PPI Performance Polymers Inc. Installation Instructions for PPI Railseal & Low Profile Spring Clamp Before you start... Use a continuous rail through out the crossing, grind welds flush, sweep rail and tops of ties free of any contaminants and ensure spikes are fully seated onto rail base and tie plates. Recommended tools for spring clamp installation...   1 1/8" deep socket with 1/2" or 1/4" drive to suit (Suitable Socket Drive - Rachet)  OR Power torque wrench (Set to 25 ft-lb) OR Powered impact driver OR 1 1/8" ratchet socket wrench OR 1 1/8" open or box end wrench OR Adjustable wrench  Installation Procedure... 1 Place and seat railseal into web of the rail with a sledge hammer (Fig1). 2 Butt ends together over tie and hammer in end clip (Fig2). 3 Disassemble and slide the "L" body under rail from the gauge side using 1 per crib (Fig3). 4 Reassemble and hand tighten threaded nut until end horn is snug to rubber (Fig4). 5 Using tool, tighten nut until gauge and field railseal are fully seated with clamp indented into the rubber approximately 1/4" per side ( approximately 25 ft-lbs. of torque or 5-7 full turns after fully seated) (Fig5). For assistance please call: TOLL FREE: 1-888-222-5968

RECOMMENDATIONS FOR PAVING A CROSSING

PPI Rubber interface is designed to provide many years of service. However it is the asphalt design and installation that is critical to assuring the long life of the entire grade crossing.

ASPHALT QUALITY:

We recommend that a high stress asphalt such as described in NAPA's publications IS 199 (Hot Mix Asphalt for High Stress Applications) and QIS 111 (Hot Mix Asphalt for High Stress Applications) be used to minimize rutting at the crossing.  In these brochures NAPA emphasizes the need for high quality crushed aggregate, proper modifiers and additives for the conditions plus good rolling techniques to ensure proper air voids.

ASPHALT INSTALLATION:

If required, a thin coat of coarse ballast can be placed on the ties to prevent sticking (maximum 1")

Three lifts of asphalt are recommended (base, binder and surface lifts or for lighter duty crossings, two binder and a surface lift).  Each lift needs to be installed to the proper depth and compacted to give the correct air void volume (approximately 3%).

The final lift should be rolled to about 1/8" above the top of the rubber. The crossing should be rolled up but not on the rubber. Place ballast or boards outside the crossing to get the roller over the rails.

CROSSING CLOSURE:

The crossing must be kept closed until cooled and the full strength of the asphalt has been achieved. Usually an overnight closure is sufficient time for the asphalt to cool.

For further assistance please call our Installation Action Line

Toll Free: 1-888-222-5968