Crossings,Heavy Loads. . .18

Improved Rail Groove Inserts. . . . . . .19

Suggested Installation . . . . . . . . . . 20

Benefits of StarTrack............................... 4

StarTrack II x 5’-0”................................... 5

StarTrack II-HD........................................7

StarTrack II x 7’-6”................................... 9

StarTrack II x17’-6”..................................11

StarTrack Inspection Pit.................... ......13

StarTrack Base Options.................... ......15

Industry, Intermodal.................................17

Curved Crossings, Heavy Loads.............18

Improved Rail Groove Inserts..................19

Suggested Installation............................. 20

Insert Assemblies.................................... 21

Rubber Inserts Installation.......................22

Joint Gap Filler Strip Installation..............24


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MATERIALS: CONCRETE: THE MINIMUM 28 DAY STRENGTH SHALL BE 6000 PSI. Optional: Special design mix utilizing Micro-Silica. Optional: Corrosion inhibitor additive in lieu of epoxy reinforcing.

REBAR: ASTM A615, GRADE 60. Optional: Epoxy-coated

SHOULDERS: “PANDROL” #6575 CAST SHOULDER DUCTILE - IRON GRADE #65-45-12

RUNNING STRIPS: 3/16” UHMW POLYETHYLENE

CLIPS: “PANDROL” #E2055 CLIPS - SPRING STEEL

INSULATORS: “PANDROL” #7400 THERMOPLASTIC / NYLON

EXPOSED SURFACE: FORM CAST CONCRETE. Optional: Hydrozo “Enviroseal” Surface Treatment

DESIGN LOADING: COOPER E-80 WITH 60% IMPACT


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4” PVC PERF. WRAPPED W/ FILTER FABRIC TO DRAINAGE STRUCTURE

FILTER FABRIC

3/8” MINUS FINE AGGREGATE


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NON-SKID3/16" DIAMOND

PLATE PATTERNRAIL BLOCK-OUT HEIGHT

EQUALS RAIL HEIGHT GROUT PLUGS(3 TYPICAL)

1:40 RAIL CANTTO CENTER

3/16" UHMWPOLYETHYLENE

NYLON INSULATORTYPE P10

“PANDROL” BRAND RAILCLIP TYPE “E 2055’

RAIL DETAIL

MATERIALS:CONCRETE: THE MINIMUM 28 DAY STRENGTH SHALL

BE 6000 PSI. Optional: Special design mix utilizing Micro-Silica.Optional: W. R. Grace’s “D.C.I.” additive

in lieu of epoxy reinforcing

REBAR: ASTM A615 GRADE 60.Optional: Epoxy-coated

SHOULDERS: “PANDROL” #5274 CAST SHOULDERDUCTILE - IRON GRADE #65-45-12

RUNNING STRIPS: 3/16" UHMW POLYETHYLENE


INSULATORS: “PANDROL” #4263THERMOPLASTIC / NYLON

EXPOSED SURFACE: FORM CAST CONCRETE.Optional: Hydrozo “Enviroseal” #40 Surface Treatment

DESIGN LOADING:COOPER E-80 WITH 60% IMPACT

“PANDROL”RAG STEM

SHOULDER

T M

STARTRACK II - HDWEIGHT = 10,400 lbs.

(Plants Nationwide)1-800-316-1660

5’-- 0”

2’-- 5 1/4”

2’-- 5 1/4”

1’-- 1 1/2”

1’-- 1 1/2”

11’-- 0”

3’-- 10 1/2”1’-- 4”

4/96

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RAIL DETAIL












SHOULDER

T M



5’-- 0”

2’-- 5 1/4”

2’-- 5 1/4”

1’-- 1 1/2”

1’-- 1 1/2”

11’-- 0”

3’-- 10 1/2”1’-- 4”

4/96

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RAIL DETAIL












SHOULDER

T M



5’-- 0”

2’-- 5 1/4”

2’-- 5 1/4”

1’-- 1 1/2”

1’-- 1 1/2”

11’-- 0”

3’-- 10 1/2”1’-- 4”

4/96

7








RAIL DETAIL












SHOULDER

T M



5’-- 0”

2’-- 5 1/4”

2’-- 5 1/4”

1’-- 1 1/2”

1’-- 1 1/2”

11’-- 0”

3’-- 10 1/2”1’-- 4”

4/96



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FILTER FABRIC



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5


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PLATE PATTERN

RAIL BLOCK-OUT HEIGHTEQUALS RAIL HEIGHT

GROUT PLUGS(3 TYPICAL)





RAIL DETAIL












SHOULDER

T M

STARTRACK II x 7'6"WEIGHT = 9,550 lbs.


