There are numerous ways to surface a highway/rail grade crossing—concrete, rubber, composite, and timber—to withstand the long-term pounding of heavy trains while providing a safe, smooth, jolt-free ride for motor vehicles. Following is a roundup of offerings from suppliers who responded to Railway Age’s inquiries about how they are continuing to innovate and improve on grade crossing surfaces.
ENSCO, Inc.
ENSCO, Inc. operates the Federal Railroad Administration (FRA) Transportation Technology Center (TTC) in Pueblo, Colo.. In cooperation with partners AtkinsRéalis and the University of South Florida’s Center for Urban Transportation Research (CUTR), ENSCO is working with industry to establish the FRA Grade Crossing Testbed (GX Testbed)—a flexible, real-world environment for evaluating grade crossing surfaces, warning systems, and communication technologies.
The GX Testbed, ENSCO tells Railway Age, will support government and industry research aimed at improving grade crossing safety through advancements such as reliable communication between motor vehicles and rail equipment, known as Cellular Vehicle-to-Everything (C-V2X). This technology will enable connected vehicles to receive real-time alerts about approaching trains or occupied crossings, improving driver awareness, and reducing collisions.
TTC’s advanced infrastructure supports full-scale testing of surface materials, sensing systems like radar, LiDAR, and AI-driven cameras, and behavioral studies to understand how people respond under varying crossing conditions.
“Through this collaborative effort, ENSCO and its partners, as well as universities and industry suppliers, are helping to shape the next generation of transportation safety by combining smart infrastructure, advanced analytics, and connected-vehicle research in support of the FRA’s mission to reducing grade crossing incidents nationwide.”
HiRAIL Corporation
“The market for grade crossings is currently strong with the Class I’s, short lines, transit agencies and industries,” according to HiRAIL Director of Sales and Marketing Jim Overfelt.
HiRAIL is continuing its work developing new full-depth rubber crossing profiles to fit new concrete tie designs and new fastening systems. “The majority of concrete ties produced domestically are not flat or rectangular shaped like a timber tie,” Overfelt explains. “Most concrete ties have an area that slopes down from the rail seat toward the middle of the tie that meets a flat section in the middle. Over the course of many years, the concrete tie manufacturers have made these areas different lengths. As these dimensions change, we change to make our product fit the contour of the concrete tie. Our design capabilities allow the client to use the same concrete tie profile throughout their entire system and not have to transition to flat concrete ties or timber ties for their crossings.
“On top of the changes in shape, there have also been new fastening systems introduced that require us to add more clearance. Consequently, we end up changing our design to fit these requirements. It seems as though every year there is a new fastening system and concrete tie design, and we are fortunate to have the ability to design a crossing product that will accommodate it. We also seem to be getting more inquires for direct-fixation track crossings, which require a lot of the same design capabilities that we use for concrete or steel tie crossings.”
“Our customers are looking for a product that is low-maintenance, reliable and competitively priced,” Overfelt adds. “Customers are also looking for a product that can be recycled at the end of its life and that is manufactured in the U.S. HiRAIL offers all of these benefits, which I believe is the reason for much of our success.”
L.B. Foster
Through L.B. Foster’s partnership with Rosehill Rail, the company offers a wide range of rubber crossing panel systems to the North American market. Rosehill Rail’s focus has always been on developing crossing systems that perform reliably in the toughest environments, the company notes.
The TITAN system, L.B. Foster tells Railway Age, “is the strongest and most durable surface-mounted crossing, designed specifically for sites that experience extreme axle loads, frequent heavy-haul traffic, or industrial vehicle movements. Built around a robust internal reinforcement structure, TITAN combines the flexibility of rubber with exceptional structural strength, allowing it to maintain stability and surface integrity even under constant impact and vibration.
“Each panel is precision molded from recycled rubber using L.B. Foster’s cold-cure manufacturing process, producing a dense, dimensionally stable unit that locks together securely via tongue-and-groove joints. The result, the company says, “is a crossing that delivers the proven resilience of our modular systems, but with enhanced rigidity and load distribution across the entire installation. From main line freight and maintenance depots to industrial sidings, TITAN offers operators a dependable, heavy-duty solution that’s quick to install, simple to maintain, and built to last.”
The TITAN system has been installed at Rio Tinto Mining in Australia, as well as ferry ports in the United Kingdom and other heavy duty crossing areas in Romania and Czech Republic.
