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Innovative

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F o r Tr a n s p o r t a t i o n

BODAN
Highway-Rail Level Grade Crossing System

Design Book

20 Jones Street, New Rochelle, NY 10801 ● Phone: 914.636.1000 ● Fax: 914.636.1282 ● Web: transpo.com
BODAN
®

Polymer Concrete Grade Crossing Systems

Improve Safety and

Reduce Maintenance
®
The BODAN highway-rail grade crossing
system consists of precast polymer concrete
panels that are reinforced with internal
rebar cages. These modular panels transfer
heavy traffic loads directly to the rails.
Panels are held in place using rubber sleeves,
with no permanent attachment to the crossties.
This unique “bridge” concept eliminates direct loading on the ties,
while maintaining a constant level with the rail throughout the life
of the crossing.

®
The BODAN system has low cost maintenence. Removing the panels
takes moments, rather than hours, so it may not be necessary to shut
down an entire crossing to perform routine track maintenance.

®
High-strength polymer concrete material enables BODAN panels to
resist the effects of wear, weather, salt and diesel fuel. The exposed
aggregate surface provides a highly skid-resistant surface even under
wet conditions.

®
BODAN is the only grade crossing system offering optional built-in
flashing warning lights. This is an important safety feature considering
the many vehicles involved in dangerous crossing incidents every year.

®
BODAN is available in various sizes to accomodate installation on
any rail crossing. Existing designs include: single or double track,
curved track, as well as turnouts and switches that require a heavy-duty
crossing surface to handle excessive traffic loads. This system has been
tested with axle loads in excess of 44,000 lbs, making it one of the
most durable crossings in the world today.
 BODAN
®

Polymer Concrete Grade Crossing Systems

®
Physical Properties*
A unique feature for the BODAN grade crossing
Property Unit of Measure Test
surface system is the LED flashing warning light option.
Mechanical
These lights are not intended to be a replacement for
Compressive Strength 14,000 psi (96 MPa) ASTM C-109
gates or signals at active grade crossings, but rather, are a
Flexural Strength 3,200 psi (22 MPa) ASTM C-384
supplemental warning system activated by the same alert
Impact Strength 100 ft. lbs.min. ASTM D-2444
system as gates and signals. The LED fixture is placed
Physical
in the edge beam of the crossing system, the part that
Freeze/Thaw Resistance No Change ASTM C666
serves as the paving stop for the highway.
* To be used as general guidelines only

Features and Advantages

■ Durable, High-Strength Polymer Concrete

■ No Attachment to Crossties
■ Easy to Install Modular Components
■ High Impact and Compressive Strength
■ Chemical and Corrosion Resistant
■ High Load-Bearing Capacity
■ Skid Resistant Surface
■ Low Maintenance
■ Class “A” Fire Rated

20 Jones Street, New Rochelle, NY 10801

Tel: 914-636-1000 ● Fax: 914-636-1282
www.transpo.com ● info@transpo.com
900 l/ 0
6/08 2K 20 0
The Only Grade Crossing System
With Built-in Flashing Warning Lights
TRANSPO’S, Bodan Level-Crossing Safety System utilizes
high-strength precast polymer concrete panels that
“bridge” between the rails and requires no fastening to
the cross ties. The modular panels are maintenance free.
They’re designed for high load-carrying capacity,
impervious to salt spray, moisture or diesel fuel and come
with a skid and wear resistant surface.The Red warning
lights alert approaching vehicles and are continuous on
both sides of the crossing. This could eliminate the need U.S. Patent
Nos. 5,799,868 and
for quad gates at crossings. 5,806,764

®
TRANSPO
INDUSTRIES, Inc.

The Smart Solutions Company For Further Information On The Bodan Level Crossing System
Te l 9 1 4 - 6 3 6 - 1 0 0 0 F a x 9 1 4 - 6 3 6 - 1 2 8 2 Call 1-800-321-7870 or visit us on our web site at www.transpo.com BODAN®
BODAN Polymer Concrete Panels

The Polymer concrete material used for precasting the Bodan modular panel consists of acrylic
resin composite and specially formulated aggregate fillers. This highly formulated polymer
concrete exhibits unique physical property performance characteristics vastly superior to those of
Portland cement. Polymer Concrete is highly resistant to water and salt penetration thus
preventing corrosion of the reinforcing bar and deterioration of the concrete.

Transpo has been manufacturing Polymer concrete material systems and precasts at its Castek
facility in Berwick, PA for over 20 years. We have supplied polymer concrete materials for the
repair of bridges, airport tarmacs, parking structures and commercial buildings. Precast Polymer
concrete products include tunnel wall liners, retro reflective Jersey barriers, curbing, utility box
covers, corrosion resistant drains, high voltage insulators, roof pavers, acid cells, architectural
fascia panels and BODAN modular panels.

The BODAN modular precast polymer concrete panels are maintenance free. They are
impervious to salt spray, moisture or diesel fuel and have a lifetime skid resistant granular
surface. The panels are designed for high load-carrying capacity with compressive strengths in
excess of 14,000 psi.

As an added safety feature, red LED warning lights to alert approaching vehicles are molded into
the edge beam of the BODAN system which runs parallel to the track on both sides of the
crossing.

