edilon)(sedra Corkelast ® LCS

(Level Crossing System)

www.edilonsedra.com
 edilon)(sedra Corkelast ® LCS
(Level Crossing System)

How can I improve the durability of and the safety at a level crossing?
How can I properly integrate a level crossing into a road structure?
What are the best options for Heavy Duty conditions?
How do I reduce the maintenance regime?
And how does all that affect the Level Crossing System?
These are just some of the valid questions, asked by international railway experts.
The answers can be found, in using one of edilon)(sedra’s core technologies: edilon)(sedra Corkelast® LCS (Level Crossing
System).

About edilon)(sedra
edilon)(sedra is an international developer, manufacturer and supplier of
varying kinds of (ballast-less) rail fastening systems. Our experience in
permanent way goes back to the 1950s after which we have developed
into a company with offices in many capitols in the EU, along with
manufacturing in North America and operations in South America, having
a fully active business in Australia and New Zealand since 2012.
4.375 trucks and 30.625 cars per day

More information www.edilonsedra.com

6
About our Corkelast® About our Corkelast® Level
Embedded Rail System (ERS) Crossing System (LCS)
Initiated by Dutch Railways and their need to have a reduced The quickly increasing number of commuters, plus having an
weight and maintenance free ballast-less rail fastening systems extensive rail-network and a completely flat country, resulted
for their thousands of (remote) steel bridges, crossing canals in thousands of heavily used at-grade level crossings. All
and rivers all over the Netherlands, we started to experiment requiring frequent inspection, regular maintenance & lots
using polymers in rail systems. of renewals. This encouraged Dutch Railways to look at
adopting the ERS concept, successfully used at their bridges.
This resulted in the development of our Corkelast® Embedded
Rail System (ERS) for bridges: rails are aligned floating, in a The new concept of ERS opened new opportunities for out-
pair of longitudinal channels. A 2-component PU is mixed on- of-the-box solutions, that tackled all the existing problems of
site and poured around the rail. Once cured, this PU (called sleeper-based level crossings, all using panels on top. Without
Corkelast ), holds and secures the rails at line & level for life.
® the need for sleepers, edilon)(sedra launched the idea of heavy
monolithic prefabricated slabs using ERS to fasten the rails.
The biggest difference between all the existing traditional
rail fastening systems and ERS, is the complete absence of The very first level crossing using ERS, was on the railway’s
clips, clamps, bolts or any other mechanical fastening (steel main-line, at a small town called Harmelen, back in 1974. The
items are no longer required to fasten the rails). The rails immediate success of this installation, resulted in thousands
are continuously supported, at all sides and every square of ERS level crossings being installed in Holland and copied
millimetre. as THE standard solution for Heavy Duty level crossings for all
European operators and beyond.
The 1st project using ERS was a single track 250 m long
concrete bridge on a freight line near Rotterdam called “Roode The 300 m radius and skewed Tata Steel level crossing “Velser
Vaart”. Installed in 1972 and in service since 1973, this bridge Traverse” in Beverwijk, Holland, takes 4.375 trucks and 30.625
didn’t need any maintenance at all until 2012, when the cars per day. Each day and every day!
economic life of the rails expired.

7
edilon)(sedra Corkelast ® LCS
(Level Crossing System)

Furthermore, LCS provides significant noise and vibration

reductions: no rattling panels on sleepers, no soil-transferred
vibration caused by trains hitting the discrete fastening.
Increasingly important if located in densely populated areas or
in the area of sensitive buildings as hospitals, elderly homes,
hotels and theatres.

