Installation Guide BODAN Level Crossing 02.02.2011e

INSTALLATION GUIDE / MAINTENANCE MANUAL
for
BODAN Level Crossing System and

LeBODAN Level Crossing Panels
Status: 02.02.2011
Gmundner Fertigteile Ges.m.b.H & CoKG. BODAN

Werk: Unterthalhamstraße 1 , A - 4694 OHLSDORF Gleiseindeckungs-
systeme
Tel.: +43-(0)7612–63065-0 Fax.: +43-(0)7612-63065-31 Level crossing systems
e-mail :gf.bodan@gmundner-ft.at www.gmundner-ft.at Le-BODAN
All rights reserved. Subject to technical modifications - in particular if implemented for the purpose of improvement.
Gmundner Fertigteile Ges.m.b.H & CoKG .
Werk: Unterthalham Straße 1, A - 4694 OHLSDORF
Tel.: +43 -(0)7612 – 63065-0 Fax.: +43 - (0)7612 - 63065-31 Level Crossing Systems
e-mail: office@gmundner-ft.at www.gmundner-ft.at Page 1 of 8
DOCUMENT:02/11 INSTALLATION GUIDE BODAN Level Crossing
Note: The installation guide for the BODAN level crossing system does not lay claim to completeness and correctness. It is intended as
a guideline, and no legal claims of any kind or nature can be derived from it against GF BETON GmbH.
Photo 1
Preparatory work
Preparatory operations can include cleaning of the
track ballast, horizontal and vertical subgrade and
track bed adjustment, fitting of fibrous web mats,
geo textiles, cable channels and similar measures.
The gauge must be checked..
The maximum permissible wear of the rail head is
5 mm (3 mm with additional wheel tyre wear)
Prerequisite for the installation is that the rail is in
its final/desired position Photo 1: The BODAN
materials can be deposited directly next to the
construction site. Please do not stack the pallets
on top of each other
Diagram 1
Diagram 1
A .... Check rail gauge

1435 mm; 1067 mm; 1000 mm; 760 mm etc.
B .... Check sleeper spacing
600 mm; special spacings
C .... ANGLE: The right (90°) angle must be
kept.
Photo 2:
See Photo 2:
Please make use of the track curve

gauge?
Photo 3 Photo 3:
Checking the sleeper spacing.
The centre distance of the rail fastenings must be
600 mm.
Care must be taken to insure that the sleepers are
positioned at a right angle to the rails.
The installation is to be "started" in the centre of

the sleeper bay.
Attention should be paid to the tolerances of the

sleeper separation acc.to Sleeper Separation for
BODAN Level Crossing attached to the Installation
Guide!
G:\GMUNDNER-MANAGEMENT\WERBUNG - Fa GF\Einbauanleitung BODAN\Einbauanleitung ab 10.2009 de-e-fr\Englisch\Einbauanleitung Zusammenstellung für Wandlung engl\LOGOINSTALLATION GUIDE BODAN Level Crossing new 02.02.2011e.doc
Page 1 of 8
Diagram 2 Installation plan
Diagram 2 B ..... The 600 mm sleeper spacing corresponds
to the width of the internal panels
(IP) (standard). Other dimensions on
request (650 mm or so)
D ..... The "start" of the panel installation is to
be marked on the rail, it is to be positioned
centrally between the sleepers and must
of necessity be aligned with the rail/road
axis of coordinates.
New: At the beginning resp. end of the level
crossing the end bearing edge beams
(l=75/105/135/165cm) are to be installed. Normally
these will project beyond the covering length on
both sides for approx 15cm.
Drawing 1:
Foundation:
Normally the working width of the foundation
trench is 600 mm. The depth, measured from the
upper edge of the rail head, is - depending on
adaptation to the course of the road - up to a
maximum of approx. 600 mm. The foundation beam
WUB is placed onto approx. 50 mm of a granular
subbase (e.g. mineral aggregate mixture 0/16).
Please get information about possible alternatives.
Diagram 3 Diagram 3
A ..... Gauge
E ..... Sleeper length up to 2.60 m
F …. Foundation distance up to approx. 2.72 m
with AP 750 and up to 4.13m with AP 1470
G ....Height from upper rail head edge to upper
edge of foundation normally is 28 cm incl.
1 cm levelling layer min. C50/60.
Tolerance levelling layer –0.2/+0.5 cm
See also attachment:

