Modular Crossing Repair

Lifting & Stabilization

modular crossing repair featured

We are modular grade crossing repair experts.  We use polyurethane grouting to correct pumping and settlement of all brands of modular (tub style) grade crossings.

Polyurethane injection is a safe, fast, and reliable alternative to rebuilding modular crossings. CJGrout geotechnical polyurethane addresses deflection, voids, settlement and deterioration of adjacent pavements.

Modular Grade Crossing Repair Process

CJGeo’s modular grade crossing repair service works by injecting high density polyurethane under the modular crossing panels. CJGrout fills voids below the panels and in the adjacent soil, and displaces water from the voids to correct deflection and instability.  For panels that have settled, additional material is carefully injected below the panels. This will gently and precisely lift them back to the correct profile.  Lifting is generally done to within 1/32 inch.

CJGrout is injected through dime-size holes drilled through the panels. CJGrout cures within seconds, allowing for immediate resumption of rail and automobile traffic.


CJGeo’s modular grade crossing repair crews use a repair process that’s specifically designed around safety. We have repaired crossings for CSX, NS, BNSF, numerous regional & short line railroads, along with numerous commuter & light rail services.

Polyurethane injection is inherently safer than alternative repairs. It does not require heavy equipment or high pressure pumping of cement-based grouts.  Additionally, polyurethane injection is much faster than alternative repairs. Therefore, it requires significantly less fouling of rail and disruption of automobile traffic.


A single polyurethane grouting crew can repair dozens of feet of modular grade crossing panels per hour.  Polyurethane cures within a few seconds. The repair can be load tested immediately afterwards. This ensures the repair has thoroughly addressed the problem.  A fast process doesn’t mean we cut corners.  Polyurethane grouting is faster than cement-based grout injection because:

  • smaller holes (5/8″) are faster to drill than the 2″ to 4″ holes required for cement grout injection
  • on demand production generates lifting polyurethane grout quickly, without batching, mixing or agitating
  • efficient equipment–a single polyurethane grouting box truck carries the equivalent of 10 trucks of mudjacking grout
  • fast curing polyurethane grouts cure within a few seconds of injection.  Mudjacking grout can take days to cure to the point of taking traffic


Polyurethane is a very resilient material which excels in dynamic loading environments.  There are few dynamic loading environments more brutal than modular grade crossings.  We use foams with bearing capacities starting around 7500PSF. They far exceed the loads which crossings see. Polyurethanes are not prone to cracking and deterioration like cement-based grouts are in the same environment.  The design life of polyurethane (100+ years) outlives the crossings themselves. However, the material is easily excavatable, which eases future work in the area.

Other Rail Applications For Polyurethane Injection

High density polyurethane injection can also be used to raise precast rail structures other than modular grade crossings, such as inspection pits.  Additional, CJGeo uses polyurethane for culvert joint repair, rebuilding failed corrugated metal pipes and void filling applications.

Speak With An Expert

Facing a challenge? Give us a shout or shoot us a text. Click the state marker for the location of the project for contact info for the appropriate rep.

Rail Crossing Grouting Project Profiles