General advantages Cost effectiveness

• superb rail/road interface • quick and easy to install
• continuous elastic rail support • minimal possession time
• well proven technology • durable structure
• working with structural monolithic units • service life of more than 30 years
• waterproof rail-fastening system • reduction of rail-wear and rail-corrugation
• NO mechanical fastenings • no inspections required
• and therefore corrosion free and increased life • no maintenance needed
span of the rail profile • reduction of noise and vibration
• reduction of noise and vibration • low Lifecycle Costs (LCC)
• excellent electrical insulation of the track

Application
LCS is applied in all possible kinds of intersections, where • crossing highways, interstates, downtown city roads
road meets rail. There are almost no restrictions. LCS • for intercity, commuter, freight, light rail & tram
combines easily with ballasted track and the paved road • industrial plants, ports, intermodal hubs
into one structural unit. By combining different LCS concrete • S-shaped roads, roundabouts,
´ skewed roads
slabs, level crossings of different lengths can be installed in
• curved track, tilted track, cant deficiency
short (night) shifts, including the removal of the old crossing.
 Technical features LCS:
Section A-A (1
LCS is based on using prefabricated : 30)
and reinforced concrete influences, such asAchanging
Detail (1 : 10) temperature Minimum
ranges
moment of hoistingday/night
strength of concrete at
f = 15 N/mm². ck

I A
ß≤ 12,5º.
slabs, combined with our ERS for fastening the rails.
FRONT and
REAR summer/winter.
10 For more information about the hoisting
350±5

VIEW VIEW
during production refer to
P
The coldest ambient temperature where ERS is used is A1711-ESA-ESP-01 Technical
specifications for edilon)(sedra
P
10

LCS-350/500 concrete slabs

Corkelast® is a unique polymer embedding compound with -38°C at the Temagami level crossing near Ontario, Canada
ß
4000±5

a pre-defined track support stiffness and optimal electrical (installed 1986) and the warmest ambient temperature where
Top View (1 : 30)
insulating properties. Once mixed on-site, it cures in just a ERS is used is 48,5 °C at Jebel Ali and the Green Line in
(4000+2x)±5 Section A-A (1 : 30) Detail A (1 : 1
couple of hours, after which train traffic is allowed to pass 1
Tapering value x Dubai VAE (installed 2008), with runner-up the 2013 installed
FRONT
I
Volume
A
REAR
Weight
10X
C
350±5

3,07 m³ VIEW7.675 kg -1220

the track again. Australian Jimblebar loading facility with 45,6 °C.
VIEW
B HOISTING FEATURES

10
650

4000±5
Ev2≥100 MN/m² (~Cs > 0,059 N/mm3)
Condition subsoil according to DIN 18134 - Plattendruckversuch
Prior to installation; to be checked on site

Top View (1 : 30) REMARKS

Corkelast® provides a stable, durable and long lasting Detail B (1 : 5) (4000+2x)±5
Top surface according to A1711-ESA-EDR-13 Reckli Rhombu
I
Top surface Reckli Rhombus
=

Tapering value x A1711-ESA-EDR-14 Broom brushed, A1711-ESA-EDR-15 Gr

continuous
A
rail support. It deals with the forces and tension A II
1
See applicable drawing of edilon)(sedra Corkelast ® ERS for
B surface treatment and S,C,H & M dimensions
2440±5

2400±5

caused by passing trains and road traffic, plus physical Markings according to A1711-ESA-ESP-01 Technical specific
650

III LCS-350/500 concrete slabs

B
Concrete surfaces to be primed according to paragraph 2.2.5
IV
Technical specifications for edilon)(sedra LCS-350/500 concr
Detail B (1 :
edilon)(sedra LCS FEATURES
Top surface Reckli
=
=

A A
I Configuration and properties of concrete according
2440±5

2400±5

Concrete
B Constructional exposure concrete
location
element classes strength class
650

Concrete
=

top surface XC4, XD3, XF4 C45/55

B 1 reinforcement I
general XC4, XD1, XF4 C45/55
CONCRETE PROPERTIES
650

B 1
800 800
Tapering value x 3
(4000-2x)±5 800 800
Tapering value x 3
(4000-2x)±5

Front and Rear View (1 : 15) Detail CFront

(1 :and
10)Rear View (1 : 15) Detail C
2400±10
2400±10
S±2 C±2 M±2 10
C
S±2 C±2 M±2 IV 10 I IV III 2
C
IV I IV III 2
H
II
10
175

