Cross Track Ultra
Concrete-based level crossing surface with embedded rail support
At highly loaded traffic corridors, the level crossing determines availability, maintenance costs and ride comfort. Conventional track support slabs frequently reach their limits due to wide flangeway gaps, corrosion on fastenings and an uneven transition between road and rail. The CrossTrack Ultra level crossing has been developed for precisely these demands. A level crossing surface with integrated continuous rail support and minimal flangeway width for mainline and tramway applications.
Product Features
- Reduced dynamic loading
- Less wear on rail and fastenings
- Lower noise emissions
- Longer maintenance intervals
Smooth transition under high traffic loads
In the CrossTrack Ultra, the rails are not mechanically clamped but elastically embedded.
The continuous support significantly reduces impact forces during crossing and improves ride comfort for cars, buses and heavy goods vehicles.
Narrow flangeway increases safety and comfort
Modern fastening systems frequently result in wide flangeways.
This increases noise, accident risk for cyclists and wear on road surfaces.
Through optimised channel geometry, CrossTrack Ultra achieves a flangeway width of approximately 50 mm in accordance with EBO.
Result in operation
- Better rideability for two-wheelers
- Lower impact loading
- Smooth transition
- Higher acceptance in urban areas
Permanent rail support without corrosion
The rail is fully embedded in an elastic grouting system.
This creates a permanent bond between rail and track slab.
The continuous encapsulation protects against moisture and de-icing salt.
Key effects
- High corrosion protection
- Electrical insulation
- Reduced maintenance
- Stable gauge retention
Flexible precast elements for new construction and refurbishment
The track slabs are delivered as precast elements and can be adapted on a project-specific basis.
Typical parameters:
- Element lengths approx. 2.4 to 3.0 m
- Flexible widths for single or multi-track crossings
- Suitable for Embedded Track systems
- Applicable for tramway and railway
Typical areas of application
- Heavily trafficked level crossings
- Inner-city junctions
- Tramway routes
- Industrial tracks
- Logistics areas
- Modernisation of existing concrete crossings
Result for planning and operation
- Predictable service life
- Smooth ride comfort
- Reduced maintenance effort
The CrossTrack Ultra combines the stability of a concrete solution with the advantages of elastic rail support and is particularly suitable for heavily loaded traffic areas. Technical documentation and project consultancy are available on request.
The level crossing surface meets the current requirements of modern transport routes:
- Continuous elastic rail support
- Tested in accordance with EN 13481-5
- Stray current insulating
- Resistant to de-icing salts
- Durable precast concrete construction
- Suitable for high axle loads
CrossTrack Ultra Gernsbach-Scheuern
A heavily frequented level crossing located at the junction of a federal road with regular truck turning traffic places high demands on the stability and maintainability of the rail fastening system. In this project, the CrossTrack Ultra level crossing system was used together with massive concrete track support slabs weighing approximately five tons each and the V Flow 60A PU rail fastening system.
The rail grout can be mixed using standard mixing equipment, enabling efficient installation. This solution ensures long-term durability, maintenance-friendly servicing, and a safe level crossing even under intensive traffic conditions.
Installation support was provided by specialist personnel from HET Elastomertechnik GmbH.
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