8’-0”

3’-10 1/2”

1’-1 1/2”

11 1/4”

7’ -6”

1’ -2” 11 1/4”

1’-1 1/2”

(5’0” versionalso available)

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PLATE PATTERN







RAIL DETAIL












SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2”

11 1/4”

7’ -6”

1’ -2” 11 1/4”

1’-1 1/2”


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PLATE PATTERN







RAIL DETAIL












SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2”

11 1/4”

7’ -6”

1’ -2” 11 1/4”

1’-1 1/2”


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PLATE PATTERN







RAIL DETAIL












SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2”

11 1/4”

7’ -6”

1’ -2” 11 1/4”

1’-1 1/2”


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5


FILTER FABRIC



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5


5


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RAIL BLOCK-OUTHEIGHT EQUALS

RAIL HEIGHT





RAIL DETAIL




REBAR: ASTM A615 GRADE 60 AND POST-TENSIONING TENDONS

Optional: Epoxy-coated Rebar








SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2

”

1’-1 1/2

”

11 1/4

”

11 1/4

”

17’ -6”

1’ -2”



PLATE PATTERN

11


RAIL HEIGHT





RAIL DETAIL













SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2

”

1’-1 1/2

”

11 1/4

”

11 1/4

”

17’ -6”

1’ -2”



PLATE PATTERN

11


RAIL HEIGHT





RAIL DETAIL













SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2

”

1’-1 1/2

”

11 1/4

”

11 1/4

”

17’ -6”

1’ -2”



PLATE PATTERN

11


RAIL HEIGHT





RAIL DETAIL













SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2

”

1’-1 1/2

”

11 1/4

”

11 1/4

”

17’ -6”

1’ -2”



PLATE PATTERN

11


RAIL HEIGHT





RAIL DETAIL













SHOULDER

T M



8’-0”

3’-10 1/2”

1’-1 1/2

”

1’-1 1/2

”

11 1/4

”

11 1/4

”

17’ -6”

1’ -2”



PLATE PATTERN

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FILTER FABRIC



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RAIL DETAIL


BE 5000 PSI.


GASKET: 3/4" x 1" NEOPRENE





ACCESSORIES: (Optional)LADDERS: (PVC MANHOLE STEPS)ROUGH ELECTRICAL, PNEUMATIC, OR HYDRAULIC PIPINGROLLING GRATING SAFETY COVERSNON-SLIP FLOOR SURFACE

DESIGN LOADING:COOPER E-80[Designed in accordance with A.R.E.A. Specifications]


SHOULDER

T M

INSPECTION PITWEIGHT = 51,000 lbs. (20’)


RAIL BYOTHERS

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RAIL DETAIL


BE 5000 PSI.










SHOULDER

T M



RAIL BYOTHERS

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RAIL DETAIL


BE 5000 PSI.










SHOULDER

T M



RAIL BYOTHERS

13




RAIL DETAIL


BE 5000 PSI.










SHOULDER

T M



RAIL BYOTHERS

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DETAIL DRAWING FOR

STARTRACK INSPECTION PIT

TYPICAL JOINT DETAILSIDE VIEW


SECTION A - A

PLAN VIEW AT ENDPLAN VIEW

[OPTIONAL: 5'-0", 10'-0", 15'-0"]

14

6’-4

”


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1-0”MIN.

1-0”MIN.

8” MIN.

9” MIN.

8” MIN.

3” MIN.

6” MIN.

1-1/2”MAX.

1-1/2”MAX.

1-0”MIN.

1-0”MIN.

1-0”MIN.

vARIeSFROST DePTH

4” PvC PeRF. PIPe WRAPPeD W/FILTeR FABRIC TO DRAINAGe STRUCTURe

(aLL OPTIONS)SUITABLe SUBGRADe

(2500 PSF MIN. BeARING)COMPACTeD TO 95% SECTION vIEW

AGGReGATe BASe

SECTION vIEWASPHALT UNDeRLAYMeNT BASe

OPTION 1

SECTION vIEWASPHALT UNDeRLAYMeNT BASe

OPTION 2

GeOTeXT MeMBRANe(BOTTOM & SIDeS)

GeOTeXT MeMBRANe(BOTTOM & SIDeS)

ASPHALT CONCReTe

ASPHALT CONCReTe

STONe (98% COMPACT)

STONe (98% COMPACT)



FINe AGGReGATe 3/8” MINUS

FINe AGGReGATe 3/8” MINUS

3/8” OPeN GRADeD CRUSHeD STONe

DeNSe GRADeD AGGReGATe(98% COMPACT)

vARIeSFROST DePTH

vARIeSFROST DePTH

1-0”MIN.