H
II

650 650
175

Reinforcement Plan
2440±10
Technical specifications for edilon)(sedra LCS-350/500 concrete slab
RELATED DOCUMENTS
DRAWN BY CHECKED BY APPROVED BY REVISION HISTORY CLIENT

650 650 NAME: J.Recio NAME: M.Peña NAME: A.de Man REV. DATE DESCRIPTION

00 22-01-2018 creation of drawing1 8 JR MP

DESIGNER

AdM
CHECKED APPROVED
DEHA 6000-5,0-0120 5 T Hoisting Anchor or
01 10-07-2018 additional anchors 2
included 2 U-shaped steel
JR profile
MP according
AdM to A1711-ES
2440±10 - - - - - -
DATE:10-07-2018 DATE:10-07-2018 DATE:10-07-2018 - - - 3 2 DEHA 6000-5,0-0180
- - 5 T-Hoisting Anchor or
STATUS - - - - - - SUBCONTRACTOR
ITEM QUANTITY PRODUCT-
ISSUED FOR USE - - - - -
- - - - - -
MOUNTING PARTS LIST
SCALE SHEET SIZE UNITS - - - - - -
DRAWN BY CHECKED BY APPROVED BY REVISION HISTORY CLIENT - - - PROJECT - - -
NAME: J.Recio NAME: M.Peña NAME: A.de Man REV. DATE DESCRIPTION DESIGNER CHECKED - APPROVED A3L mm - - - - edilon)(sedra LCS-350/500
- -
Standard designs
00 22-01-2018 creation of drawing JR MP AdM
01 10-07-2018 additional anchors included JR MP AdM TITLE
Nijverheidsweg 23, 2031 CN Haarlem
edilon)(sedra Corkelast ® LCS
(Level Crossing System)

202
Track Gauge
Track Gauge
64 7 20

3
0
Top of Rail

20

3
60E1 - UIC60
45

6 1
55G2-41GP R10 7 1
8
8

2
187

2
3

167
3 3

5
6
5
Incl. 1:40
4
4
15

15
20 150 20 15 141,5 30

190 186,5

LEGEND LEGEND
Legend
®
edilon)(sedra
1. Corkelast Corkelast VA-60 1 edilon)(sedra Corkelast® VA-60
®
1
2 edilon)(sedra
2. ERS CorkERS Cork
Wegde Wedge
(temp. 2 edilon)(sedra ERS Cork Wedge
aligning, while rail is being embedded)
3 edilon)(sedra
3.
ERS Polymer
ERS Filler Blocks
Filler Block 3 edilon)(sedra ERS Polymer Filler Block
4 edilon)(sedra ERS Polymer Shims 4 edilon)(sedra ERS Polymer Shims
4. ERS Polymer Shim ´ (temp. aligning, while rail is being embedded)
5 edilon)(sedra ERS Polymer Inclination Shim 5 Channel
6 Channel
5. longitudinal channel in prefabricated concrete slab 6 Steel profile
7 Steel
6. profile
steel profile (conrete channel protection) 7 Rail
8 Rail 8 edilon)(sedra Primer U90WB
9 7. rail
edilon)(sedra Primer U90WB
8. Primer

The slabs can be customized for tight curves, integration of cables, variation in slab length, weld pockets and for axle loads of
more than 40 tonnes. Corkelast® LCS is integrated easily in different interfaces, as asphalt, cobble stones and concrete.