Plan No. 507: “Detail Distance WUB“
Please make use of the levelling gauge for getting
the upper edge of the foundation !
Prefabricated foundation beams:

The levelling gauge is adjusted to height T =
approx. 58 cm (standard).
This corresponds to the height of the rail upper
edge down to the upper edge of the granular
subbase in compacted condition.
Photo 5:
After compacting the height T= 58 cm is to be
Photo 4:
checked again and to be levelled out, if
necessary, with gravel.
Photo 4 / Photo 5
Making use of the levelling gauge, and
compacting the subbase for the foundation beam
WUB.
Page 2 of 8
Raising and lowering of the foundation beams WUB Drawing 2:
and bearing edge beams (AST):
For the raising and lowering of the foundation beam

and the bearing edge beame (AST) the values as give
the tablele Amount of Superelevation AP 750 (see
attachment: Plan No. 16) and the values of the table
Amount of Superelevation AP 1470 (see attachment:
No. 504) apply.
Also see attachment::

Plan No. 501 and Plan No. 502: “Schematic
Representation of AP Raising and Lowering"
Photo 6: Photo 7: Mounting the foundation beams WUB

Foundation beam WUB
Photo 8:
Levelling layer between foundation beam WUB
and bearing edge beam (AST/H, AST/HD, AST/HL):
The levelling gauge is adjusted to the height

T = 27 cm (standard).
Apply levelling concrete, min. C50/60, approx. 1.0
to 1.8 cm onto the pre-wetted prefabricated
foundation beam WUB and level off *in sections
with the levelling gauge.
*in sections: Choose sections in such dimensions

that the levelling layer will not become hard
before the AST is set.
Diagram 4: Diagram 4
F ...Foundation distance see Diag.3 and Drawing 1

H ..Distance rail to bearing edge beam AST H
H = 1465 mm with AP1470 + 10 mm for DS
H = 745 mm with AP750 + 10 mm for DS
Please make use of the stone gauge? for creating

the distance!
H = To make sure that the panels will be

securely seated we recommend to remain below
the above detailed planned dimensions by up to 3
mm.
Page 3 of 8
Securing bolt and recess in the bearing edge beam Drawing 3:
Outside of the hardened shoulder of the road

securing bolts are to be drilled in and mounted on
the foundation beam to prevent any slipping
dislocation of the bearing edge beam.
See attachment:
Plan No. 530: “Mounting of Securing Bolt AST“,

Plan No. 531: „At Both Ends of the Level
Crossings“.
Securing of the bearing edge beam by additional in- Skizze 4:

situ concrete wedge:
In the case of LCs with extremely diagonal traffic
additional securing of the bearing edge beam by an
in-situ concrete wedge (asphalt concrete) is
required as well. This in-situ concrete wedge will
reach from the upper edge of the foundation beam
up to approx. 5 cm below the upper edge of the
bearing edge beam and must be carried out over
the entire width of the excavation right to the
existing hardened ground structure.
Also see attachment:
Plan No. 507: “Detail Distance WUB“
Pay attention to the road construction guidelines!
I ..... a) Inserting of rubber profiles for the
external panels (1. PA300 + 2. PA600 + .)
b) Mounting external panel, as shown.
Please use the special tool set for transporting and

mounting the panels !
PLEASE NOTE: After mounting the panel, check if
the same really is lying on the rubber bearing strip
(GS)!
Depending on the local situation, mounting can

also be started with the internal panels, followed
by the external panels
J ..... Pressing in of the external panel, as

