Mass Concrete Tie Fabrication
Loading Inserts in forms
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Left:  After test pouring several concrete ties using several different brands and shapes of inserts we determined this one to be the best suited for the screws we are using.  We are using the same screws as Train Mountain.  This insert is cylindrical.  It is not tapered.  We found the tapered ones would spin and or pull up and out when the screw was tightened down to the tie plate.  This Tubular Anchor has fluting or splines which keep it from rotating in the concrete allowing the screw to tight up without pulling the insert out.

Right:  We found that the inserts need to be heated up to make them softer and easier to push over the pegs or nails on the plywood gang forms.  A crock pot with water is the best way to achieve that.  The inserts cool rapidly so don't take more than a small hand full out at one time.  If you don't heat the inserts they tend to crack or take on a eliptical shape when pushing them over the pegs.

Left:  A 1/4" nut driver with a hollow shaft is used to push the inserts down onto the pegs. 
Below:  Installing the inserts can take a while without plenty of help.  Charlie Robbins, Dave Grounds and Pete Pedigo are installing inserts in preparation to pour a batch of concrete ties. Each batch of 270 ties takes 1080 inserts.
Screw information :  Marker & Darts, P/N 51280, 8-15x1 MOD. Truss, 8000 in a box, weight 46.29 pounds.
www.Marker-Darts.com
New Unionville and Western Railroad - Southern Indiana Live Steamers, Inc.
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