TECHNICAL NOTE Civil Issue Date 27/03/2018 Expiry Date Until Withdrawn

TECHNICAL NOTE Civil Issue Date 27/03/2018 Expiry Date Until withdrawn

CCT 18/05 Standard Concrete Level Crossing Design – Rev D

AUDIENCE MAIN POINTS VERSION HISTORY

∼ Civil & Structures Engineers ∼ Rev D of the Standard Concrete Level Crossing design ∼ Version 1.0

∼ Project Delivery - ∼ Requirement to introduce interface between Rail section Superintendents, Engineers and and external concrete panel supervisors ∼ Addition of extra U-Shape bars at corners ∼ Maintenance Delivery– Superintendents, Engineers and supervisors

1. Introduction

This technical note is issued to identify a design change to the standard concrete level crossing (drawing no. CC000234). Due to an identified cracking issue on previously constructed level crossings, additional requirements as identified in this Technical Note have been added. These requirements are additional to the design details previously shown on drawing CC000234 Rev “C”, and are now notated as Rev “D” on the currently issued drawings. This Technical Note will remain in force until the standard design drawing is updated to amendment “D” by the designer.

Changes includes: 1) Addition of U-Shape N12 bars at top and bottom end of both external concrete panels as shown in Figure below.

Disclaimer. This document was prepared for use on the CRN Network only. John Holland Rail Pty Ltd makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by JHR. JHR accepts no liability whatsoever in relation to the use of this document by any party, and JHR excludes any liability which arises in any manner by the use of this document.

Copyright. The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of JHG. Page 1 of 2

CCT 18/05 Issue Date 27/03/2018

2) Introduce interface between the rail section and the external concrete panels as shown in Figure below.

The materials specified are typical concrete jointing products. Jointflex is a Parchem product and is basically a compressible filler (see attached data sheet). The Jointflex will need to be cut around the bolts for the guard angle and the denso tape around the bolts will help to keep it in place. When concreting care needs to be taken that the Jointflex remains in place and as the concrete pour exerts pressure it should follow the profile of the rail holding it in place.

Jointflex (Parchem)

Emer-Seal Roadseal, (also a Parchem product), is a silicone rubber joint sealant. This is applied after concreting to seal the joint filler gap. (see attached data sheet). The Roadseal is not to be applied until the concrete has attained a minimum 25MPa strength.

Attachments: - CC000234 – Rev D - Jointflex – Technical Data - Roadseal – Technical Data

Authorised for issue

Stewart McCarthy A/Principal Track & Civil Engineer

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ȭ I:\NBIF\PROJECTS\NB00116\DELIVERABLES\DRAWINGS\NB00116-ST-DG-0001.DWG File Plotted 22 Jul 2016 - 11:37am SIGNATURE Principal Track & Civil Engineer TITLE Ⱦ 23/07/2016

DATE Plot Date & Time This drawing and the information contained thereon have been created solely for a particular purpose and client. This is protected by copyright. You may not reproduce any of it in any DRAWN form without the written permision of JHR-CRN. If you do, you may have to pay damages to JHR-CRN or you may be prosecuted. DESIGNED STANDARD DRG CHECK 100 Christie Street ALL LINES St Leonards NSW 2065 Australia Telephone: 02 9928 2100 DESIGN CHECK CONCRETE ROAD LEVEL CROSSING Facsimile: 02 9928 2500 GUARD ANGLES C 20.07.16 REISSUED FOR CONSTRUCTION P.T. D.T. APPROVED PROJECT No. NB00116 B 16.05.16 REISSUED FOR CONSTRUCTION P.T. D.T. FILE No. SHEET 1 OF 4 A1 SHUTTLA A 07.04.15 ISSUED FOR CONSTRUCTION L.L. D.T. STATUS: ISSUED FOR CONSTRUCTION VERIFIED APPROVED AMD REFERENCE DESCRIPTION Plotted by SIGN./DATE SIGN./DATE C DF 801*554 A1 REINFORCEMENT GENERAL

PREPARATION UNDER SLABS ON GRADE

CONCRETE

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DESIGN I:\NBIF\PROJECTS\NB00116\DELIVERABLES\DRAWINGS\NB00116-ST-DG-0002.DWG File Plotted 22 Jul 2016 - 11:59am Ⱦ SIGNATURE Principal Track & Civil Engineer TITLE 23/07/2016