9
2 examples of available LCS types

Corkelast ® LCS types LCS-350 and LCS-500

The edilon)(sedra Corkelast® LCS type LCS-350,

with the LCS-350 Concrete Slab and the
edilon)(sedra Corkelast® LCS type LCS-500, with
the LCS-500 Concrete Slab have been designed
for rail vehicles up to Heavy Rail and rubber tyred
road vehicles up to 30 tonnes per axle. These level
crossing systems are recommended for application
in areas with moderate to excellent bearing capacity
and with little to moderate settlement activity:
• Type LCS-350 for Ev2 ≥ 100 MPa,
• Type LCS-500 for Ev2 ≥ 80 MPa.
The systems are also suitable for industrial and side
tracks.
Within ERS, a variety of rail types can be combined with the two LCS concrete slabs. If Vignole rail types are applied, room
next to the rail head shall be kept free for the wheel flange to pass. This is especially important in case of curved track. For
details and dimensions of the Corkelast® ERS, please see the edilon)(sedra standard design drawings as reference or starting
point for further customizing.

Features:
• Increased safety due to a minimized width of the flangeway and the high skid resistance of the slab’s top surface;
• Virtually maintenance free, long life time expectation and maximum track availability;
• Waterproof system, NO mechanical fastenings and therefore corrosion free;
• Maximum electrical insulation;
• Easy to install on stabilized subgrade;
• Reduction of noise and vibration due to full elastic fixation of the rail;
• Favourable cost of ownership.

There are different design options for individual slabs such as a single protection plate facility to protect the level crossing front
and back end or a flangeway widening to allow for a smooth wheel entry. The concrete slabs can be tapered upon demand to
accommodate for curved track; the tapering depends on the track radius. The concrete slabs have slightly inclined side walls.
Different installation methods can be carried out. edlon)(sedra provides for facilities for undergrouting slabs in case of a top-
down installation method. Injection holes for grout are optional.
Optionally the slab is equipped with steel corner profiles around the top part of the slab to improve the integrity and the
durability of the concrete surface.
Two 80 mm diameter tubes in slab length direction are an option for safe transit of signalling cables.

9
 Installation of LCS (method on sand layer):
edilon)(sedra Corkelast® ERS - Regular edilon)(sedra Coc
ERS with prefab

with prefab
(sedra Stepconcrete
Corkelast
1 slabs,
ERS bottom-up
- Regular
Step 2 installed
ERS
edilon)(sedra with prefab concrete slabs,
®
Corkelast
Step 3
ERS bottom-
- Reg
®
Bare cunet Leveling of cunet Placing of edilon)(sedra LCS slabs
Step 1: Step 2: Step
Step 3:
1:
Bare cunet Leveling of cunet Placing of edilon)(sedra
Bare cunet LCS slabs

Step 4 Step 5 Step 6

abs,
ERSbottom-up
- Regular installed
ApplicationERS with prefab concrete
of edilon)(sedra
Application
Application Cleaning of theslabs,
of edilon)(sedra
Step 4:
Step 6:
rail
Primer
Step
of edilon)(sedra
andof
2: bottom-up
Application ofinstalled
to reachable
Jointelast
rail
channel
between edilon)(sedra Primer
slabsparts
Step 5:
Step
ApplicationCleaning
7:
of edilon)(sedra ®
Stepof3:the railDex -G 20 Placing of
Application of the
Step
Step 8:
edilon)(sedra
edilon)(sedraStep
6:
Trackelast ® RS (Rail Strip)
4: to reachable
Primer channel parts Pla
Leveling cunet Step 1:
Placing of edilon)(sedra LCS slabs Step
Application of edilon)(sedra 2:
Jointelast between slabs
and rail
Jointelast between slabs Bare cunet
to reachable channel parts and rail
Leveling of cunet

Step 7 Step 8 Step 9

Step
Step 11:
9: Step 10:
Step 12: Step
Step 13:
11: ®
Strip) Fixation of edilon)(sedra
Placing of Filler Blocks with wedges
Step
Polymer afterfor
7:Shims horizontal alignment
vertical alignment Final
Placing of rail andalignment
Step 8: checkFiller Blocks
edilon)(sedra edilon)(sedra
Fixation of Filler Corkelast
Blocks withStep 9: afterpouring
wedges horizontal alignment edilon)(sedr
nel parts
abs Application of edilon)(sedra Step 5:
Application of edilon)(sedra Dex ® -G 20
Cleaning of the rail
Step 3:
Placing of the edilon)(sedra StepTrackelast
Placing of the edilon)(sedra
Application of edilon)(sedraStep
6:
Primer
® RS (Rail Strip)