shown.
Please use the special tool set for mounting the

panels !
Page 4 of 8
Photo 9:
Photo 9:
Mounted external panels AP with bearing edge

beams and Lupolen
® (DS) strips for compensating adjusting errors

after the Plugging.
Diagram 7: Diagram 7:
L ..... a) Inserting of rubber profiles for the

internal panels (1. PIU300 + 2. PIU600)
First and last internal profile PIU300 L/R
b) Mounting internal panel, as shown.
Please use special tool set for transporting and

mounting the panels
Photo 10:
Photo 10
Inserted rubber profiles (PIU) for the internal

panels (IP).
The rubber profiles are equally applied to the
second rail.
After resting the panel on the rail head the panel

is to be pressed, using the "wedge mounting
lever", into the direction
M ..... of the fish plate chamber of the opposite

rail, and
N ..... then the panel is lowered onto the lower
rubber profile (PIU) at the mounting side.
Please use the special tool set for transporting

and mounting the panels!
Page 5 of 8
Diagram 9:
Diagram 9:
O ..... using the wedge mounting lever (KH) the
panel is pressed down in oder to laterally insert
the upper rubber profile (PIO).
Both internal and external panels are to be fit in

directly/precisely touching their contact surfaces.
Please use the special tool set for transporting

and mounting the panels !
Plan 532: BODAN Level Crossing at Curved Track
In the case of a curved track the plastic wedges

provided by the manufacturer are to be fastened
to the internal resp. external panels - with the
included fastening pins - at the spots designated
in the panels.
Warning! Wedges not properly fastened can

cause accidents.
Also see attachment:

Plan No. 532: “Mounting Instruction Wedges“
Deflector plate (KAL) and panel retainer (PLH) are Photo 11

fitted after mounting the panels, at each rail and at
both ends of the BODAN level crossing.
The clamp panel retainers are to be fixed directly
in front of the first rail.
Please note: Before leaving the LC all the panel
retainer adjusting screws must be re-tightened
resp. secured!
For all LCs: The AST panel holders for securing
against longitudinal movement, as provided, must
be mounted to the bearing edge beams (panels
and rubber bearing strips).
For all level crossings applies: The panel retainers
provided for the end bearing edge beams as a
securing tool against longitudinal creep must be
mounted on the end bearing edge beams.
See details end bearing edge beam. Plan. No. 534
Photo 12
Work site Connection BODAN Level Crossing with

Road Surface:
The work site has to be compacted with a suitable

compactor after re-filling, following the relevant
road construction guidelines (section on
foundation and substructure).
Proper compacting will prevent a gradual

dislocation of the foundation beam.
Page 6 of 8
Drawing 5:
Road Connection Asphalt to Bearing Edge Beam

(AST):
The upper edge of the asphalt is to be carried out

with its surface lying 1 cm higher than the upper
edge of the bearing edge beam (AST).
Tolerance ± 0.3 cm
Drawing 6:
Maintenance BODAN Level Crossing
In order to realize as long a service life of the

BODAN level crossing as possible the LC should
be visually checked no less than twice a year.
A check list of the maintenance and service points

can be found in the attachment: “BODAN
Maintenance Manual“
Photo 13 Level Crossing, Austria Photo 14 Level Crossing, Japan
Photo 15 Level Crossing, Thailand Photo 16 Level Crossing, Germany
Page 7 of 8
Diag. 1 Diag. 1
Le-BODAN
The two panels are to be, as a pair,
● linked together and, as a folded pair,
● lowered down onto the rubber profiles, and then
● laid, as a folded pair, between the rails.
● Also see Photo 1 to Photo 6
WARNING: Risk of injury !

