Railway infrastructure
PREFABRICATED RAILWAY LEVEL CROSSING WITH AN INTEGRATED TRANSITION ZONE
The CONTRACK prefabricated railway level crossing with an integrated transition zone is a technological innovation that addresses the most critical gap in previously available level crossing structural solutions.
About the product
CONTRACK railway crossing
Time Is Money
Modern railway infrastructure projects are carried out under increasing time pressure. Limited track possession windows, high traffic management costs, and the need to maintain uninterrupted rail operations mean that every hour of construction has a direct impact on both the project budget and schedule. The CONTRACK prefabricated railway level crossing was developed in response to these challenges, offering a solution that significantly accelerates project delivery while maintaining the highest standards of quality and durability.
Thanks to the use of prefabricated structural elements, on-site installation is fast, efficient, and predictable. This minimizes the risk of delays and enables optimal use of the available construction windows.
Structure
CONTRACK Railway Level Crossing System
The CONTRACK railway level crossing system is an innovative solution featuring an integrated transition zone.
What is the transition zone and what challenges does it present?
Conventional ballastless level crossing systems have traditionally ended at the edge of the prefabricated slab, leaving unresolved the challenge of creating a smooth transition to the conventional ballasted track structure. As a result, the greatest operational issues occurred precisely within the transition zone, where the structure experiences a sudden change in stiffness.
As railway vehicles pass over this area, increased dynamic forces are generated, leading to differential settlement, deterioration of track geometry, higher maintenance costs, and accelerated wear of both the track structure and the substructure. Despite the high durability of the ballastless crossing itself, the transition zone has remained the weakest element of the entire system.
How does CONTRACK address these challenges?
CONTRACK technology is among the first to integrate a complete transition zone into the level crossing structure, effectively eliminating the problem of abrupt stiffness changes.
The solution consists of two complementary zones working together:
- Track reinforcement zone – steel sections integrated with the prefabricated slab gradually transfer loads from the ballastless crossing structure to the conventional ballasted track, ensuring a smooth load distribution.
- Substructure reinforcement zone – an additional stabilized layer is constructed before and after the crossing, reducing differences in subgrade stiffness and improving overall structural performance.
The combination of these two solutions provides a seamless transition between different track structures, reduces dynamic impacts, minimizes differential settlement, and significantly enhances the durability and long-term performance of the entire track system.
Advantages of the product
WHY CHOOSE THE CONTRACK PREFABRICATED RAILWAY LEVEL CROSSING?
- The first solution to comprehensively address the challenges of the transition zone.
- Prefabricated slabs available in lengths of up to 17 metres.
- Installation of a single-track level crossing within 24 hours, with rails integrated into the slabs during the manufacturing process.
- Installation without dismantling the overhead catenary system, thanks to the use of PWP gantry systems.
- Optional integrated features, including built-in drainage and/or embedded road-level lighting.
Modernisation and Maintenance
Modernisation with CONTRACK Technology
The CONTRACK prefabricated railway level crossing is an ideal solution for both new railway infrastructure projects and modernisation works.
Its rapid installation makes the system particularly suitable for upgrading existing level crossings, where minimising infrastructure downtime is essential.
The use of prefabricated components also reduces the scope of future maintenance activities. High manufacturing quality, precision production, and durable materials ensure long service life with minimal maintenance requirements.
Should future infrastructure upgrades become necessary, the prefabricated system enables the efficient replacement or reconstruction of selected components, reducing both time and operational disruption.
Additional Features
CONTRACK technology is synonymous with tailor-made solutions, and our prefabricated railway level crossings are no exception.
The prefabricated crossing slabs can be equipped with a range of integrated features, including:
- integrated drainage systems built directly into the slab,
- custom slab extensions to meet project-specific requirements,
- embedded road-level lighting to enhance safety, particularly at challenging or high-risk locations.
These additional options allow each crossing to be adapted to the specific operational and technical requirements of the project.
Durability and Quality
Durability and Quality of the Railway Level Crossing
Manufacturing prefabricated components under controlled factory conditions ensures a high level of consistency in technical parameters and a quality of workmanship that is difficult to achieve with systems constructed entirely on site. Every component is produced in accordance with stringent quality standards, resulting in outstanding durability, high load resistance, and a long service life.
An additional pillar of quality is the material engineering support provided by SIKA. Thanks to the company's extensive experience and specialist expertise, the optimal selection of materials and production technologies is ensured, further enhancing the durability, performance, and long-term reliability of the railway level crossing.
Project Execution
Technology Designed Around the Project
A SOLUTION DEVELOPED FOR SHORT TRACK POSSESSION WINDOWS
CONTRACK prefabricated railway level crossings have been specifically designed for projects carried out within highly restricted track possession windows. Thanks to a high degree of prefabrication, most construction work is completed during the manufacturing stage, significantly reducing on-site installation time and minimising the amount of work required directly on the track.
A key advantage of the system is the integration of the rails into the prefabricated structure during production. This approach minimises the number of activities that must be carried out during track possession, enabling installation to be completed in as little as 24 hours for a single-track level crossing. This represents a major benefit for investors and infrastructure managers, for whom every hour of track closure results in additional costs and operational disruption.
As a result, CONTRACK level crossings are ideally suited for the modernisation of existing infrastructure, high-traffic railway lines, and any project where the rapid restoration of full operational functionality is essential. Shorter possession times not only reduce costs but also improve schedule predictability and minimise the risk of project delays.
PLANNED FROM START TO FINISH
The success of projects carried out within short possession windows depends not only on the product itself but also on efficient logistics and installation planning. That is why CONTRACK provides a comprehensive delivery and installation concept, taking into account the construction schedule, the availability of dedicated transport and installation equipment, and the specific conditions at the construction site. As with all CONTRACK solutions, the railway level crossing is not merely a prefabricated slab—it is a complete technology.
An important feature of the system is the possibility of installing the level crossing using PWP gantry systems. This enables the prefabricated elements to be installed without dismantling the overhead catenary system, eliminating additional work and significantly reducing project execution time.
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