20 Jones Street, New Rochelle, NY 10801-6098

Tel. 914.636.1000  Fax: 914-636-1282  Web: www.transpo.com
AN EQUAL OPPORTUNITY EMPLOYER
BODAN® RR Level Crossing
Precast Polymer Concrete Panels

Physical Properties*

Property Value Test Method

Average Compressive Strength 14000 psi (96 MPa) ASTM C109
Average Flexural Strength 3200 psi (22 MPa) ASTM C384
Average Impact Strength 100 ft● lb/min (0.23 m●kg/s) ASTM D2444
Fire Resistance Class “A” ASTM E8487
UV Sensitivity 2.0 max ASTM G53
Resistance to Freeze/Thaw “Zero” Change ASTM C666

* To be used as general guidelines only.

20 Jones Street, New Rochelle, NY 10801-6098

Tel. 914.636.1000  Fax: 914-636-1282  Web: www.transpo.com
AN EQUAL OPPORTUNITY EMPLOYER
 BODAN®
Level Railroad Crossing System
Standard Drawings
System Drawings:

Drawing Number Description Latest Rev. Date

BD-750-STG Model BD-750, Single Track General Plan Details May 2006

BD-750-S-2 Model BD-750, Single Line May 2007

Cross-Section Details

BD-750-D-2 Model BD-750, Double Line Cross Section Details May 2007

BD-1400-STG Model BD-1400, Single Track General Plan Details May 2006

Model BD-1400, Single Track Cross Section

BD-1400- STXS May 2007

Model BD-1400, Double Track Cross Section

BD-1400-D-210 May 2007
Rubber Profile Component Details
601-BD-RPD May 2006

BD-EB-1 Model BD-EB-1, Edge Beam Details for use on Single May 2007
Track Models

Model BD-EB-1, Edge Beam Details for use on Double

BD-EB-1 May 2007
Track Models

Model BD-EBWL-1B, Edge Beam Details With Warning May 2007

BD-EBWL-1B
Light Option

BD-1400-S-1C Model BD-1400-S,-Plan View, Milwaukie Street April 2005

Crossing, Boise, ID

BD-1400-S Model BD-1400-S,Lighting Detail October 2003

223-BD-1400-CWGLTM Model BD-1400, Cross Walk with Lights, ADA Tile & March 2011
Pavement Markings

Transpo Industries, Inc., 20 Jones Street, New Rochelle, NY 10801-6098

Phone: 914-636-1000 Fax: 914-636-1282 Web: www.transpo.com
Component Drawings:

Drawing Number Description Latest Rev. Date

BD-EP750-401 External Panel Type EP-750 April 2006

Sheet 401 Model BD-750.

BD-EP1400-402 External Panel Type EP-1400 April 2006

Sheet 402 Model BD-1400.

BD-IP1435-403 Internal Panel Type IP-1435 April 2006

Sheet 403

BD-EB-501 Edge Beam April 2006

Sheet 501

BD-EBL-502 Edge Beam with Warning Light April 2006

Sheet 502

BD-CB-503 Center Beam (for Double Track) April 2006

Sheet 503

BD-BF-504 Beam Foundation April 2006

Sheet 504

BD-RPD-601 Rubber Profile Details April 2006

Sheet 601

BD-SR-602 Slab Retainer April 2006

Sheet 602

BD-DP-603 Deflector Plate April 2006

Sheet 603

Transpo Industries, Inc., 20 Jones Street, New Rochelle, NY 10801-6098

Phone: 914-636-1000 Fax: 914-636-1282 Web: www.transpo.com
AST/H AST AST/H

AST

May 2007
 AST/H AST/H

AST/H

May 2007
AST/H AST/H

AST/H

May 2007
AST/H AST AST/H

AST

May 2007
AST/H

For Use on Single Track Models

May 2007
AST

For Use on Double Track Models

May 2007
 AST/H

BODAN Level Crossing System

Edge Beam Details
with Warning Light Option
Scale: Not to Scale Date: May 2007
Drawing No. BD-EBWL-1B Sheet 1 of 1
BODAN® Level Crossing Luminaires
Applications: Railroad Crossing, Pedestrian Crosswalk Safety,
Traffic Delineation, Tunnel, Platform Edge

Luminaire: Flush (zero elevation above ground level)

Light Source: Two LUXEON Star LEDs

Light Pattern: Bidirectional, Wide

Photometrics: From 5° to 80° in vertical plane; ± 65° in

horizontal plane in each direction. Peak
intensity 15 candelas.

Colors: RED AMBER GREEN CYAN BLUE

Electrical: LED power consumption 2.5-watts. Power

inputs 120/240 volts AC; or low voltage
operation AC/DC from 9-volts to 24-volts,
polarity independent.

Mechanical: Drive over, snow

plow proof,
weatherproof,
completely sealed
against road salts &
chemicals, shock
and vibration
resistant,
2.5 inch Ø, 1.46
inches deep,
weight 6-ounces

20 Jones Street, New Rochelle, NY 10801-6098

Tel. 914.636.1000 Fax. 914.636.1282 www.transpo.com
 BODAN BD-1400-S Shelby, NE

BD-1400-S w/LED Surface Mounted Lights Boise, ID

BODAN BD-1400-S Norfolk, NE

BODAN BD-750-S Flemington, NJ

BODAN Rail Section Detail

BODAN Edge Beam Detail

PANEL REINFORCING CAGE

CROSS SECTION PANEL CUT