Do not let any objects or body parts project into
the open gap of the folded panel pair !
Photo 1: Le-EHB-01.jpg Photo 2: Le-EHB-02.jpg

The panel with the tool set The two panels are linked together

The two panels are lifted as a folded pair The two panels are lowered into the mounting position

The two panels as a mounted pair –tools hanging loosely The two panels are being joined
Date of documentation : 17.Mai 2010 Photography : GF- Grafik

We cannot be held liable for any defects arising from faulty installation, inadequate routine maintenance work and neglected maintenance and
servicing procedures.
Page 8 of 8
Gmundner Fertigteile Ges.m.b.H & Co KG
Werk: Unterthalham Straße 1, A - 4694 OHLSDORF BODAN
Gleiseindeckungssysteme
Tel.:++43 -(0)7612 – 63065-0 Fax.:++43 - (0)7612 - 63065-31 Level crossing systems
e-mail: gf.bodan@gmundner-ft.at www.gmundner-ft.at
Prepared by: GH
BODAN MAINTENANCE MANUAL Created on : 15 June.2010
Printed on: 07.02.2011 14:22:00
All rights reserved. Subject to technical modifications. Techn. status: 05/10
Precautionary Measures
Safety regulations, directives, instructional leaflets etc. of the relevant railway companies must be complied with.
Safety regulations, ordinances, instructional leaflets etc. of the road traffic authorities must be complied with.
Prior to any maintenance work at the railway facilities safeguarding measures have to be taken in accordance with
the relevant regulations.
Maintenance Measures
The operator has to visually check the level crossings once a year. At level crossings with more than 15,000 load
cycles per day (1 load cycle = one vehicle axle) the frequency of this visual inspection has to be increased
accordingly (not less than twice a year
Rubber profiles are subject to wear and must therefore be replaced depending on traffic load and degree of wear
Damaged BODAN level crossing panels have to be exchanged resp. replaced depending on the extent of damage.
Check List
Line: Location: Line kilometre:
Office: Inspector: Date:
Initiate
Maintenance and Service Points Measures measures
Yes No
Visual check of the BODAN level crossing Damaged BODAN level crossing panels are to
panels for mechanical damage. be replaced.
Note to Pos ago:
Visual check of the BODAN level crossing Cracks of up to 0.3 mm width do not require any
panels for cracks measure, cracks of more the 0.3 mm width
should be filled and sealed with resin resp. be
pressed out.
Note to Pos ago:
Reprinting, any kind of reproduction, including excerpts or in other media or data carriers, require(s) the permission by the management of Gmundner Fertigteile Ges.m.b.H &
Co KG, Unterthalhamstrasse 1, A-4694 Ohlsdorf
G:\GMUNDNER-MANAGEMENT\WERBUNG - Fa GF\Einbauanleitung BODAN\Einbauanleitung ab 10.2009 de-e-fr\Englisch\Einbauanleitung Zusammenstellung für Wandlung engl\MAINTENANCE MANUAL Wartungsblatt (E)
10.08.2010.docCopyright:
Page 1 of 4
Prepared by: GH
Printed on: 07.02.2011 14:22:00
Initiate
Yes No
Note to Pos ago:
Visual check of the connection to the road: If the traffic has caused the asphalt surface to be
Joint asphalt – bearing edge beam lower with relation to the bearing edge beam,
repair work is required in that area (road
connection 10 mm higher than bearing edge
beam).
Note to Pos ago:
Visual check of the bearing edge beams for If the bearing edge beams have become lowered
height and level position and lateral due to traffic load or unfavourable ground
dislocation. conditions, the height differences in that area are
to be levelled out. If the lowering of the bearing
edge beams is not fixed in time that may cause
damage to the BODAN level crossing panels.
Note to Pos ago:
Visual check of the panel retainers and If necessary, the screws and/or nuts have to be
deflector plates for tight and secure seat of re-tightened.
the screws and nuts
Note to Pos ago:
Check of the BODAN level crossing panels If the BODAN level crossing panels move or are
for movements (tilting, lowering, rattling) by lowered considerably, the rubber profiles are to
walking over them. be checked for wear. Lowerings or considerable
movements of the internal panels can also be
caused by a widening of the gauge. The gauge is
to be checked.
Note to Pos ago:
Check of the rubber profiles for correct The position of the rubber profiles is to be
position (slow dislocation of the rubber corrected; damaged, worn rubber profiles are to
profiles) be replaced.
Check of the rubber profiles for wear
Page 2 of 4
Prepared by: GH
Printed on: 07.02.2011 14:22:00
Initiate
Yes No
Note to Pos ago:
Visual check of the distancing strips for correct If distancing strips show any deviations they are to be
height, dislocation or mechanical damage. fastened to the bearing edge beams or to be replaced.
Note to Pos ago:
At curved track - visual check of the radius wedges