DATE Plot Date & Time This drawing and the information contained thereon have been created solely for a particular purpose and client. This is protected by copyright. You may not reproduce any of it in any DRAWN form without the written permision of JHR-CRN. If you do, you may have to pay damages to JHR-CRN or you may be prosecuted. DESIGNED STANDARD DRG CHECK 100 Christie Street ALL LINES St Leonards NSW 2065 Australia Telephone: 02 9928 2100 DESIGN CHECK CONCRETE ROAD LEVEL CROSSING Facsimile: 02 9928 2500 TYPICAL SECTION C 20.07.16 REISSUED FOR CONSTRUCTION P.T. D.T. APPROVED PROJECT No. NB00116 1 TRACK B 09.09.15 REISSUED FOR CONSTRUCTION I.C. D.T. FILE No. SHEET 2 OF 4 A1 SHUTTLA A 07.04.15 ISSUED FOR CONSTRUCTION L.L. D.T. STATUS: ISSUED FOR CONSTRUCTION VERIFIED APPROVED AMD REFERENCE DESCRIPTION Plotted by SIGN./DATE SIGN./DATE C DF 801*554 A1 ȭ ȭ

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Ⱦ I:\NBIF\PROJECTS\NB00116\DELIVERABLES\DRAWINGS\NB00116-ST-DG-0003.DWG File Plotted 20 Jul 2016 - 9:12am SIGNATURE Principal Track & Civil Engineer TITLE 23/07/2016

DATE Plot Date & Time This drawing and the information contained thereon have been created solely for a particular purpose and client. This is protected by copyright. You may not reproduce any of it in any DRAWN form without the written permision of JHR-CRN. If you do, you may have to pay damages to JHR-CRN or you may be prosecuted. DESIGNED STANDARD DRG CHECK 100 Christie Street ALL LINES St Leonards NSW 2065 Australia Telephone: 02 9928 2100 DESIGN CHECK CONCRETE ROAD LEVEL CROSSING Facsimile: 02 9928 2500 TYPICAL SECTION C 20.07.16 REISSUED FOR CONSTRUCTION P.T. D.T. APPROVED PROJECT No. NB00116 2 AND 3 TRACKS B 09.09.15 REISSUED FOR CONSTRUCTION I.C. D.T. FILE No. SHEET 3 OF 4 A1 SHUTTLA A 07.04.15 ISSUED FOR CONSTRUCTION L.L. D.T. STATUS: ISSUED FOR CONSTRUCTION VERIFIED APPROVED AMD REFERENCE DESCRIPTION Plotted by SIGN./DATE SIGN./DATE C DF 801*554 A1 ȭ ȭ ȭ ȭ

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Ⱦ I:\NBIF\PROJECTS\NB00116\DELIVERABLES\DRAWINGS\NB00116-ST-DG-0004.DWG File Plotted 21 Jul 2016 - 10:17am SIGNATURE Principal Track & Civil Engineer TITLE 23/07/2016

DATE Plot Date & Time This drawing and the information contained thereon have been created solely for a particular purpose and client. This is protected by copyright. You may not reproduce any of it in any DRAWN form without the written permision of JHR-CRN. If you do, you may have to pay damages to JHR-CRN or you may be prosecuted. DESIGNED STANDARD DRG CHECK 100 Christie Street ALL LINES St Leonards NSW 2065 Australia Telephone: 02 9928 2100 DESIGN CHECK CONCRETE ROAD LEVEL CROSSING Facsimile: 02 9928 2500 TYPICAL SECTION C 20.07.16 REISSUED FOR CONSTRUCTION P.T. D.T. APPROVED PROJECT No. NB00116 4 TRACKS B 09.09.15 REISSUED FOR CONSTRUCTION I.C. D.T. FILE No. SHEET 4 OF 4 A1 SHUTTLA A 07.04.15 ISSUED FOR CONSTRUCTION L.L. D.T. STATUS: ISSUED FOR CONSTRUCTION VERIFIED APPROVED AMD REFERENCE DESCRIPTION Plotted by SIGN./DATE SIGN./DATE C DF 801*554 A1 Technical Data Jointflex Sheet

Closed cell polyethylene joint filler External walling and cladding Jointflex is used as a readily compressible, low load transfer Uses joint filler in joints surrounding brick infill panel walling. It is Jointflex is a closed-cell polyethylene joint filler for use as an also used as a gap filler, back-up strip and bond breaker to expansion joint filler in brick and blockwork, isolation joints fill open joints in panel construction to provide support for and hinge joints where a readily compressible low load joint sealants. transfer joint filler is required. Jointflex is also used as back-up strips for elastomeric Compression joint in brick infill panel sealants placed in joints of concrete floors subject to foot traffic and light wheel loads. For joints subject to heavy loads or joints in water retaining structures Stiffjoint should be used (see separate Technical Data Sheet). Back-up/bond breaker strip to support sealants 2 2 5 1 Bridge decks, abutments, pier hinge joints 3 or 4 Brick and blockwork in building superstructures 1. Jointflex Advantages 2. Suitable joint sealant Readily compressible 3. Blockwork Low load transfer 4. Brick panel external Easily cut on-site 5. Concrete beam Excellent recovery after compression Non-absorbent Properties Rot proof CFC free Form: Cross linked, compressible, closed cell foam sheet Description Colour: Grey Jointflex is a flexible, readily compressible, closed-cell Weathering: Very good weather resistance polyethylene joint filler supplied in sheet form and in rolls of Recovery: Greater than 90% rectangular sections. Jointflex is available in a range of Water absorption: <0.02 g/cm³ widths and thicknesses to suit common applications and can be pre-slit to assist in forming a slot to accept joint sealants. Effects of fire: When tested to AS1503 Pt.3 Jointflex can also be supplied with a self adhesive backing. Spread of flame index 0 Heat evolved index 0 Design Criteria Smoke development 4 index (smoke given off Trafficked surface expansion joint is non-toxic) Being a thermoplastic material, Jointflex will melt. It is 2 combustible but rate of flame spread will be reduced 3 when confined within a joint Nominal density: 25 kg/m³ 1 Chemical resistance: Resists most common acids and chemicals Thermal conductivity: K factor 0.031 WMK 0°C