1-0”MIN.



5

1-0”MIN.

vARIeSFROST DePTH

1-0”MIN.

8” MIN.

1-1/2”MAX.


FINe AGGReGATe 3/8” MINUS(aLL OPTIONS)SUITABLe SUBGRADe

(2500 PSF MIN. BeARING)COMPACTeD TO 95%

CONTROLLeD LOW-STReNGTH MATeRIAL (PeR ACI 229 R-99)

FLOW FILL(MIN Fc = 100 PSI)

SECTION vIEWCONTROLLeD DeNSITY FILL BASe

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Preliminary Subsurface Investigation(Optional)

Prior to removal of ties and ballast, soil samples shallbe taken by a recognized soil testing laboratory andthrough laboratory analysis, sufficient data is collectedto evaluate the depth of excavation and thickness ofbase required.

STARTRACK Suggested Installation

Procedure

Subgrade Preparation

The resulting subgrade shall be scarified and com-pacted to 95% of its peak dry density. Drainage tileshall then be installed in a trench area, surrounded byopen graded stone or filter fabric. The entire excavated area and sides shall be lined with an approved fabric equal in performance charac-teristics to “TYPAR” style 3401. The base course material shall be applied in 4" lifts compacted to 98% of peak dry intensity. The leveling course (1-1/2" maximum thickness) shall be carefully screeded to the grade shown. Screeded surface to be within +/- 1/4" of grade. Fill and compact entire exca-vation. See Startrack’s “Startrack Base Options” for other acceptable subgrade procedures.

Module Placement

Modules shall be placed on the resulting base as snugas possible to one another and to within +/- 1/4" in alignment, utilizing lifting hardware provided. Butylrubber sealant shall be applied as shown on thedrawing details. Should any screeded surface irregularity becomeevident during placement of modules, the module shallbe removed and the surface corrected.

Rails, ties, asphalt, ballast, and sub ballast will beremoved from an area comprising the length of thecrossing plus 15' on each end and 10' wide (13' widefor HD) to a minimum depth of 12" below precastmodules, or as determined above. If any areas ofpumping or other indications of instability are encoun-tered, they shall be undercut as required and backfilledwith compacted base course material.

Final Completion

Surface the adjacent track construction with new 10'switch ties in the transition area. Install signal wiring inconduit if required. Apply foam backer rod and sealantto all module joints if required. Clean all debris from excavation and apply asphaltpaving alongside, up to and flush with module. Protectall exposed concrete from asphalt roller. Apply asphaltat ends of crossing to provide a 5' transition from tiesurface to module surface (optional). If asphalt is used for rail groove filler, run locomotive across to cut flangeway.

Remove all construction debris from site and leavecompleted crossing in a clean condition. Package andship loaned lifting hardware to plant (freight prepaid.)

Placing and Fastening of Rail

Rail shall then be placed along StarTrack modules on both sides and all rail splicing completed, making sure all polyethylene pads are in place. After laying rail into blockout groove, start rail installation by centering rail between a set of shoul-ders, inserting nylon insulators, and then pull the clips into place over the insulators with the puller provided. Repeat this process throughout the crossing, then connect rail to track rail by normal methods. If neces-sary, adjust final alignment by moving modules with rail jacks or backhoe.

1-888-965-3227

Preliminary Subsurface Investigation(Optional)

Prior to removal of ties and ballast, soil samples shallbe taken by a recognized soil testing laboratory andthrough laboratory analysis, sufficient data is collectedto evaluate the depth of excavation and thickness ofbase required.

STARTRACK Suggested Installation

Procedure


The resulting subgrade shall be scarified and com-pacted to 95% of its peak dry density. Drainage tileshall then be installed in a trench area, surrounded byopen graded stone or filter fabric. The entire excavated area and sides shall be lined with an approved fabric equal in performance charac-teristics to “TYPAR” style 3401. The base course material shall be applied in 4" lifts compacted to 98% of peak dry intensity. The leveling course (1-1/2" maximum thickness) shall be carefully screeded to the grade shown. Screeded surface to be within +/- 1/4" of grade. Fill and compact entire exca-vation. See Startrack’s “Startrack Base Options” for other acceptable subgrade procedures.

Module Placement

Modules shall be placed on the resulting base as snugas possible to one another and to within +/- 1/4" in alignment, utilizing lifting hardware provided. Butylrubber sealant shall be applied as shown on thedrawing details. Should any screeded surface irregularity becomeevident during placement of modules, the module shallbe removed and the surface corrected.