for correct height, wear and mechanical damage. If the radius wedges show any deviations they are to
be re-fastened to the BODAN level crossing panels or
to be replaced
Note to Pos ago:
In case of imminent danger

The operator has to be informed immediately
Note to Pos ago:
A documentation of the maintenance measures carried out has to be produced and to be given to the operator.
Note to Pos ago:
Signed _______________________________ on _______________________
Proof of changes to the previous state of edition
Changed Points/Items Kind of Change Who Date

First release Reference to warranty terms and conditions 2006 GH 02 Oct 2006
Page 3 of 4
Prepared by: GH
Printed on: 07.02.2011 14:22:00
Page 4 of 4
Prepared by: GH
SLEEPER SEPARATION Created on: 19.10.2009
Printed on: 07.02.2011 14:23:00
Sleeper Separation for BODAN Level Crossing
Basics
The centre distance of the rail fastening at straight rails tracks must be 600 mm (650 mm or so) in the case of standard
level crossings. At a curved track the sleeper spacings have to be calculated on the basis of the tables B2-Curved
Track AP 750 (Attachment 1) and B2 Curved Track AP 1470 (Attachment 2) according to the required radii.
Care must be taken to insure that the sleepers are positioned at a right angle to the rails. The sleeper separation should
be continued at both ends of the level crossings for at least three more sleepers.
The sleeper separation has to be measured on the running strip.
Tolerance of the Sleeper Separation
The tolerance of the sleeper separation depends on the width of the rail fastening (track superstructure fastening).
The individual tolerance values can be seen from Table 1.
The stated tolerance values refer to a single fastening and to a package of 5 sleepers.
Formula for 5 sleepers: 4 x sleeper separations ±.1 x tolerance = min./max. sleeper sum
(Formula for length of panel covering: Number of sleepers x separation ±.1 x tolerance = sleeper sum)
At a curved track the tolerance dimension is the same, the package dimension has to be increased by the package
value (4 x X1 x 0.5 from the Curvature Table).
Table 1 for sleeper separation 600 mm without curved track
1 sleeper separation Four sleeper bays Five sleepers

Width of the sleeper One sleeper bay
600 mm tolerance mm (separation 600 mm)
fastening mm tolerance mm
Min. Max. Min Max
180 ±5 595 605 ±5 2395 2405
170 ±5 595 605 ±5 2395 2405
160 ± 10 590 610 ± 10 2390 2410
150 ± 10 590 610 ± 10 2390 2410
140 ± 15 585 615 ± 15 2385 2415
130 ± 20 580 620 ± 20 2380 2420
120 ± 25 575 625 ± 25 2375 2425
110 ± 30 570 630 ± 30 2370 2430
100 ± 35 565 635 ± 35 2365 2435
≤ 100 ± 35 565 635 ± 35 2365 2435
Proof of changes to the previous state of edition