1. Jointflex 2. Suitable joint sealant 3. Concrete slab

Page 1 March 2008 Jointflex

Application Instructions

Joint sealing slots When used as an expansion or isolation joint filler in brickwork, Jointflex should be positioned to provide for a surface sealing slot of the required dimensions ensuring that the sealing slot is free from mortar droppings or slurry bridging. Jointflex may be fixed into position using a suitable general construction adhesive. Care should be taken not to contaminate the surfaces of the sealing slot with adhesive. Where Jointflex is used as the joint filler no additional bond breaker is necessary. Used as a back-up/bond breaker strip Jointflex serves both; regulate depth of sealing slot required and to ensure movement of the joint sealant is not restricted by adhesion to base of sealing cavity.

Storage There are no special storage requirements for this product, however, it should be stored in the dry and not left exposed to the elements for extended periods, especially in hot climates.

Supply Jointflex sheet thickness: 10, 12, 15, 20, 25, 30, 40 and 50 mm. Jointflex standard sheet size is 2.4 m x 1.2 m. Other sizes of Jointflex are available to specific order. Jointflex is supplied in 25 metre rolls in the following sizes : 10 mm thick: 50, 75, 100, 125, 150, 200, 250 and 300 mm depth Note: other widths are available to specific order.

Important notice A Safety Data Sheet (SDS) and Technical Data Sheet (TDS) are available from the Parchem website or upon request from the nearest Parchem sales office. Read the SDS and TDS carefully prior to use as application or performance data may change from time to time. In emergency, contact any Poisons Information Centre (phone 13 11 26 within Australia) or a doctor for advice.

Product disclaimer This Technical Data Sheet (TDS) summarises our best knowledge of the product, including how to use and apply the product based on the information available at the time. You should read this TDS carefully and consider the information in the context of how the product will be used, including in conjunction with any other product and the type of surfaces to, and the manner in which, the product will be applied. Our responsibility for products sold is subject to our standard terms and conditions of sale. Parchem does not accept any liability either directly or indirectly for any losses suffered in connection with the use or application of the product whether or not in accordance with any advice, specification, recommendation or information given by it.

Parchem Construction Supplies Pty Ltd 7 Lucca Road, Wyong NSW 2259 Phone: 1300 737 787 www.parchem.com.au ABN 80 069 961 968 Page 2 Distributed in New Zealand by: Concrete Plus Ltd 23 Watts Rd, Sockburn 8042 Ph: 03 343 0090 Technical Data Emer-Seal® Roadseal Sheet

High performance, low modulus, high Properties joint movement accommodation, one- Data quoted are typical for these products, but do not component silicone rubber joint sealant constitute a specification.

Uses Form: Non slump, thixotropic paste Sealing joints in: Colour: Concrete Grey Concrete roads & pavements Physical or chemical Chemical cure, moisture Bridge decks and car parks Change: activated Aircraft runways and aprons Hardness (Shore A): 17 +/- 5 Application temperature: Minimum 5°C Advantages Service temperature: Minus 50°C - 150°C Ready to use Tooling time @ 23°C : 20 minutes Easy contractor application Tack free time @ 23°C: 45 - 60 minutes No mixing required Movement accommodation Plus 100% - minus 50% factor: Fast rate of cure Elongation ASTM D412 : 1000% Excellent adhesion to clean dry concrete Chemical resistance to Resistant to dilute acids Excellent weathering - UV and ozone resistant occasional spillage: and alkalis. Not resistant to organic solvents Dispensed from a bulk container by hand or air powered pump Design Criteria Large joint movement accommodation Roadseal is designed for use in joints between concrete pavements. All moving joints should be designed with an Standards Compliance optimum width to depth ratio of 2:1 and an overriding NSW RTA Bridge Decks QA Spec. B312 Ed 3/ Rev 0, 9/98 minimum sealant depth of 10 mm. In all joints either a polyethylene bond breaker tape or backing rod must be used • Type GN - Accepted for use to ensure that the correct width to depth profile is achieved • Type GT - Meets performance requirements (except and to prevent the sealant from adhering to the base of the hardness) joint. The sealant should be applied and tooled so that the sealant surface is about 5 mm below the pavement surface. NSW RTA Rigid Pavements Spec R83.4 Ed 2/Rev 3, 8/99 • Accepted for use Application Instructions