Rails, ties, asphalt, ballast, and sub ballast will beremoved from an area comprising the length of thecrossing plus 15' on each end and 10' wide (13' widefor HD) to a minimum depth of 12" below precastmodules, or as determined above. If any areas ofpumping or other indications of instability are encoun-tered, they shall be undercut as required and backfilledwith compacted base course material.

Final Completion

Surface the adjacent track construction with new 10'switch ties in the transition area. Install signal wiring inconduit if required. Apply foam backer rod and sealantto all module joints if required. Clean all debris from excavation and apply asphaltpaving alongside, up to and flush with module. Protectall exposed concrete from asphalt roller. Apply asphaltat ends of crossing to provide a 5' transition from tiesurface to module surface (optional). If asphalt is used for rail groove filler, run locomotive across to cut flangeway.

Remove all construction debris from site and leavecompleted crossing in a clean condition. Package andship loaned lifting hardware to plant (freight prepaid.)


Rail shall then be placed along StarTrack modules on both sides and all rail splicing completed, making sure all polyethylene pads are in place. After laying rail into blockout groove, start rail installation by centering rail between a set of shoul-ders, inserting nylon insulators, and then pull the clips into place over the insulators with the puller provided. Repeat this process throughout the crossing, then connect rail to track rail by normal methods. If neces-sary, adjust final alignment by moving modules with rail jacks or backhoe.

1-888-965-3227

Preliminary Subsurface Investigaton(Optional)

Prior to removal of ties and ballast, soil samples shall be taken by a recognized soil testing laboratory and through laboratory analysis, sufficient data is collected to evaluate the depth of excavation and thickness of base required.


Rails, ties, asphalt, ballast, and sub ballast will be removed from an area comprising the length of the crossing plus 15’ on each end and 10’ wide (13’ wide for HD) to a minimum depth of 12” below precast modules, or as determined above. If any areas of pumping or other indications of instability are encountered, they shall be undercut as required and backfilled with compacted base course material.

The resulting subgrade shall be scarified and compacted to 95% of its peak dry density. Drainage tile shall then be installed in a trench area, surrounded by open graded stone or filter fabric.

The entire excavated area and sides shall be lined with an approved fabric equal in performance characteristics to “TYPAR” style 3401.

The base course material shall be applied in 4” lifts compacted to 98% of peak dry intensity. The leveling course (1-1/2” maximum thickness) shall be carefully screeded to the grade shown. Screeded surface to be within +/- 1/4” of grade. Fill and compact entire excavation. See Startrack’s “Startrack Base Options” for other acceptable subgrade procedures.

Module Placement

Modules shall be placed on the resulting base as snug as possible to one another and to within +/- 1/4” in alignment, utilizing lifting hardware provided. Butyl rubber sealant shall be applied as shown on the drawing details.

Should any screeded surface irregularity become evident during placement of modules, the module shall be removed and the surface corrected.


Rail shall then be placed along StarTrack modules on both sides and all rail splicing completed, making sure all polyethylene pads are in place.

After laying rail into blockout groove, start rail installation by centering rail between a set of shoulders, inserting nylon insulators, and then pull the clips into place over the insulators with the puller provided. Repeat this process throughout the crossing, then connect rail to track rail by normal methods. If necessary, adjust final alignment by moving modules with rail jacks or backhoe.

Placing of Rail Groove Filler

Install rubber rail groove filler according to Startrack’s “rail Groove Filler Installation Instructions for Startrack Rubber Inserts.”

Final Completion

Surface the adjacent track construction with new 10’ switch ties in the transition area. Install signal wiring in conduit if required. Apply foam backer rod and sealant to all module joints if required.

Clean all debris from excavation and apply asphalt paving alongside, up to and flush with module. Protect all exposed concrete from asphalt roller. Apply asphalt at ends of crossing to provide a 5’ transition from tie surface to module surface (optional). If asphalt is used for rail groove filler, run locomotive across to cut flangeway.

Remove all construction debris from site and leave completed crossing in a clean condition. Package and ship loaned lifting hardware to plant (freight prepaid.)

Thank YouBenefits of StartrackStartrack IIStartrack II HDStartrack II x 7'-6"Startrack II x 17'-6"Inspection PitStartrack Base OptionsIndustry, IntermodalCurved Crossings, Heavy LoadsImproved Rail Groove InsertsSuggested InstallationInsert AssembliesRubber Inserts InstallationJoint Gap Filler Strip Installation

Documents

Presents The Complete Product Line of - SEPTAApr 17, 2017 · rail block-out height equals rail height grout plugs (3 typical) 1:40 rail cant to center. 3/16" uhmw polyethylene nylon