Changed Points/Items Kind of Change Who Date
Prepared by Approved on 17 Jan 2008

Mister Herbert Gruber Mister Dipl. Ing. Bernhard Neumann
Copyright: Reprinting, any kind of reproduction, including excerpts or in other media or data carriers, require(s) the
permission by the management of Gmundner Fertigteile Ges.m.b.H & Co KG, Unterthalhamstrasse 1, A-4694 Ohlsdorf.
G:\GMUNDNER-MANAGEMENT\WERBUNG - FA GF\EINBAUANLEITUNG BODAN\EINBAUANLEITUNG AB 10.2009 DE-E-FR\ENGLISCH\EINBAUANLEITUNG ZUSAMMENSTELLUNG
FÜR WANDLUNG ENGL\SLEEPER SEPARATION FOR BODAN LEVEL CROSSING E 15.06.2010 S2.DOC
Page 1 of 2
Prepared by: GH
SLEEPER SEPARATION Created on: 19.10.2009
Printed on: 07.02.2011 14:23:00
Attachment 2
Attachment 1
Copyright: Reprinting, any kind of reproduction, including excerpts or in other media or data carriers, require(s) the
permission by the management of Gmundner Fertigteile Ges.m.b.H & Co KG, Unterthalhamstrasse 1, A-4694 Ohlsdorf.
G:\GMUNDNER-MANAGEMENT\WERBUNG - FA GF\EINBAUANLEITUNG BODAN\EINBAUANLEITUNG AB 10.2009 DE-E-FR\ENGLISCH\EINBAUANLEITUNG ZUSAMMENSTELLUNG
FÜR WANDLUNG ENGL\SLEEPER SEPARATION FOR BODAN LEVEL CROSSING E 15.06.2010 S2.DOC
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INSTALLATION GUIDE / MAINTENANCE MANUAL

BODAN Level Crossing System and

Gmundner Fertigteile Ges.m.b.H & CoKG. BODAN

A .... Check rail gauge

Please make use of the track curve

The installation is to be "started" in the centre of

Attention should be paid to the tolerances of the

Please get information about possible alternatives.

See also attachment:

Prefabricated foundation beams:

For the raising and lowering of the foundation beam

Also see attachment::

Photo 6: Photo 7: Mounting the foundation beams WUB

The levelling gauge is adjusted to the height

*in sections: Choose sections in such dimensions

F ...Foundation distance see Diag.3 and Drawing 1

Please make use of the stone gauge? for creating

H = To make sure that the panels will be

Outside of the hardened shoulder of the road

Plan No. 530: “Mounting of Securing Bolt AST“,

Securing of the bearing edge beam by additional in- Skizze 4:

Please use the special tool set for transporting and

Depending on the local situation, mounting can

J ..... Pressing in of the external panel, as

Please use the special tool set for mounting the

Mounted external panels AP with bearing edge

® (DS) strips for compensating adjusting errors

L ..... a) Inserting of rubber profiles for the

Please use special tool set for transporting and

Inserted rubber profiles (PIU) for the internal

After resting the panel on the rail head the panel

M ..... of the fish plate chamber of the opposite

Please use the special tool set for transporting

Both internal and external panels are to be fit in

Please use the special tool set for transporting

In the case of a curved track the plastic wedges

Warning! Wedges not properly fastened can

Also see attachment:

Deflector plate (KAL) and panel retainer (PLH) are Photo 11

Work site Connection BODAN Level Crossing with

The work site has to be compacted with a suitable

Proper compacting will prevent a gradual

Road Connection Asphalt to Bearing Edge Beam

The upper edge of the asphalt is to be carried out

Maintenance BODAN Level Crossing

In order to realize as long a service life of the

A check list of the maintenance and service points

Photo 13 Level Crossing, Austria Photo 14 Level Crossing, Japan

Photo 15 Level Crossing, Thailand Photo 16 Level Crossing, Germany

WARNING: Risk of injury !

Photo 1: Le-EHB-01.jpg Photo 2: Le-EHB-02.jpg

Photo 3: Le-EHB-03.jpg Photo 4: Le-EHB-07.jpg

Photo 5: Le-EHB-05.jpg Photo 6: Le-EHB-06.jpg

Date of documentation : 17.Mai 2010 Photography : GF- Grafik

Line: Location: Line kilometre:

Office: Inspector: Date:

Note to Pos ago:

Note to Pos ago:

Note to Pos ago:

Note to Pos ago:

Note to Pos ago:

Note to Pos ago:

Check of the rubber profiles for wear

Signed _________ on _