Oldcastle Infrastructure’s StarTrack line was first released in 1987.
Oldcastle Infrastructure
The market for concrete tub-style crossings “was strong in 2025,” says John Jackson, National Account Manager – StarTrack Rail Products. “I expect that trend to continue as infrastructure upgrades remain a high priority. StarTrack has a strong reputation in the market, and customers want and expect a product that is cost-effective, durable, and virtually maintenance-free. Since its release in 1987, the StarTrack line of precast rail products has delivered the quality that customers expect from Oldcastle Infrastructure.”
New products are in review to add to the StarTrack line; however, Jackson says he is “still reviewing the addition and how it would potentially affect my current product line.”
Omega Industries Tub-style crossing, Hawaii Narrow Gauge Railroad.
Omega Industries Inc.
“The year started with notable uncertainty due to the tariff rollercoaster,” Omega tells Railway Age. “Some projects were put on hold, and customers were reluctant to place orders as they had in the past year. As this year has progressed and companies have adapted to changing conditions, the industry has shown its resilience, and orders have now exceeded last year.”
Omega has developed and tested a new modular “Tub” style crossing panel built using a high strength 8,000 psi concrete mix. The Tub, the company says, “eliminates the need for ties, plates, and ballast, and does an excellent job of load distribution. As a result, the Tub excels in grade crossings with heavy load applications like port terminals, steel mills, and recycling facilities.”
Recently, Omega purchased a new property in North Carolina and is in the process of moving its current Sanford, N.C., production operation. The new location will give the company more space and allow for more efficient material flow and product storage, according to Omega, which adds that “as always, our customers are looking for good communication, short lead times, fair pricing and a durable product.”
Omni Products Inc.
“As 2025 unfolds, OMNI remains firmly positioned at the forefront of custom concrete grade crossing fabrication, supplying high-profile rail projects across the U.S., Canada, and Mexico, the company tells Railway Age. “With decades of engineering expertise, we confidently tackle virtually any grade crossing challenge—from standard installations to extreme 30-plus-degree curves—delivering precision, durability, and consistent performance.”
OMNI’s product lineup, the company says, “reflects its long-standing commitment to manufacturing excellence. Whether clients require concrete panels, full-depth virgin rubber, or one of the company’s proprietary virgin rubber rail guard concrete tub modules, each solution is engineered for longevity and manufactured to exacting standards. Made proudly in America, OMNI’s rubber products come with a robust six-year factory warranty against rips and tears—an industry-leading guarantee unmatched by competitors.”
Among OMNI’s exclusive offerings is its steel-reinforced rubber, purpose-built for the most demanding environments, including heavy fork truck traffic. OMNI’s original VRA (Virgin Rubber Railguard) and the advanced VRA2 Railguard, both manufactured in-house, “provide the toughest solid virgin rubber rail seal available, designed to stand up to the harshest rail conditions,” the company notes.
OMNI’s capabilities extend even further through its ECR product line and Improved Concrete (IC) designs, which, the company says, “give clients flexible, application-specific options.” Its proprietary TraCast concrete tub modules are available in two configurations, including custom wide, heavy-duty versions engineered for extreme use. “The newest addition, TraCast 3 Heavy Duty Concrete Tub, delivers exceptional strength paired with cost efficiency, making it an ideal solution for demanding installations.”
With business “strong and steady heading into 2026,” OMNI says it “remains focused on meeting production schedules, delivering consistent on-time performance, and upholding its reputation for quality supported by responsive, expert customer service. Exceeding customer expectations continues to be the driving force behind the company’s growth.”
Looking ahead, OMNI says it is preparing to launch its “next major innovation,” OMNI HDPE EnviroTrakPans, “a high-density polyethylene spill containment system engineered for long-term reliability in rail environments. Designed for superior spill capacity and exceptional resistance to impacts, UV exposure, and extreme temperatures, EnviroTrakPans install easily without motorized equipment and fit 115-pound rail and larger on both tangent and curved track. With minimal installation and maintenance costs, these HDPE pans offer a durable, cost-effective alternative for environmentally focused spill containment, the company noted. OMNI will also continue to provide a full array of steel spill pans—available in carbon, galvanized, stainless steel, and aluminum—to meet diverse operational needs.”
“With advanced engineering, unmatched warranties, and a growing portfolio of specialized solutions, OMNI remains a proven leader dedicated to supporting the rail industry’s evolving infrastructure demands,” the company says.