QLD Main Roads - MRS11.82 Joint preparation • Approved for use All concrete to which Roadseal is to be applied must be a QLD Main Roads - Concrete Pavements Spec MRS 11.40 minimum of 14 days old. All joint surfaces must be clean, dry 7/96 Table 4.3.4 and free from any concrete slurry, oil, dirt or loose material, form release or curing compounds. • Suitable for use Saw cut joints must be thoroughly cleaned of all concrete slurry by a high pressure water wash, followed by drying with Description high pressure compressed air. After air blasting the surface Roadseal is a one-part, gun applied, silicone rubber joint water away, the joints must be allowed to dry normally for an sealant designed to effectively seal joints in concrete roads, additional 16 hours. Where atmospheric conditions are not runways, carparks and pavements. The low modulus conducive to good drying e.g. low temperatures, high characteristics of Roadseal allow it to accommodate cyclic humidity or rain; Primer 10 or Primer 13 should be used. joint movements of plus 100% and minus 50%. Roadseal is Where previously sealed joints are to be re-sealed, designed to be applied to joints between concrete pavements mechanically remove all of the existing sealant prior to saw in order to prevent running water from undermining the cutting the joint. Care should be taken not to melt residual pavement. Roadseal also serves to prevent stones from asphaltic sealant and spread it onto the joint faces with the being deposited in the joints which would otherwise lock the hot saw blade. joints and restrict the free thermal movement of adjacent pavement segments. Before application of the Roadseal remove any wind blown debris from the joints with a blast of dry, oil free, compressed air.

February 2011 Page 1 Emer-Seal® Roadseal

An approved closed cell polyethylene backer rod or bond Limitations breaker tape must be installed into the joint before sealant Elastomeric sealants such as Roadseal should not be application. When placing the backer rod allow for a 5 mm applied in close proximity to bituminous materials as these set down of the sealant from the pavement surface. may contain components which can migrate into the sealant and result in staining, reduced performance or a loss of Priming adhesion. Priming is not normally required provided the joint faces are clean and free from any trace of laitance and surface Joints in asphalt roads should only be sealed with Roadseal contamination. Primer 10 is recommended on concrete and SL, an ultra-low modulus version of Roadseal designed for masonry surfaces to achieve the best possible adhesion. A sealing sawn joints in asphalt pavements and abutment primer must be used if the sealant is to be submersed for joints between concrete and asphalt. long periods, such as joints in a flood crossing or where fuel Where asphalt is to be applied over the concrete pavement or chemical spillage may occur. Consult your local Parchem containing the Roadseal, a non-adhesive bond breaker tape sales office for advice on priming. Primer 13 must be used in must be applied over the sealant surface to prevent direct applications where Roadseal is to be subjected to permanent contact with the asphalt and to prevent the asphalt bonding water immersion. to the sealant surface.

Application Estimating Roadseal is applied from 600 ml sausages or bulk containers into the joints using a suitable sealant gun. On larger Packaging projects, an air assisted gun and pump may be used allowing faster application. Within 10 minutes after application, the Roadseal: 600 ml sausage (PC: 610402) sealant must be tooled in order to improve contact with the 20 litre drum (PC: 610401) joint faces, and to lower the sealant surface to a level about 200 litre drum (PC: 610405) 5 mm below the pavement surface. Tooling is essential to Primer 10: 250 ml tin force the sealant to make good contact with the joint faces Primer 13: 250 ml pack (two-part epoxy) and achieve good adhesion. Solvent 10: 4 and 20 litre drums Equipment Coverage Complete high volume application units include an air powered pump, follower plate, hose, gun, and applicator Each 20 litre drum will seal approximately 200 metres of joint nozzle. The extrusion pumps are available with various with a 10 mm wide by 10 mm deep sealant bead. output capacities. The hoses and connections must not allow moisture penetration. Teflon lined hoses are recommended Storage because of their low moisture permeability. It should be Storage life of 18 months in original containers when kept in noted that the rate of sealant delivery is affected by air cool, dry conditions. pressure, hose length, hose diameter and nozzle diameter.

Clean up Equipment may be cleaned of uncured sealant by wiping, or soaking and wiping with Solvent 10. Any sealant allowed to cure becomes very difficult to remove and can only be removed using Solvent 10 in combination with steel wool.