4: to reachable channel parts

Placing of edilon)(sedra Polymer Step 7:Shims for vertical alignment
Placing of edilon)(sedra Polymer
Application of edilon)(sedra
Step 5: Dex ® -G 20 P

Dex®-G 20
Placing of edilon)(sedra LCS slabs
Trackelast RS (Rail Strip) ®and rail
Application of edilon)(sedra Jointelast between slabs
Shims for vertical alignmentCleaning of the rail

Step 10 Step 14:

Step 16:
® ERS with Pre-fabricated slabs
Step 11 Step 15: Step 12 Step 16:
Finished
edilon)(sedra edilon)(sedra
Corkelast ® ERSCorkelast
withStep 12:
Pre-fabricated slabs installation completed Application of edilon)(sedra Corkelast ® between LCS slabs and asphalt
Step 13: Step ®14:
Finished edilon)(sedra Corkelast ERS with Pre-fabricated slabs
lignment Step 10: check
Final alignment edilon)(sedraStep 11: ® pouring
Corkelast edilon)(sedra Corkelast ® ERS withStep 12:
Pre-fabricated slabs installation completed Applicati
gnment
Placing of rail and edilon)(sedra
Placing of rail and edilon)(sedra Filler Blocks
Step 8:
Placing of the edilon)(sedra Trackelast ® RS (Rail Strip)
Fixation of Filter Blocks with wedges
Fixation of Filler Blocks withStep
wedges
9: after horizontal alignment
Placing of edilon)(sedra Polymer Shims for vertical alignment
Final alignment check
Final alignment
Step 10: check
Placing of rail and edilon)(sedra Filler Blocks
Filler Blocks after horizontal alignment

ated slabs
Step 13 Step 15:
Step 14 Step 16:
Step 15
ation completed Application of edilon)(sedra Corkelast ® between LCS slabs and asphalt Finished edilon)(sedra Corkelast ®ERS with Pre-fabricated slabs
edilon)(sedra Corkelast pouring edilon)(sedra Corkelast ERS with Application of edilon)(sedra
Step 13: Step 14: Step 15:
edilon)(sedra Corkelast ® pouring
® ®
edilon)(sedra Corkelast ® ERS with Pre-fabricated slabs installation completed Application of edilon)(sedra Corkelast ® between LCS slabs and asphalt

Pre-fabricated slabs installation Corkelast ® between LCS slabs and

completed T2015-0506/JvdA/27-05-2016/Ha2016-0535
asphalt
edilon)(sedra Corkelast ® LCS
(Level Crossing System)

1. optimally engineered prefabricated and reinforced

concrete slabs 2
1
2. rail fastening with ERS, using the elastic
edilon)(sedra Corkelast®
3
3. edilon)(sedra Filler Blocks

4. edilon)(sedra Rail Strips, to achieve lower track 4

stiffness

Single protection plate

in order to prevent damage to the LCS slabs, or possibly
even a derailment when loose train couplings grab the
concrete slab.

8
 Rail alignment with shims & wedges

Buckets for each slab-length, with the required

amount of shims & wedges come as a kit. You’ll never
run short on alignment materials.

These LCS kits also contain the required quantity of

primer per slab (paint-brushes included).

Slab-Coupling

An unlimited number of our LCS slabs can be com-

bined, to get the required length of the level crossing.

To save time during installation, 2 or 3 slabs can also

be jointed and hoisted on-site with ERS pre-installed.

More information? info@edilonsedra.com or www.edilonsedra.com

9
edilon)(sedra
Nijverheidsweg 23
NL-2031 CN Haarlem
T +31 / (0)23 / 531 95 19
F +31 / (0)23 / 531 07 51
mail@edilonsedra.com
www.edilonsedra.com
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