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Installation Instructions For The

RFR Flange Insert System

Installing RFR flangeway inserts is a simple and quick procedure. It requires no special tools or equipment to complete the job. A lining bar, hand-held tamping bar or square-nosed shovel is all that is necessary. Soapy water, using ordinary dishwashing soap, helps lubricate the inserts during installation.

The RFR Flange Insert System is designed for use with common standard full-depth concrete panels or full-depth timber planks. RFR inserts fit all common RE rail sections, accommodate any type of rail fastener, and works with or without rail anchors.

THE FOLLOWING STEPS WILL FACILITATE THE JOB

CLICK ON PICTURE TO SEE A LARGER IMAGE

This is a BNSF Mainline in Emhouse, Texas. When the crossing was first installed, it was installed with 115# RE rail. The following year, as part of a rail changeout program, the rail was changed to 136# RE rail. The rubber was re-used with the new rail, and the roadway approaches were left in tact.

PHOTOGRAPH INSTRUCTION ILLUSTRATION

FOREGROUND - previously installed RFR Flange Insert System inserts have been removed and will be reinstalled upon completion of rail changeout.

Position field inserts along the outside rail, making sure lower tip of insert is between spike or other type of rail fastener and against base of rail.

Place field crossing panel tightly against insert. Connect next insert with connecting pin. Repeat through completion. RFR field inserts act as a template, ensuring proper placement of panels in track. Field inserts are connected as crossing panels are installed.

Panel compressing rubber against rail.

Speed Swing or Boom Truck weight completes the position of the panel.

Panel and field inserts completed.

Gauge section with concrete panels in place. Positioned with equal space on both sides.

End view of center panels being installed.

After all center panels have been placed between the rails, layout the RFR Pop-Down ® Gauge Inserts as shown. Once the guage inserts are laid-out, end-to-end, connect them together with the connector pins at each joint. Be sure to match profiles when connecting.

Starting at one end of the crossing, push gauge insert into gap between center panel and rail, rotating the insert around the railhead.

Using a lining bar, drive gauge insert down into flangeway, angling bar toward the center panel.

After the gauge insert is driven to proper depth, pinch the seal flap underneath the railhead with a tamping bar or square-edged shovel.

*TIP FOR THE FINAL STEP OF THE CROSSING INSTALLATION - Tack weld a steel strap on each vertical face of the crossing to prevent movement.

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PHOTOGRAPH	INSTRUCTION		ILLUSTRATION
	FOREGROUND - previously installed RFR Flange Insert System inserts have been removed and will be reinstalled upon completion of rail changeout.
	Position field inserts along the outside rail, making sure lower tip of insert is between spike or other type of rail fastener and against base of rail.
	Place field crossing panel tightly against insert. Connect next insert with connecting pin. Repeat through completion. RFR field inserts act as a template, ensuring proper placement of panels in track. Field inserts are connected as crossing panels are installed.
	Panel compressing rubber against rail.
	Speed Swing or Boom Truck weight completes the position of the panel.
	Panel and field inserts completed.
	Gauge section with concrete panels in place. Positioned with equal space on both sides.
	End view of center panels being installed.
	After all center panels have been placed between the rails, layout the RFR Pop-Down ® Gauge Inserts as shown. Once the guage inserts are laid-out, end-to-end, connect them together with the connector pins at each joint. Be sure to match profiles when connecting.
	Starting at one end of the crossing, push gauge insert into gap between center panel and rail, rotating the insert around the railhead.
	Using a lining bar, drive gauge insert down into flangeway, angling bar toward the center panel.
	After the gauge insert is driven to proper depth, pinch the seal flap underneath the railhead with a tamping bar or square-edged shovel.